Service Manual Documentation Plan by olliegoblue26

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									 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

								
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