Get documents about "Service Manual Documentation Plan
Document Sample
Service Manual
Documentation Plan
Contents
Purpose of this Document .................................................................................... 1
Purpose of the Product.......................................................................................... 1
Purposes of the Service Manual .......................................................................... 1
Audience Profile .................................................................................................... 1
Task Analysis......................................................................................................... 1
Design Implications .............................................................................................. 2
Constraints.............................................................................................................. 2
Publication Organization ..................................................................................... 3
Overview by Section ............................................................................................. 3
Preface ....................................................................................................... 3
Contents .................................................................................................... 3
Figures & Tables ...................................................................................... 3
Mnemonics................................................................................................ 3
Warnings, Cautions, and Notices........................................................... 3
Unpacking & Setup ................................................................................. 4
Section 1 - Introduction........................................................................... 4
Section 2 - General Information............................................................. 4
Section 3 - Technical Specifications ...................................................... 4
Section 4 - Principles of Operation........................................................ 4
Section 5 - Circuit Theory ....................................................................... 5
Section 6 - Checkout Procedures............................................................ 5
Section 7 - Maintenance Procedures...................................................... 5
Section 8 - Troubleshooting.................................................................... 6
Section 9 - Replacement Procedures...................................................... 6
Section 10 - Repair Policy........................................................................ 6
Appendix A - Software Error Messages ................................................ 6
Appendix B - Service Parts List.............................................................. 7
Appendix C - Assembly Prints/Schematics .......................................... 7
Appendix D - OEM Schematics and Parts List .................................... 7
Index .......................................................................................................... 7
Completion Schedule............................................................................................ 8
Purpose of this Document
This document will guide the development of the service manual for the CUSA 300. It
will help ensure that the service manual meets Valleylab strategies and goals.
Purpose of the Product
The CUSA 300 is a microprocessor controlled ultrasonic surgical aspirator. It will be
used in hospitals throughout the world in a variety of surgical specialties for rapid and
selective tissue fragmentation and aspiration.
Purposes of the Service Manual
The service manual will provide:
• warnings, cautions, and notices
• unpacking and installation procedures
• product overview
• technical specifications
• functional descriptions and circuit theories
• service and maintenance requirements
• checkout and repair procedures
• troubleshooting procedures
• list of service parts
• assembly drawings and schematics
Audience Profile
The service manual will be written for trained bio-med and Valleylab service technicians
who have two-year college degrees in electronics or equivalent experience. No prior
knowledge of Valleylab products is assumed. It will be assumed that the technicians
have access to a limited set of tools which will include a multimeter or VOM which they
will use to troubleshoot to a board or assembly level.
A secondary audience will be service technicians in Valleylab service centers and
hospital bio-med technicians who have access to a full range of tools and test equipment
including an oscilloscope. The secondary audience will use the manual including the
schematics to troubleshoot to a component or subassembly level. This audience
includes technicians overseas who may not have immediate access to Valleylab parts or
service centers.
Task Analysis
The tasks that the service manual will be used for will include:
• setup and installation
• service and maintenance
• troubleshooting
• parts replacement and repair
Design Implications
The service manual will have a sturdy binder and be easy to update. These
requirements would best be met by a three-ring binder. The size of the manual will be
8-1/2 in. by 11 in. Tab pages will make the sections easy to access.
All illustrations and engineering drawings will be originated by Valleylab Engineering
in Stamford and final layout and production will be done in Boulder.
An appropriate quick reference card will also be included and a separate document with
unpacking and installation instructions is also being proposed.
Constraints
The criteria for including procedures will be based on an estimate of the components
that are most likely to fail (fuses, fans, power supplies, etc.) and which components and
subassemblies can be repaired or replaced in the field.
Other constraints include:
o Access to documents: To include circuit descriptions and parts lists from bills of
material, ASCII files will needed. Engineering drawings in a suitable electronic
format and additional documents such as test procedures, calibration
procedures, assembly procedures, and parts specification sheets may also be
required.
o Force 40 Electrosurgical Generator: The Force 40 will have its own service
manual, however it has not been determined where to put functional
descriptions and troubleshooting procedures that involve a CUSA 300
connected with a Force 40 Electrosurgical Generator.
o Design stability: The design is stable, however, changes in packaging the
design are ongoing.
o Subject matter experts: The individuals responsible for the various subsystems
of the CUSA 300 are Art Schoennan – aspiration and irrigation; Mel Hoffman
and Jim Bernitt – ultrasonic generator; Alex Kreizman – power; Alice Silverstein
– software; and Athan Efstathiou – analog interface, motherboard, and digital
CPU. Mike Coppola will be the primary source for selecting troubleshooting,
repair, and replacement procedures.
o Reviews: Dan Dragoon and Catherine Wilson will distribute review copies.
Review comments will be incorporated in the final draft.
o Information availability: Information availability is good, although there are
differing points of view about how much information should be made available
for particular procedures and individual components and subassemblies
Publication Organization
The overall organization of the manual has been set and generally follows Valleylab
convention:
Preface
Table of Contents
Figures & Tables
Mnemonics
Warnings & Cautions
Unpacking & Installation
Section 1 - Introduction
Section 2 - General Information
Section 3 - Technical Specifications
Section 4 - Principles of Operation
Section 5 - Circuit Theory
Section 6 - Checkout Procedures
Section 7 - Maintenance Procedures
Section 8 - Troubleshooting
Section 9 - Replacement Procedures
Section 10 - Repair Policy
Appendix A - Software Error Messages
Appendix B - Service Parts List
Appendix C - Assembly Prints/Schematics
Appendix D - OEM Schematics and Parts Lists
Index
Overview by Section
Procedures will be preceded by a list of tools needed. It needs to be determined if the
tool set should be metric, U.S. or both.
Preface
The Preface will introduce the service manual and briefly explain the manual’s purpose,
design, and organization.
Contents
All first, second, and third level headings and page numbers will be listed.
Figures & Tables
References and pages numbers for all the figures with cutlines and tables with titles will
be listed.
Mnemonics
A list of mnemonics will contain all terms and phrases with acronyms.
Warnings, Cautions, and Notices
All warnings, cautions, notices and symbols associated with the CUSA 300 will be listed.
All product labels will also be included.
Unpacking & Setup
Objective: To provide step-by-step instructions for unpacking and setting up the CUSA
300. Instructions for attaching the Force 40 to the CUSA 300 may also be needed. These
instructions should also be printed in a separate document and packed at the top of the
shipping container. This will enable the customer who may not have access to the
service manual to setup the system.
Topics: Unpacking the CUSA 300
Installing the CUSA 300
Removing the vacuum pump lock down bolts
Attaching the Force 40 to the CUSA 300
Checking the power connector
Ensuring proper grounding
Performing a system check
Parts supplied
Responsibility of the manufacturer
Section 1 - Introduction
The Introduction section from the User’s Manual will be used.
Section 2 - General Information
The General Information section from the User’s Manual will be used.
Section 3 - Technical Specifications
Objective: To provide customers and regulatory agencies with a complete set of
technical specifications.
The Technical Specifications section from the User’s Manual will be used. Additional
detail may be required.
Section 4 - Principles of Operation
Objective: To provide a functional overview and identify the elements of the system
that will be used to maintain and troubleshoot the CUSA 300. This information will
include connectors, pin numbers and signals, cable routing, LEDs, test points, jumpers,
and switches.
Topics: Introduction
Power Distribution System
Backplane
196 CPU
Analog
Ultrasonics
Handpiece
Irrigation
Aspiration
Bargraphs
Software
Section 5 - Circuit Theory
Objective: To provide an appropriate technical understanding as an aid to
troubleshooting and repair. Valleylab engineers will originate circuit theories for each
printed circuit board, and these will be edited for consistency.
Topics: Introduction
Power Distribution System
Motherboard
196CPU PCB
Output Stage PCB
Amplifier PCB
Analog PCB
Generator PCB
Keyboard/Control Panel PCB
LCD Module PCB
LCD Backlight Inverter PCB
LCD Controller Daughter PCB
LED Display PCB
LED Control PCB
Aspiration Flow Control PCB
Section 6 - Checkout Procedures
Objective: To provide step-by-step procedures for routine system checkout procedures.
Topics: General test information
Recommended test equipment
Mechanical inspection
Power on self-test
Handpiece test
Functional test
Current leakage and ground resistance tests
Opening the unit
Test procedures
Power supplies
Control panel
Bar graphs
LCD
Motors
Pumps
Vacuum solenoids
Generator
Wave form illustrations
Section 7 - Maintenance Procedures
Objective: To provide step-by-step procedures for routine maintenance procedures.
Topics: Routine maintenance and inspection schedule
Cleaning instructions
Storing the CUSA 300
Handpiece interface connector
Calibration procedures
Precalibration check procedure
Equipment required
Calibration procedure
Maximum and quiescent ultrasonic power calibration
Section 8 - Troubleshooting
Objective: To provide a series of steps to isolate a problem to a board level from a
limited set of symptoms. This section may be expanded to include, for example,
troubleshooting down to a limited set of components such as the transmitters and
receivers on selected PCBs.
Topics: Recommended equipment
General guidelines
Fuses
Front panel
Power supplies
Vibration
Aspiration
Irrigation
Section 9 - Replacement Procedures
Objective: To provide step-by-step procedures for replacing printed circuit boards and
major subassemblies such as power supplies. This section is subject to change based on
the costs and feasibility of replacing subassemblies. For example, when a keyboard fails,
it may be more efficient to replace the entire front panel as opposed to disassembling the
front panel to access the keyboard.
Topics: Installing a software upgrade
Recommended equipment
Replacing printed circuit boards
Replacing the main power supply
Replacing the switching power supply
Replacing the linear power supply
Replacing the solid state relay
Replacing the front panel assembly
Replacing the LCD backlight inverter
Replacing the keyboard
Replacing the irrigation motor control
Replacing the vacuum pump
Replacing a flute valve
Replacing the irrigation encoder, pump, motor
Assembly drawings with exploded views for locating critical items
Common views for locating parts
Section 10 - Repair Policy
Objective: To provide standard return, repair, and replacement procedures.
Topics: Returning equipment for service
Returning a handpiece
Returning the CUSA 300 console for service
Returning PCBs and other subassemblies
Ordering replacement parts
Appendix A - Software Error Messages
Objective: To provide a complete list of software error messages and probable causes.
This information has already been provided by Valleylab Software Engineering.
Appendix B - Service Parts List
Objective: To provide lists of replacement parts and part numbers.
Topics: The parts lists will come primarily from edited ASCII files generated from
Valleylab bills of material.
Replaceable modules: Irrigation motor
Base, Upper Irrigation motor encoder
Fan 1 Irrigation pump
Fan 2 Transformer, Isolation
Output Stage PCB Line Filter, 15 A
Amplifier PCB Time meter
Motherboard Panel, Rear Electronics
Card Guide Equipotential Ground Term
196 CPU PCB Receptacle, 9 Position
Analog PCB IV Pole, various sections
Generator PCB Keyboard, Control Panel
LCD Module PCB
LCD Backlight Inverter PCB
Switch, Circuit Breaker, 12 A
LED Display PCB
LED Control PCB
Fan Cord and Plug
Plug, Female Hospital Grade
Base, Console
Castors, 4.5 Conductive
Casters w/Brake
Pump, vacuum
Muffler
Irrigation control module
Relay, solid state 240 VAC, 10A
Fuse Block
Fuses
Power Supply MS65D
Power Supply, +/-12/15V
Shroud, Lower
Cover, Back Lower
Cavity, Footswitch
Port, Tissue Release/Contamination
Guard
Valve, Solenoid, NC
Valve, Solenoid, NO
Aspiration Flow Control PCB
300 Ancillary Items
LCD Controller Daughter PCB
Extender boards
Printed Circuit Boards: Parts lists for
printed circuit boards will be sorted by
reference designators.
Output Stage PCB
Amplifier PCB
Motherboard
196 CPU PCB
Analog PCB
Generator PCB
Keyboard/Control Panel PCB
LCD Module
LCD Controller PCB
LCD Backlight Inverter PCB (vendor
supplied?)
LED Display PCB
LED Control PCB
Aspiration Flow Control PCB
Irrigation Control Module (vendor
supplied)
Appendix C - Assembly Prints/Schematics
This section will include all the appropriate engineering drawings for the product. The
method of final production has not been determined.
Appendix D - OEM Schematics and Parts List
This section will include schematics and parts lists from OEMs. Securing permissions to
use this information will be done by Valleylab Engineering.
Index
An index of the entire manual will be compiled using the indexing features of Microsoft
WORD 5.0.
Completion Schedule
Section Task Requirements Completion
Date
Preface Write Final manual 12/23
Contents List & edit Final manual 12/23
Figures & Tables List & edit Final manual 012/23
Mnemonics Search & edit Final manual 12/23
Warnings, Cautions Edit Final manual 12/23
Unpacking & Setup Write Production units with final 12/11
shipping container
1 Introduction Edit Final approval on section 10/30
from user’s guide.
2 General Information Edit Final approval on section 10/30
from user’s guide.
3 Technical Specifications Edit Final approval on section 10/30
from user’s guide.
4 Principles of Operation Write PCB assembly drawings 11/15
Functional descriptions
Block diagrams
List of signals
5 Circuit Theory Edit Circuit theories from 12/4
Engineering
6 Checkout Procedures Write Field service support 12/11
Production version of CUSA
7 Maintenance Write Field service support 12/11
Procedures Production version of CUSA
8 Troubleshooting Write Troubleshooting meeting 11/15
Working CUSA
9 Replacement Write Field service support 12/4
Procedures Production version of CUSA
10 Repair Policy Edit Existing repair policy 10/30
A Software Error Edit Firmware error summary 10/30
Message
B Service Parts List List & edit Production bills of material 12/11
C Engineering Drawings List & edit Production release drawings 12/11
D OEM Schematics/Parts List & edit Engineering input 12/11
Index List & edit Final manual 12/23
