Service Manual Cryo V6 ENG

Zimmer Elektromedizin GmbH Junkersstraße Junkersstraße 9

Tel. 0731 / 9761-0 Fax 0731 / 9761-118

[email protected] www.zimmer.de

Product roduc t Documentation ocumentation

Project:

Cryo 6

Topic:

Service Manual

Cryo V6.0 Service

Table Table of contents 1. Safety Instructions..............................................................................................................................................................................3 2. Returning a device.............................................................................................................................................................................4 2.1. Packaging Packaging....................................................................................................................................................................................4 ....................................................................................................................................................................................4 3. Repairing printed circuit boards.......................................................................................................................................................5 4. Incidents...............................................................................................................................................................................................5 5. Device Description.............................................................................................................................................................................6 5.1. Overview......................................................................................................................................................................................6 5.2. Electronics...................................................................................................................................................................................6 5.3. Refrigeration Sy System..................................................................................................................... stem.................................................................................................................................................................7 ............................................7 5.3.1. Compressor................................................................................................................................................................7 5.3.2. Security Pressure Control........................................................................................................................................7 5.3.3. Condenser..................................................................................................................................................................8 5.3.4. Filter Dryer..................................................................................................................................................................8 5.3.5. Therm Thermostatic ostatic Expan Expansion sion Valve Valve................................................................................................................................8 ................................................................................................................................8 5.3.6. Evaporator Evaporator..................................................................................................................................................................8 ..................................................................................................................................................................8 5.3.7. Refrigerant..................................................................................................................................................................8 5.4. Safety Measures........................................................................................................................................................................8 5.5. Technical Data............................................................................................................................................................................9 5.6. Accessories........................................................................................................................................................................... Accessories.................................................................................................................................................................................9 ......9 6. Block Block Diagram.................................................................................................................................................................................. Diagram.................................................................................................................................................................................. 10 7. Problem Solving............................................................................................................................................................................... Solving............................................................................................................................................................................... 11 7.1. Starting Starting Problems Problems.................................................................................................................................................................... 11 7.1.1. The device device does not run; the display is is dark and does not respond respond to key presses................................... presses...................................11 11 7.1.2. Low Cooli Cooling ng Powe Powerr................................................................................................................................................ 11 7.1.3. “Condensa “Condensate te container full” full” message essage appears appears on the display........................................................................ 11 7.1.4. “Clean filter filter”” message essage lights........................................................................................ lights................................................................................................................................. .........................................11 11 7.1.5. Error Messages essages....................................................................................................................................................... ....................................................................................................................................................... 12 7.2. Service Service Report......................................................................................................................................................................... Report......................................................................................................................................................................... 13 8. Acces Accessory sory List.................................................................................................................................................................................. List.................................................................................................................................................................................. 14 9. Service Service Mode.......................................................................................................................................... ode................................................................................................................................................................................... .........................................15 15 9.1. Opening Opening Service Mod Mode e........................................................................................................................................................... 15 9.2. Freeze-over Freeze-over Simulation.......................................................................................................................................................... Simulation.......................................................................................................................................................... 16 9.3. Cryo Device Ty Type pe.................................................................................................................................................................... .................................................................................................................................................................... 16 9.4. Hour Meter............................................................................................................................................................................... eter............................................................................................................................................................................... 16 9.5. Manual Manual Component ponent Control.................................................................................................................................................. Control.................................................................................................................................................. 17 10. Troubleshooting............................................................................................. Troubleshooting............................................................................................................................................................................. ................................................................................ 19 10.1. Start Starting ing Problems................................................................................................................................................................. Problems................................................................................................................................................................. 20 10.2. Problems Problems without error message........................................................................................................................................ essage........................................................................................................................................20 20 10.3. EEPRO EEPROM M wri write te error............................................................................................................................................................. error.............................................................................................................................................................20 20 10.4. WATCH ATCHDO DOGerror................................................................................................................................................................ error................................................................................................................................................................ 21 10.5. Temperature Temperature Sensor Sensor (Evaporator) (Evaporator)..................................................................................................................................... ..................................................................................................................................... 21 10.6. TemperatureSensor(Compresso (Compressor)................................................... r)................................................................................................................................... ................................................................................ 21 10.7. Refrigeration Refrigeration System Te Tem mperature Sensor...................................................................................................................... Sensor...................................................................................................................... 21 10.8. Compressor Compressor Temperature Temperature > +80 °C.................................................................................................................................. ° C..................................................................................................................................21 21 10.9. Overpressure Overpressure > 2800 kPa kPa................................................................................................................................................... ................................................................................................................................................... 22 10.10. Incorrect Mains Frequency Frequency <45H <45Hz z or >65Hz >65Hz................................................................................................................. ................................................................................................................. 22 11. Assem Assembly bly........................................................................................................................................................................................ ........................................................................................................................................................................................ 23 11.1. Device Device Structure.................................................................................................................................................................... Structure.................................................................................................................................................................... 23

1 R:\Dokumente\Geräte\Cryo6\Englisch\Service\Service Handbuch Cryo V6.0.doc

Cryo V6.0 Service

Table Table of contents 1. Safety Instructions..............................................................................................................................................................................3 2. Returning a device.............................................................................................................................................................................4 2.1. Packaging Packaging....................................................................................................................................................................................4 ....................................................................................................................................................................................4 3. Repairing printed circuit boards.......................................................................................................................................................5 4. Incidents...............................................................................................................................................................................................5 5. Device Description.............................................................................................................................................................................6 5.1. Overview......................................................................................................................................................................................6 5.2. Electronics...................................................................................................................................................................................6 5.3. Refrigeration Sy System..................................................................................................................... stem.................................................................................................................................................................7 ............................................7 5.3.1. Compressor................................................................................................................................................................7 5.3.2. Security Pressure Control........................................................................................................................................7 5.3.3. Condenser..................................................................................................................................................................8 5.3.4. Filter Dryer..................................................................................................................................................................8 5.3.5. Therm Thermostatic ostatic Expan Expansion sion Valve Valve................................................................................................................................8 ................................................................................................................................8 5.3.6. Evaporator Evaporator..................................................................................................................................................................8 ..................................................................................................................................................................8 5.3.7. Refrigerant..................................................................................................................................................................8 5.4. Safety Measures........................................................................................................................................................................8 5.5. Technical Data............................................................................................................................................................................9 5.6. Accessories........................................................................................................................................................................... Accessories.................................................................................................................................................................................9 ......9 6. Block Block Diagram.................................................................................................................................................................................. Diagram.................................................................................................................................................................................. 10 7. Problem Solving............................................................................................................................................................................... Solving............................................................................................................................................................................... 11 7.1. Starting Starting Problems Problems.................................................................................................................................................................... 11 7.1.1. The device device does not run; the display is is dark and does not respond respond to key presses................................... presses...................................11 11 7.1.2. Low Cooli Cooling ng Powe Powerr................................................................................................................................................ 11 7.1.3. “Condensa “Condensate te container full” full” message essage appears appears on the display........................................................................ 11 7.1.4. “Clean filter filter”” message essage lights........................................................................................ lights................................................................................................................................. .........................................11 11 7.1.5. Error Messages essages....................................................................................................................................................... ....................................................................................................................................................... 12 7.2. Service Service Report......................................................................................................................................................................... Report......................................................................................................................................................................... 13 8. Acces Accessory sory List.................................................................................................................................................................................. List.................................................................................................................................................................................. 14 9. Service Service Mode.......................................................................................................................................... ode................................................................................................................................................................................... .........................................15 15 9.1. Opening Opening Service Mod Mode e........................................................................................................................................................... 15 9.2. Freeze-over Freeze-over Simulation.......................................................................................................................................................... Simulation.......................................................................................................................................................... 16 9.3. Cryo Device Ty Type pe.................................................................................................................................................................... .................................................................................................................................................................... 16 9.4. Hour Meter............................................................................................................................................................................... eter............................................................................................................................................................................... 16 9.5. Manual Manual Component ponent Control.................................................................................................................................................. Control.................................................................................................................................................. 17 10. Troubleshooting............................................................................................. Troubleshooting............................................................................................................................................................................. ................................................................................ 19 10.1. Start Starting ing Problems................................................................................................................................................................. Problems................................................................................................................................................................. 20 10.2. Problems Problems without error message........................................................................................................................................ essage........................................................................................................................................20 20 10.3. EEPRO EEPROM M wri write te error............................................................................................................................................................. error.............................................................................................................................................................20 20 10.4. WATCH ATCHDO DOGerror................................................................................................................................................................ error................................................................................................................................................................ 21 10.5. Temperature Temperature Sensor Sensor (Evaporator) (Evaporator)..................................................................................................................................... ..................................................................................................................................... 21 10.6. TemperatureSensor(Compresso (Compressor)................................................... r)................................................................................................................................... ................................................................................ 21 10.7. Refrigeration Refrigeration System Te Tem mperature Sensor...................................................................................................................... Sensor...................................................................................................................... 21 10.8. Compressor Compressor Temperature Temperature > +80 °C.................................................................................................................................. ° C..................................................................................................................................21 21 10.9. Overpressure Overpressure > 2800 kPa kPa................................................................................................................................................... ................................................................................................................................................... 22 10.10. Incorrect Mains Frequency Frequency <45H <45Hz z or >65Hz >65Hz................................................................................................................. ................................................................................................................. 22 11. Assem Assembly bly........................................................................................................................................................................................ ........................................................................................................................................................................................ 23 11.1. Device Device Structure.................................................................................................................................................................... Structure.................................................................................................................................................................... 23


Cryo V6.0 Service 12. Overview......................................................................................................................................................................................... 24 12.1.1. Spare Spare Parts Parts Handling............................................................. Handling............................................................................................................................................. ................................................................................ 24 12.1.2. Required Required Equipm Equipment........................ ent.............................................................................................................................................. ......................................................................................................................24 24 12.1.3. Safety Notice........................................................................................................................................................... 24 12.2. Removing Removing and Attaching tthe he Therapy Tube Tube..................................................................................................................... .....................................................................................................................25 25 12.3. Replacing the Conden Condensate sate Drain Drain....................................................................................................................................... ....................................................................................................................................... 25 12.4. Opening Opening the Housing............................................................................................................................................................ Housing............................................................................................................................................................ 26 12.5. Closing Closing the Housing Housing............................................................................................................................................................. ............................................................................................................................................................. 27 12.6. Test Test Run................................................................................................................................................................................. 27 13. Repairs and Component ponent Replacem Replacement............... ent..................................................................................................................................... ......................................................................................................................28 28 13.1. Electronics.............................................................................................................................................................................. Electronics.............................................................................................................................................................................. 28 13.1.1. Mains Supply Supply Side.................................................................................................................................................. 28 13.1.2. Low-voltage Low-voltage Side.............................. Side.................................................................................................................................................... ......................................................................................................................28 28 13.1.3. Board............................................................................................................................... Board........................................................................................................................................................................ .........................................29 29 13.1.4. Board Board Replacem Replacement ent................................................................................................................................................ ................................................................................................................................................ 29 13.2. Replacement Replacement of Mains Filter Filter Input Socket, Main Switch................................................................................................ Switch................................................................................................ 30 13.3. Replacement Replacement of LCD LCD and Keyboard.................................................................................................................................. Keyboard..................................................................................................................................30 30 14. Refrigeration Refrigeration System System Com Compone ponents...................... nts............................................................................................................................................ ......................................................................................................................31 31 14.1. Refrigeration Refrigeration System............................................................................................................................................................ System............................................................................................................................................................ 31 14.2. Evaporator Evaporator Sensor Replacem Replacement....................................................................................................................................... 31 14.3. Replacem Replacement ent of Com Compressor Temperature Temperature Sensor........................................................................................................ Sensor........................................................................................................31 31 14.4. Replacem Replacement ent of Refri Refrigeration geration System System Temperature Sensor......................................................................................... Sensor......................................................................................... 32 14.5. Replacement of Therapy Fan.................................................................................................... Fan............................................................................................................................................. .........................................32 32 15. Pin Assignments ssignments andCompone Component nt Names....................................................................................... es................................................................................................................................ .........................................33 33 15.1. Board Board mains mains input connection connection............................................................................................................................................ ............................................................................................................................................ 33 15.2. Power Power Side Connec Connections tions..................................................................................................................................................... ..................................................................................................................................................... 34 15.3. Evaporator Evaporator temperature temperature sensor sensor connection connection..................................................................................................................... .....................................................................................................................34 34 15.4. Compresso Compressorr temperature temperature sensor connection................................................................................................................... connection...................................................................................................................34 34 15.5. Refrigeration Refrigeration system temperature sensor sensor connection.................................................................................................... connection.................................................................................................... 34 15.6. Keyboard Keyboard connection............................................................................................................................................................ connection............................................................................................................................................................ 34 15.7. Display control control signals connection............................................................................................ connection..................................................................................................................................... .........................................35 35 15.8. Display powe powerr supply connection....................................................... connection....................................................................................................................................... ................................................................................ 35 15.9. Level Level sensor connection...................................................................................................................................................... connection...................................................................................................................................................... 35 15.10. Board Board external external control in/out connection.. connection........................................................................................................................ ......................................................................................................................35 35 15.11. Therapy Therapy fan control control line line connection................................................................................................................................. connection.................................................................................................................................35 35 15.12. Pressure Pressure sensor sensor connection connection............................................................................................................................................. ............................................................................................................................................. 36 15.13. Firmware Firmware update update connection connection............................................................................................................................................ ............................................................................................................................................ 36 15.14. Com Compresso pressorr start-up start-up electrics electrics connection...................................................................................................................... connection...................................................................................................................... 36 16. Test Protocol.................................................................................................. Protocol.................................................................................................................................................................................. ................................................................................ 37


Cryo V6.0 Service

1. Safety Instr ucti ons Zimmer Elektromedizin GmbH as the manufacturer of electromedical devices can only accept liability for the safety and reliability of the device under the following conditions: •

the electrical installation conforms to the requirements specified for operation of the device

•

the device is operated as specified by the operating manual

•

extensions, new settings or changes are only carried out by persons authorized by Zimmer Elektromedizin.

Zimmer Elektromedizin reserves the right to makes changes to delivery options and technical features. Contract service partners are responsible for all repairs that they conduct. Screws that must be removed to open the housing are protected by a special warranty seal. Only authorized persons are permitted to remove them. If the seal is missing or has been manipulated, the device will no longer be under warranty. The information in the service documentation is the property of the manufacturer and intended for internal use by our technicians only. Publication of this information or distribution to unauthorized persons is prohibited. If the service contract is canceled, the technician(s) is/are required to return the service documentation to Zimmer Elektromedizin GmbH. Warning! Unauthorized modifications or repairs to the device may cause it to malfunction and cause serious injuries.


Cryo V6.0 Service

2. Retur nin g a device 2.1. Packaging Every unit that is sent to the manufacturer for service must be packed in the original packaging to prevent any damage during shipping. Always include a detailed description of any faults. Please use the service report included with the documentation (Chap. 7.2 )

Defrost the device and drain the condensate container before packaging it


Cryo V6.0 Service

3. Repairing p rinted cir cuit boards Faulty boards must be repaired by the manufacturer only. After replacing a module, the faulty part must be labeled with the serial number of the device and returned to the manufacturer with the service report (1.4.6.).

4. Incidents Zimmer Elektromedizin is required to record malfunctions and incidents of any type. Please report all unusual incidents (e.g. electric shock, freezing etc. ). Please use the service report included with the documentation (Chap. 7.2 ) Your reports will contribute to improving the quality and reliability of our products.


Cryo V6.0 Service

5. Device Descripti on 5.1. Overview The Cryo V6.0 is a refrigerated air therapy device that pulls in room air and cools it to therapeutically effective temperature ranges down to -30 °C. The device is mounted on rollers for ease of use in various locations. The device has a metal housing and a plastic top attached to an aluminum frame. The power supply connection, main switch with fuse and air filter are on the back of the device. The condensate container is on the front of the device. A therapy fan, which can be set to any of nine speeds, directs roomair through a coarse dust filter into the evaporator, where it is refrigerated and directed to the patient through an insulated application tube. The air pulled into the therapy fan is not used to cool the device. The device is operated by a capacitive keyboard behind a glass plate and a LCD display. All device functions and the regulation and monitoring of the cold circuit are controlled by a microprocessor. The device should be left for half an hour after transport and repairs to allow the oil to accumulate in the bottom of the compressor.

5.2. Electronics The electronic hardware of the Cryo V6.0 is on one printed-circui t board mou nted under the device top. The controller and power unit with the device power supply are combined on one board. The device and the treatment regime are monitored and controlled by the microprocessor with appropriate peripherals. Functions include a self-test on start-up, monitoring of limit values of critical components, including temperatures, control of function status and monitoring of supply voltages. The analog hardware consists of a mains power and output unit, motor controller, display and input components and temperature sensors.


Cryo V6.0 Service

5.3. Refrigeration System The Cryo V6.0 refrigerated air device draws in air at room temperature, refrigerates it, blows out the refrigerated therapeutic air. The room-temperature air is cooled by a single-stage, refrigerated cooling circuit .The heat from the refrigeration process is released to the room air. The device is capable of producing a temperature of –45°C (230-V devices) or –38 °C (120-V devices) very quickly and maintaining this continuously, resulting in a released air temperature of no more than approximately –30°C. The refrigeration system contains the following components (for the layout in the device seeFigure 10 and Figure 11): Kühltemperatur erreicht betriebsbereit Total load of cooling temperature ready status

CPU Abschaltung Switch off

Sicherheitsdruckwächter Safety pressure controler max. 28 bar Kühlmittel gasförmig Gazeous cooling agent

Kondensator C ondenser

ca.60°C

Kompressor Compressor

max. 80°C ca.60°C

ca.-5°C

ca.12-15 bar

ca.0,3-0,4 bar ca.-17°C

Kondensatorlüfter Condenser fan Druck Pressure

Abluft Output air

Therapieluft Therapy air

Temperatur Temperature

ca.20°bis24°C

Kühlmittel flüssig Liquid cooling a gent

Überhitzungsmessung Overheating m easurement

Therapielüfter Therapy fan

Filtertrockner Filter/Dryer

Verdampfer Evaporator

ca.-38°bis-42°C ca.12-15 bar

Hochdruck/High pressure

ca.0,3-0,4 bar Niederdruck/Low pressure

Thermostatisches Expansionsventil Temperature control expansion valve

Figure 1

5.3.1. Compressor The compressor (hermetically sealed in a steel housing) extracts overheated refrigerant vapor from the evaporator. An additional compression step increases the pressure of the refrigerant vapor (to approx. 15 bar) and the temperature (to approx. 60 °C. A temperature sensor monitors the compressor temperature and switches it off at 80 °C. The compressor is fitted with a special start-up device to ensure that it starts even at a high pressure difference.

5.3.2. Securit y Pressure Control A manometer is installed in the refrigeration system between the compressor and the condenser. It shuts down the compressor if the pressure exceeds 28 bar.


Cryo V6.0 Service 5.3.3. Condenser The heated refrigerant is cooled in the condenser at a steady pressure (to approx. 20 °C) to liquefy it. This process is assisted by a radial fan located below the condenser. It draws in the room air behind the dust filter through the condenser (compression heat is absorbed) and expels it to the outside. 5.3.4. Filter Dryer The filter dryer collects residual humidity, solder residue and dirt to prevent blockage of the expansion valve. 5.3.5. Thermostati c Expansion Valve The pressure and temperature are reduced at the expansion valve (from approx.15 bar / 20 °C to approx. 0.3 bar -> -45 °C /-38°C (110V device)). The precise quantity of liquid refrigerant that can evaporate completely during the heating process is injected into the evaporator. The injected quantity is regulated by a preset overheating temperature (approx. –17 °C), which is measured at the evaporator output and coupled back to the expansion valve. 5.3.6. Evaporator Heat is extracted from the evaporator and thus the therapy air by evaporation of the refrigerant. The roomair drawn into the therapy fan is available as refrigerated therapy air at the outlet of the application tube. A defrost drain is installed at the bottom of the evaporator housing to drain defrosted water. Thedefrosted water flows through a tube to a container at the back of the device. 5.3.7. Refrigerant The refrigerant R507 consists of an azeotropic mixture with an ozone destruction potential of “0”. R507 is nonflammable and non-toxic. There is danger of suffocation if the volume in the air exceeds approximately 12%. There is 960 g of R507 in Cryo V6.0.

5.4. Safety Measures The Cryo V6.0 refrigerated air device has numerous hardware and software safety features for the safety of patients and users. The main switch also includes an automatic circuit-breaker that switches off the device in case of malfunction. Dangers that may arise from undefined control conditions or functional errors in the device are prevented by various safety circuits. A pressureswitch monitorsthe high pressure size of the refrigeration system and triggers the device controller to shut down all activities if the limit value of 28 bar is exceeded. A temperature monitor prevents compressor overload and overheating. Ii is also protected by an integrated overload protection in the compressor. If the device malfunctions, the software initiates a controlled shutdown of the device by setting all modules to a safe status and indicating the fault with a warning sound. The reason for this action is shown on the display by an error message.


Cryo V6.0 Service The device runs a self-test when switched on to check all important components. The 5V operating voltage is also checked. If a fault occurs, a fault display will be shown. The device can only be switched off in this case. If the processor operating voltage is not 5 V, it will remain on reset continuously. The device cannot be reactivated. The processor functions are monitored by a watchdog device. It monitors the program operation and initiates a processor reset in the event of malfunction (such as an endless loop).

5.5. Technical Data Operating voltage: Powerconsumption in stand-by mode: Mains fuses: Noise emission (max.): Protection class: MedGV(medical devices act): MDD/MPG: Treatment tube length: Ambient temperature in operation: Housing dimensions: Height: Weight: Packaging:

220-240V, 50Hz/60Hz 100-120V, 50/60Hz 1-1.2 kW max. approx. 260 W 16A, slow-blow power system switch 70 dB(A) IEC 601-1, Class 1, Type B Group 3 Class IIa 180 cm +10 °C to +35 °C W390 mm D 680 mm 75 mmrollers 100 mmrollers 55 kg the device should only be shipped in the original packaging

H 645 mm H 660 mm

5.6. Accessories Only original accessories from Zimmer Elektromedizin should be used. If accessories are combined, note the approved combinations and the relevant legal regulations. If third-party accessories are used, this will result in a new medical system and the user will be solely responsible for the correct combination or modification.


Cryo V6.0 Service

6. Block Diagram Main switch (S1)

PC B RS 232

Main fuse (F1)

Buzzer (H1)

Trafo1+2

J8

J4

Keyboard

J5/ J6

Display

Line filter (Z1)

Relay

J1

µC User Interface

Condensor fan (M2)

Capacitor (C100)

Relay J1 X1 J1

Compressor starting circuit K1

Optocoupler

Compressor (M1)

Cooling circuit

J9

J2

J3

J12

J6

Therapy fan (M3)

Temperature cooling circuit (P3)

Water tank control switch (P4)

pressure switch (P5)

Vaporizer

J10

Temperature Compressor (P1)

Temperature Vaporizer (P2)

Figure 2 (230V/250V devices)

Main switch (S1)

PC B RS 232

Main fuse (F1)

Buzzer (H1)

Trafo1+2

J8

J4

Keyboard

J5/ J6

Display

Line filter (Z1)

Relay

J1

µC User Interface

Condensor fan (M2)

Capacitor (C100)

Relay J1 X1 J1 Optocoupler

Compressor (M1)

Cooling circuit

J9

Temperature cooling circuit (P3)

J2

J3

J12

J10

Therapy fan (M3) Water tank control switch (P4)

pressure switch (P5)

Vaporizer

J6

Temperature Vaporizer (P2)

Temperature Compressor (P1)

Figure 3 (115V device) 10 R:\Dokumente\Geräte\Cryo6\Englisch\Service\Service Handbuch Cryo V6.0.doc

Cryo V6.0 Service

7. Problem Solvi ng 7.1. Starting Problems 7.1.1. The device does not r un; the dis play is dark and does not respond to k ey presses. Ø Ø

Ø

Plug in power cable. The main switch is also an automatic circuit-breaker that may switch off the device immediately at low mains voltages. If the device does not start up after several attempts, contact a qualified service technician (a separate power supply for the Cryo V6.0 may be necessary). The device display is operating and precooling menu is displayed but the compressor does not start. Please contact our customer service.

7.1.2. Low Cooli ng Power Ø Ø Ø Ø Ø Ø Ø

Ø

Start a defrosting process. Check the location of the device. It must not be too close to heat sources (radiator, sauna, etc.). Minimum distance from walls: 0.5 m Increased humidity and room temperatures over 30 °C may affect the refrigeration output. Devices with strong electromagnetic fields (x-ray and diathermal devices) may influence the function of the Cryo V6.0. The air output is too weak. Detach the therapy tube from the device and check it for blockage by blowing through it. Empty the condensate container and run a defrosting process. If no water is found in the condensate container the drainage tube is blocked. Attach the therapy hose and repeat therapy mode several times in succession. The pressure build-up in the evaporator may clear the drainage tube, otherwise remove the drainage tube (see Chap. 12.3). If the above measures are not successful, please contact customer service.

7.1.3. “ Condensate cont ainer full” message appears on the display A new therapy cannot be started. Follow the directions on the display and drain the condensatecontainer, which is on the front of the device. When reinstalling the condensate container in the device make sure that the container is pushed in completely and locked in position.

7.1.4. “ Clean filt er” message lights Clean the air filter (metal filter) from the outside. Larger dirt particles can be easily removed by surface vacuuming. The filter display will indicate that cleaning is required every 150 hours. After cleaning the filter the signal can be reset by pressing the OK button.


Cryo V6.0 Service

7.1.5. Error Messages Important hardware components are tested while the device is starting up and at times while the device is operating. If an error is detected, the treatment session will be stopped, all inputs and outputs prevented and an error message will be displayed in the top line of the display. An acoustic warning will also be sounded and repeated every three seconds. Ø

Ø

Many errors can be resolved by shutting off the device, waiting 5 seconds and re-starting the device. These errors are referred to as fleeting errors, which do not influence continued operation of the device. If the same error occurs repeatedly, please prepare a detailed description of the error. Inform the customer service or use the attached service report. Give it to a field representative or send it directly to the factory. If error messages indicating excessive temperature or pressure occur, the device should not be switched on again for 30 minutes because this is an excess temperature or pressure situation. The Cryo V6.0 requires time to cool down. This may be caused by high outside and room temperatures that affect the refrigeration capacity. If the error occurs again in a short time, please contact customer service.

Possible error messages: Ø Ø

UNKNOWN ERROR: EEPROM data lost:

Ø

EEPROMfault: Overpressure in refrigeration system:

Ø

Temp. sensor board fault

Ø

Temp. sensor compressor fault

Ø

Temp. sensor evaporator fault:

Ø

Temp. sensor in refrigeration systemfault:

Ø Ø

Low board temperature: High board temperature Lowcompressor temperature

Ø

High compressor temperature

Ø

High evaporator temperature

Ø

High evaporator temperature

Ø

Low refrigeration systemtemperature

Ø

High refrigeration systemtemperature

Ø

Ø

Error is not explicitly defined in the system The data stored in the EEPROM has been lost because of external influences (e.g. EMC interference). This means that the software must be reinstalled The processor system cannot access the EEPROM An error in the refrigeration systemhas caused an overpressure that has caused a safety shutdown. The cause for this may be a non-functional condenser fan, a blockage in the refrigeration system or high ambient temperature The temperature sensor on the board does not supply data to the processor system The temperature sensor mounted on the compressor is not sending data to the processor system The temperature sensor mounted on the evaporator is not sending data to the processor system The temperature sensor mounted on the refrigeration system is not sending data to the processor system The temperature on the board has fallen below –10 °C The temperature on the board has risen above 60 °C The temperature at the compressor housing has fallen below –10 °C The temperature at the compressor housing has risen above 80 °C The temperature in the evaporator has fallen below –52 °C The temperature in the evaporator housing has risen above 60 °C The temperature at the refrigeration system has fallen below –10 °C The temperature at the refrigeration systemhas risen above 80 °C


Cryo V6.0 Service

7.2. Service Report Seri al no .: Soft ware Versi on Date/signature Name

........................................... ........................................... ........................................... ...........................................

Customer Information Customer: ..............................................................

Date: ............................

Description of fault:

................................................................................................................................................................................................ ................................................................................................................................................................................................ ................................................................................................................................................................................................ ................................................................................................................................................................................................

Occurrence of fault:

once

several times

frequent

always with

............................................................................................................ Under the following conditions:

after switching on

with a warmdevice

during treatment (after ………….. minutes) Other: ....................................................................................................................................………….............................................

Special environmental conditions: Humidity:............... Temperature:............... Power connection:........………………………….................................................. State of air filter:....................................................................................……………………..................................................... Other:.............................................................................................................................................................…..................... Prior repairs and installed spare parts (name, serial number):

................................................................................................................................................................................................ ................................................................................................................................................................................................ Other notes:..........................................................................................................……………..............................….............. .............................................................................................................................................…...............................................


Cryo V6.0 Service

8. Accessory List If accessories are combined, note the approved combinations and the relevant legal regulations. If third-party accessories are used, this will result in a new medical system and the user will be solely responsible for the correct combination or modification.


Cryo V6.0 Service

9. Service Mode 9.1. Opening Service Mode Various service programs have been implemented for the test field and subsequent testing of the device. This program level can only be opened by entering a 4-digit password. The password (secured by Zimmer) can be input after selecting the “Service” button (Figure 4), and the input is confirmed by pressing OK.Then the program switches to the service level (Figure 5), in which the functions of individual components can be tested. Navigation in the service menu is similar to operation in standard operation and is not described in detail here. Please enter password: [............]

OK

Start/ Stop 1

2

3

4

Figure 4

OK

Freeze-over simulaton Freeze-over simulation Cryo devie type Cryo device type Componet Rutime Coute Component Runtime Counter Manual component control Manual component control Automa tic S ervice Progra m S01 Automatic Service Program S01 Automa tic S ervice Progra m S02 Automatic Sevie Program S02

Start/ Stop Back

Select

Figure 5


Cryo V6.0 Service

9.2. Freeze-over Simul ation Freeze-over simulation at condenser ?

Freeze-over simulation at condenser?

OK

Start/ Stop Yes

No

Figure 6 In standard operation an hour meter monitors how long the device operates continuously without being switched off. After more than 24 hours an information message is shown on the display to prompt the user to run a defrost cycle. This function can be enabled and tested by selecting “Freeze-over Simulation” in the menu. When “Freeze-over Simulation” is enabled and the user returns to the standard therapy level the warning message to defrost must appear on the display. The “Freeze-over Simulation” is disabled when the device is switched off.

9.3. Cryo Device Type Setup parameters corresponding to factory default values can be set in this menu item depending on the type of use of the device. ---Cryo-THERM Cryo-DERMA Cryo-PHYSIO

OK

----

Start/ Stop Back

Select

Figure 7 Cryo-THERM: design stage of device currently not implemented and cannot be selected Cryo-DERMA: sets the therapy parameters to the values defined for laser treatment. Cryo-PHYSIO: sets the therapy parameters to the values defined for physical therapy.

9.4. Hour Meter As in the service level the hour meters for the various components are shown. The meters for the individual components can also be reset to 0 in the service level, for example, if a component is replaced.


Cryo V6.0 Service

9.5. Manual Component Contr ol In this program menu every component can be actuated and controlled individually. The status of the control inputs (temperature values, etc.) is also displayed and can be monitored.

OK

KOM 50°C

VER -15°C

KRE 30°C

PCB 22°C

KOM = 0

CLR = 16

TLR = 800

HZG = 0

P=0

ExO = 0

ExI = 0

ExS = 0

f = 50Hz Compressor

Start/ Stop Cond.-Fan

Th.-fan

Heating

Figure 8

-

-

-

-

The component (compressor, condenser fan, therapy fan) is started or stopped by pressing the relevant button. The speed of the condenser fan can be increased by pressing and holding the OK button and pressing the condenser fan button once at the same time. Every time the condenser fan button is pressed the speed is increased one step. The speed of the fan can be reduced by pressing and holding the Start/Stop button and pressing the condenser fan button once at the same time. Every time the condenser fan button is pressed the speed is reduced one step. The speed of the fan can be increased by pressing and holding the OK button and pressing the therapy fan button once at the same time. Every time the therapy fan button is pressed the speed is increased one step. The speed of the fan can be reduced by pressing and holding the Start/Stop button and pressing the therapy fan button once at the same time. Every time the therapy fan button is pressed the speed is reduced one step. This menu can only be closed by pressing the OK and the Start/Stop buttons simultaneously.


Cryo V6.0 Service Legend for Figure 8: Display

Meaning

Values

KOM 50 °C

Display of compressor temperature

Tmin = -10 °C Tmax= 80 °C

VER –5 °C

Display of temperature in evaporator


Display of temperature of refrigeration system; in standard mode the speed of the condenser KRE 30 °C fan is regulated depending on this temperature. The higher the temperature the faster the condenser fan Display of board temperature; it is measured near the power parts of the board (load relay, PCB 22 °C transformers, etc.) and represents the maximum temperature on the board. KOM = 0

CLR = 0

TLR = 800

HZG = 0

P=0

ExO = 0 ExI = 0 ExS = 0 f = 50Hz

Status of compressor

Status of condenser fan

Status of therapy fan

Tmin = -10 °C Tmax= 100 °C


Solutions If the compressor temperature exceeds the limit value this indicates inadequate cooling of the compressor. Clean the filter at the back of the device If the temperature does not reach the specified set temperature even after defrosting and extended cooling time (> 30 min.), there is a fault in the refrigeration systemor its actuation relay on the board.

-

If the temperature exceeds the upper limit value the air filter is dirty or the ventilation duct under the device cover is blocked.

0 = compressor off 1 = compressor running

If the compressor does not start, check electrical connections and start-up current limitation. If the fan does not start, check the electrical The fan speed can be connections. manually controlled in If the fan runs continuously at max. speed, 0 – 23 steps. the frequency detection on the board may be faulty. The speed is shown in steps of 50 from 0– 1000; the displayed If the fan does not start, check the electrical values do not always connections to the fan. correspond to the speed.

Not in use Status of pressure-relief valve in refrigeration system. Excessive pressure in the refrigeration system triggers the valve

If the valve is triggered first check the 0 = pressure OK function of the condenser fan; it is required to 1 = pressure too high draw off heat from the refrigeration system. (> 25 hPa) If the fan is OK, the refrigeration system may be blocked.

Not in use Not in use Not in use Detection of main frequency

f = 50Hz f = 60Hz

If an incorrect frequency is shown, check that the power supply frequency is stable. If it is, the frequency detection on the board may be faulty.


Cryo V6.0 Service

10. Troubleshoot ing If you are here, you have not been able to resolve your problem with the information in chapter 1.4. ProblemSolving. It is not a user error but probably an equipment error (defective hardware or a defective part in the refrigeration system). Important hardware components are tested while the device is starting up and at times while the device is operating. If an error is detected during this process, active therapy is stopped, all inputs and outputs are disabled and an error message is output. An acoustic warning will also be sounded and repeated every three seconds. These error measures protect the patient by bringing the device into a safe status with all components switched off. The error messages are shown in plain text on the top line of the display (status line). Therapy is no longer possible; the device canonly be switched off. Overpressure circuit Overpressure Cooling Colig circuit

P2

7

10:00

OK

Start/ Stop

Figure 9 Many errors can be resolved by shutting off the device, waiting 5 seconds and re-starting the device. These errors are referred to as fleeting errors, which do not influence continued operation of the device. If an overtemperature error of a component or an overpressure error in the refrigeration system is indicated, the device should not be switched on again for at least 30 minutes because the temperature or pressure has been exceeded. The Cryo V6.0 requires time to cool down. This may be caused by high outside and room temperatures that affect the refrigeration capacity.


Cryo V6.0 Service

10.1. Start ing Problems The device does not switch out of the “Precooling” menu and the status bar that displays the cooling process remains static without changing its value. I.

Compressor test: switch to manual component control in the service level and switch on the compressor as described in 9.4. Ø Thecompressor does not start: compressor is faulty or load relay or actuator on the board is faulty. Replace load relay or board.

II.

Refrigeration test 1. Run device for half an hour 2. Switch to manual component control (9.4) and start therapy fan and run at maximumspeed. Ø If cold air comes out, a faulty evaporator sensor is the cause of the long flashing; it must be replaced Ø If uncooled room air comes out, the refrigeration systemis faulty.

III.

Refrigeration test 1. The function of the evaporator sensor can be tested in the manual component control (9.4). Switch the condenser fan to setting 10 and then switch on the compressor. The temperature gauge must now count down to approx. –38 °C (110Vdevices) or -45 °C (230Vdevices). If the temperature gauge remains still, jumps back and forth or does not count down, replace the evaporator sensor. 2. If the temperature gauge only moves between values of approx. +5 °C and -14 °C, the refrigeration system is faulty. It may be blocked or refrigerant may have been lost. In this case the fault must be located by a refrigeration technician and repaired.

10.2. Problems without error message I.

No air is blown out or the air streamis too weak: Ø Disconnect the therapy tube from the device and blow through it to check for blockage, holes or compression points. Ø Check therapy fan function in manual component control (see 9.4 ) Ø Empty the condensate container and run a defrosting process. If no water is found in the condensate container the drainage tube may be blocked. Ø Attach the therapy hose and repeat therapy mode several times in succession. The increased pressure in the evaporator may clear the drainage tube.

II.

If there is oil leaking under the Cryo the fault is in the refrigeration system(compressor fault, leakage in refrigeration system, etc. ). Call a refrigeration mechanic or contact Zimmer Elektromedizin.

10.3. EEPROM write error It is not possible to write at least one cell of the EEPROM correctly. Device-specific parameters such as pitch, volume, language, etc. are stored in the EEPROM. Remedy: Ø Reflash program Ø Replace CPU board


Cryo V6.0 Service

10.4. WATCHDOG error This error indicates that the monitoring systemfor program crashes integrated in the microprocessor has been activated. If this error occurs sporadically, this indicates external sources of interference. If it always occurs at the same place, this generally indicates a program error. Remedy: Ø Replace program (EPROM) (2.3.2) Ø Replace CPU board (2.3.4.)

10.5. Temperature Sensor (Evaporator) The sensor shows temperature values outside the range of -50 °C and +55 °C. The cause of this may be a faulty sensor, cable or CPU board. Remedy: Ø Check the sensor cable and the terminals for defects (cracks, oxidation, contact problems) Ø Replace sensor Ø Replace CPU board

10.6. Temperature Sensor (Compressor) The sensor shows temperature values outside the range of -20 °C and +110 °C. The cause of this may be a faulty sensor, cable or CPUboard. Remedy: Ø Check the sensor cable and the terminals for defects (cracks, oxidation, contact problems) Ø Replace sensor Ø Replace CPU board

10.7. Refrigeration System Temperature Sensor The sensor shows temperature values outside the range of -20 °C and +110 °C. The cause of this may be a faulty sensor, cable or CPU board. Remedy: Ø Check the sensor cable and the terminals for defects (cracks, oxidation, contact problems) Ø Replace sensor Ø Replace CPU board

10.8. Com pressor Temperature > +80 °C This fault occurs if the compressor is overheated. This fault may occur after repeated long therapy cycles at high room temperatures by, e.g., overload. Remedy: Ø Clean air filter (vacuum cleaner) Ø Check function of condenser fan and clean it (vacuum cleaner or compressed air) Ø Check compressor temperature sensor (see 15.4) Ø Check compressor in manual component control (possibly change operational capacitor) Ø If the fault occurs frequently, the problem is in the refrigeration system (iced, dirty, etc.). Call a refrigeration technician or contact Zimmer Elektromedizin. 21 R:\Dokumente\Geräte\Cryo6\Englisch\Service\Service Handbuch Cryo V6.0.doc

Cryo V6.0 Service

10.9. Overpressur e > 2800 kPa This fault occurs if the pressure on the hot-gas side exceeds the approved value (> 2500 kPa/28 bar). This fault may occur after repeated long therapy cycles at high room temperatures by, e.g., overload. Remedy: Ø Clean air filter (vacuum cleaner) Ø Check function of condenser fan and clean it (vacuum cleaner or compressed air) Ø If the fault occurs frequently, the problem is in the refrigeration system (iced, dirty, etc.). Call a refrigeration technician or contact Zimmer Elektromedizin.

10.10. Incorrect Mains Frequency <45Hz or >65Hz This fault occurs if the mains frequency is out of range (45 Hz …65 Hz) or if the mains supply is not sinusoidal for more than three half-waves. Remedy: Ø Check mains supply Ø Check power supply Ø Replace CPU board


Cryo V6.0 Service

11. Assembly 11.1. Device Structure

Air outlet

Safety valve

Compressor Combi dryer

Evaporator Condenser Drip tray

Condenser fan

Figure 10

Therapy fan

Start-up electrics (230V/250V devices only)

Figure 11 23 R:\Dokumente\Geräte\Cryo6\Englisch\Service\Service Handbuch Cryo V6.0.doc

Cryo V6.0 Service

12. Overview 12.1.1. Spare Parts Handling Electronic spare parts, such as boards, must be handled in accordance with the general ESD guidelines (electrostatic discharge) The electrical parameters of new modules (e.g. CPU, etc.) supplied by Zimmer Medizinsysteme have been preset at the factory. All boards must be inspected before installation (shipping damage, etc.). 12.1.2. Required Equipm ent Ø Ø Ø Ø

A workplace with antistatic protection A digital multimeter A oscilloscope – 20 MHz (digital or analog) NSP3000 safety tester

12.1.3. Safety Notic e Do not touch modules or parts in the device when working on an open device with the power cable plugged in. Electrical cables and wires may have a voltage up to 240 V. Unplug power cable before opening and closing the device. Some parts of the refrigeration system may become very hot during operation (e.g. compressor, condenser) and other parts may become very cold (e.g. evaporator, thermal expansion valve) Temperatures may vary from –45 °C to +90 °C. Caution! - Do not touch parts!


Cryo V6.0 Service

12.2. Removing and A ttaching the Therapy Tube Removal: Ø In Version A of the tube connection unscrew the Allen screw on the side and pull the tube off the air outlet Ø In Version B of the tube connection it is held by a bayonet catch. è To release the tube push the connection back and turn it slightly counterclockwise. è Then pull the tube forward. Attachment: Ø In Version A push the tube on to the air outlet and screw in the Allen screw. Ø In Version B of the tube connection it is held by a bayonet catch. è To attach the tube place the connection on the air outlet and rotate until the connection can be pushed on to the air outlet. è Push the connection up as far as possible and then rotate slightly clockwise and pull down slightly.

12.3. Replacing the Condensate Drain The condensate drain is attached to the water bottle below the evaporator housing. Ø Ø Ø Ø Ø Ø Ø

Defrost the device first Remove the water bottle from the device Then release the drainage outlet with a pipe wrench The drain can now be unscrewed by hand Check the drain for blockage or faults. Clean the drain under running water if necessary or replace it if it cannot be cleaned. To install the condensate drain wind standard plumbing sealant (Teflon tape, etc.) around the thread. Screwthe drain into place.


Cryo V6.0 Service

12.4. Opening the Housing ! Caution with pri or operation: parts of the refrigeration system may still be very hot ! 1. Unplug power cable from power source. 2. Remove the condensate tray. 3. Remove the tube (see 12.2 ) 4. Remove the glass plate (see chap. X) 5. Unscrew the 4 nuts [M5] on the top of the cover and remove them with the nuts and the 4 threaded pins [M5]. 6. Removing the cover: a. Stand on the right side of the device as viewed from the front. b. Lift the cover at the back slightly (see Figure 12, step 1) and slide it forward (step 2) to free the cover from the air outlet. c. Caution! Do not li ft the cover any higher at this po int! d. Place the cover to the side on the device surface. Place a foamrubber mat under the cover to prevent it from scratching the surface of the cover. e. Pull the cable from the cable binders on the cover. f. Pull the protective conductor cable from the terminal block. 2 1

Figure 12 7. Now the cover can be placed aside. 8. Removing panels: Ø Remove the dust filter; also unplug the protective conductor cable from the terminal block. Ø Unscrew the 4 screws [M4] on the panel and remove it. Ø Unscrew the 8 screws [M4] on the back of the enclosure. Ø Unscrew the 4 screws [M4] on the front of the enclosure. Ø Lift the enclosure above the 4 wheel covers and spread it at the back and push it forward.


Cryo V6.0 Service

12.5. Closing the Housing Before closing the housing always check the following: Ø The displays and keyboard with connectors are correctly installed Ø Correct fuses are installed Ø All boards and other components are fastened in place Ø No loose parts (such as screws) in the housing Ø All foam parts installed 1. Installing cover: Ø Ø Ø Ø Ø Ø Ø

Slide the cover from the front over the base frame until it encloses the device Press the cover past the wheel covers and down until it lies on the wheel holders Screwthe 2 screws [M4] into the device at the front Screw the 6 screws [M4] into the device at the back Unscrew the 4 screws [M4] on the panel and remove it. Screw the back panel to the device with the 4 screws Install the dust filter and plug in the protective conductor to the terminal block

2. Cover installation: g. Stand on the right side of the device as viewed from the front. h. Place the cover to the side on the device surface. Place a foamrubber mat under the cover to prevent it from scratching the surface of the cover. i. Plug in the cables to the board according to their numbers j. Plug in the protective conductor to the protective conductor terminal k. Rotate the cover until it is parallel to the device and remove the foamrubber mats l. Check that all plug connectors are correctly plugged in m. Lift the back end of the cover slightly n. Slide it carefully forward so the cutout can be lifted over the air outlet. o. Slide the cover back until it is in the correct position. 3. Screw the threaded pin [M5] in and fasten the cover by screwing on the nuts [M5]. A toothed washer [M5] is required with every threaded pin. 4. Install the glass plate (see chap. X) 5. Slide the condensate tray into the opening in the front of the device.

12.6. Test Run The following is required after every Cryo V6.0 repair (module replacement): Ø Ø Ø Ø

The device must be visually inspected (loose parts, protective conductor, defrosted water container, solder points clean and solid, etc.) Device must remain standing for 30 minutes to allow the oil to collect in the compressor A tec hnic al saf ety check must be co nducted (see 16, Electrical safety) Device must pass the S01 test program (see instructions for use) If no error messages are triggered the device can be placed back in operation 1st cooling phase < 30 min O OK 2nd cooling phase < 30 min O OK 3rd cooling phase < 30 min O OK 0 min < defrost < 60 min O OK


Cryo V6.0 Service

13. Repairs and Comp onent Replacement 13.1. Electronics The controller board and motherboard components are combined on one single board. All plug connectors are sequentially numbered with J(y); there is only one sequential numbering system for the entire device for unique identification of every connector. 13.1.1. Mains Supply Side The mains supply side on the device starts at the mains socket. It is designed as a high-current type of a nonheating device socket to allow different mains cable to be supplied for different countries. The main switch is designed for mains voltages of 115 V and 230 VAC. A 15 A mains fuse is integrated in the main switch to monitor both mains cables and it provides a 2-way shutdown. The mains voltage is distributed to the individual components on the board and is monitored by fuses where necessary. The compressor is switched on and off by the µC via an ELRload relay. Further switch-on control uses a switch-on electrical system that is supplied by the compressor manufacturer (230V model) or integrated into the compressor (115 V model). The condenser fan is also controlled by the µC. This is a phase section controller, which also controls the fan by an ELR. It controls the speed of the fan depending on the temperature of the refrigeration system. The speed of the therapy fan is controlled by a 0-10 V signal, which also switches the fan on and off. The low voltage for the board is supplied by two transformers. The second transformer is supplied the technical safety reasons. The voltage generated by this transformer is used for the control voltage of the therapy fan and the switching voltage of the pressure sensor. It is electrically isolated from the low voltage of transformer 1, which supplies the voltage for the rest of the board and low-voltagecomponents. All ELR, transformers and optocouplers that connect to low voltage and mains voltage are tested with an electrical isolation of 4 kV and are defined as UL-listed components. When these components are replaced it is very important to replace them with the same types; no other types are approved.

13.1.2. L ow-volt age Side The low-voltage side of the device includes the processor section of the board with various signal inputs and outputs. The signal inputs are three temperature sensors, the safety-valve monitor, the dripper tray level monitor and the keyboard input along with an input for a sensor in the handpiece of the tube. The signal outputs are the display and the therapy fan controller, using a 0-10 V signal.


Cryo V6.0 Service

13.1.3. Board The controller and power circuit of the device are combined on one board. The controller, RAM, EPROMs, ADUs, DAUs, multiplexer, graphics controller and corresponding logic blocks are the digital components of the Cryo V6.0. The device and the treatment regime are monitored and controlled by the microprocessor with appropriate peripherals. Functions include a self-test on start-up, monitoring of limit values of critical components, including temperatures, control of function status and monitoring of supply voltages. The analog hardware consists of a mains power and output unit, motor controller, display and input components and temperature sensors. The minimum evaporator temperature in 115 V devices can be defined as –38 °C by jumper J2.

13.1.4. B oard Replacement Removal: Ø To replace the board first release and remove the cover (see 12.4). Ø Then disconnect all remaining plugconnectors from the board and unscrew the board. Installation: Ø Before installing the board check to make sure you have the board with the correct mains voltage range. The adjustment must be made manually by the soldering jumper beside fuse F5 (see Figure 13). - Jumpers BR2 and BR3 and jumpers BR5 and BR6 must be set for a board with the voltage range 90 – 120V. - Jumpers BR1 and BR4 must be set for a board with the voltage range 210 – 250 V.

F5

Figure 13 Ø Ø Ø Ø Ø Ø Ø

Soldering jumper

Screw the board into the cover. Connect all cables inside the cover. Place cover to the side of the device (foamunderneath). Connect all cables from the device. Run function test. Mount cover (see 12.5). Run function test again. 29 R:\Dokumente\Geräte\Cryo6\Englisch\Service\Service Handbuch Cryo V6.0.doc

Cryo V6.0 Service

13.2. Replacement of Mains Filter Input Socket, Main Swit ch Removal: Ø To replace these components first release and remove the cover (see 12.4). Ø Then the specific component can be released and the replacement part installed. Installation: Ø After replacement of the component all cables in the cover must be connected. Ø Place cover to the side of the device (foamunderneath). Ø Connect all cables from the device. Ø Run function test. Ø Mount cover (see 12.5). Ø Run function test again.

13.3. Replacement of LCD and Keyboard Removal: Ø The cover must first be released and removed (see 12.4). Ø Then check whether the display and keyboard are glued or screwed in place. The keyboard and LCD are attached in two ways. The keyboard and display were glued in place in the first device series. The device must be returned to the Zimmer factory to replace the LCD or keyboard; it cannot be done by the user. Ø If the display and keyboard are screwed in place, the keyboard must be unscrewed (even when replacing the display) and the faulty components (display or keyboard) must be replaced. The display cable and the display power supply and the 4 screws [M4] that fix the keyboard and display must be unscrewed. The display and keyboard can then be removed. Ø Now the display can be replaced by unscrewing the 2 screws [M4]. Installation: Ø After replacement of the display and/or the keyboard attach the keyboard to the cover with the 4 screws [M4]. Make sure that the dust seal is correctly positioned. Ø Place cover to the side of the device (foamunderneath). Ø Connect all cables from the device. Ø Run function test. Ø Mount cover (see 12.5). Ø Run function test again.


Cryo V6.0 Service

14. Refrig eration System Components 14.1. Refrigeration System The refrigeration systemis a reliable complex system. Only refrigeration technicians may perform repairs on the refrigeration system. If faults are detected in the refrigeration systemplease contact customer service or use the enclosed service report (see 7.2). Send it directly to the factory.

14.2. Evaporator Sensor Replacement Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø

If the device was recently in operation, run a defrost first (see user instructions). Remove the cover (see 12.4) and place it to one side. It is not necessary to remove the panels. Release the front fastening bracket. Remove the foam insert in the front section (where the evaporator sensor cable was). Pull the evaporator sensor carefully by the cable out of the evaporator. Push a new evaporator sensor into the opening. Seal the evaporator with some silicone. Replace the foam insert. Screw the front fastening bracket in place. Place cover to the side of the device (foam underneath). Connect all cables from the device. In the service menu switch to manual component control and check the sensor temperature display. Now run complete function test. Mount cover (see 12.5). Run function test again.

14.3. Replacement of Compressor Temperature Sensor Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø

Remove the cover and panel (see 12.4) and place it to one side. Release the temperature sensor from the evaporator by pulling the Armaflex adhesive band. Pull the cable of the compressor temperature sensor out of the device by releasing all cable clips and removing the cable. Pull the cable of the new temperature sensor into the device. Fasten the sensor to the compressor by attaching a new Armaflex adhesive band. Run the cable into the device and attach it to the places provided with the cable clips. Place cover to the side of the device (foamunderneath). Connect all cables from the device. In the service menu switch to manual component control and check the sensor temperature display. Run function test. Mount cover (see 12.5). Run function test again.


Cryo V6.0 Service

14.4. Replacement of Refrigeration System Temperature Sensor Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø

Remove the cover and panel (see ?) and place it to one side. Release the temperature sensor from the evaporator by pulling the Armaflex adhesive band. Pull the cable of the compressor temperature sensor out of the device by releasing all cable clips and removing the cable. Pull the cable of the new temperature sensor into the device. Fasten the sensor to the compressor by attaching a new Armaflex adhesive band. Run the cable into the device and attach it to the places provided with the cable clips. Place cover to the side of the device (foamunderneath). Connect all cables from the device. In the service menu switch to manual component control and check the sensor temperature display. Run function test. Mount cover (see 12.5). Run function test again.

14.5. Replacement of Therapy Fan Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø Ø

Remove the cover and panel (see ?) and place it to one side. Release the two brackets under the foam. Open the air duct by reaching into it from behind and lifting it. Pull the plug connector off the therapy fan. Reach under the therapy fan and pull the connector off. Lift the fan out of the foam. Align the gasket to the evaporator housing. Insert new fan by pressing the gasket together with a thin steel plate and sliding the fan along the plate to insert it. Connect plug connectors Position air duct cover. Screw on the two fastening brackets. Mount panel and cover (see 12.5).


Cryo V6.0 Service

15. Pin Assignments and Compo nent Names Name F1 J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J12

Note Cryo6 main fuse Board mains voltage outputs for all AC devices Board compressor temperature sensor Board evaporator temperature sensor Board keyboard terminal Board display signal terminal Level sensor terminal Board external control in/out Board mains voltage input Board therapy fan control signal Board pressure sensor Board condenser fan temperature sensor

J13

Board RS232 port for firmware update

J14

Board display power supply terminal

J18 J19 J20 J23 J24

Board K1 board side K1 compressor side terminal Compressor terminal Condenser fan terminal Therapy fan terminal Plug connector terminal on glass keyboard

J25 J26

External In/Out interlock terminal on device

J27 J28

Level sensor terminal Pressure monitor terminal

Name K1 M1 M2 M3 P1 P2 P3

Note Compressor start-up current limitation Compressor Condenser fan Therapy fan Compressor temperature sensor Evaporator temperature sensor Condenser fan temperature sensor

P4

Water level sensor

P5

Pressure monitor

S1

Main switch

Z1

Mains filter

C100

Capacitor for condenser fan phase shifting

15.1. Board mains input connection J8 1 2

Mains filter Load N Load P

Signal Zero Phase


Cryo V6.0 Service

15.2. Power Side Connections J1 1 2 1 2 3 4

Plug/pin J20/2 J20/1 J18/2 J18/1 J23/2 J23/1

Component Compressor K1 start-up electrics Compressor K1 start-up electrics Compressor K1 start-up electrics Compressor K1 start-up electrics Condenser fan M2 Condenser fan M2 Primary side heater isolator transformer T1

Signal Zero Phase Zero Phase Zero Phase

5

J21/2

6

J21/1

Primary side heater isolator transformer T1

Phase

7 8

J24/4 J24/5

Therapy fan M3 Therapy fan M3

Zero Phase

Note for 115V device for 115V device for 230V device for 230V device

Zero

15.3. Evaporator temperature sensor connection J3 1 2 3 4

Signal GND Signal 5V Spare (for I²C)

15.4. Compressor temperature sensor connection J2 1 2 3 4


15.5. Refrigeration system temperature sensor connection J12 1 2 3 4


15.6. Keyboard connection J4 1 2 3 4 5 6 7 8 9 10

J25 1 2 3 4 5 6 7 8 9 10

Signal GND 5VDC Key 0 Key 1 Key 2 Key 3 Key 4 Key 5 spare spare


Cryo V6.0 Service

15.7. Display control signals connection J5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Signal Reset (/RES) Master (/CSA) Slave (/CSB) Data or command selection (A0) Serial data (SCL) Serial clock (SI) Power supply (3V) GND DC/DC converter DC/DC converter DC/DC converter DC/DC converter DC/DC converter DC/DC converter Crystal power supply (3V) Crystal power supply (3V) Crystal power supply (3V) Crystal power supply (3V) Crystal power supply (3V) N.C. Selection for voltage setting N.C.

15.8. Display power supply connection J14 1 2

Signal VCC GND

15.9. Level sensor connection J6 1 2

Signal GND GND

15.10. Board external control in/out connection J7

J26

1

1

2 3 4

2 3 4

Signal Interlock In (+), 5-20V >10mA Interlock In (-) Interlock Out Interlock Out

15.11. Therapy fan control line connection J9 1 2

Therapy fan 1 2

Signal GND Signal


Cryo V6.0 Service

15.12. Pressure sensor connection J10 1 2

Signal 12V Signal

15.13. Firmware update connection J13 1 2 3 4 5 6 7 8 9 10

Signal 5V MD2 RX TX N.C. Reset MD0 GND N.C. N.C.

15.14. Compressor start-up electrics connection J19

Plug/pin

1

J20/1

2

J20/2

Compon ent Compressor K1 start-up electrics Compressor K1 start-up electrics

Signal Zero Phase


Service Manual Cryo V6 ENG

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