Aseptico ADU-40CF Command Air Troubleshooting guide

OPERATIONS,
SERVICE MANUAL
& PARTS LIST
ADU-40CF
NSN: 6530-01-456-5380
P.O. Box 1548 Woodinville, WA 98072-1548
1-800-426-5913 * 425-487-3157 * Fax: [phone]
email: [email protected] * Internet: www.aseptico.com
04/00
P/N 420203

Page 2
TABLE OF CONTENTS
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Items Furnished . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Preparation For Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Water Source Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Principles Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Water Delivery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Waste Water Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Daily Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Daily Functional Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Cleaning And Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Performance Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Disassembly, Repair, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Spout Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chassis Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Heating Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Intake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Spout Guide Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Preparation For Shipment & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-21
Table of Illustrations
Figure A - Open Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Figure B - Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Figure C - Pouch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Figure D - Pouch 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Figure E - Spout Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure F - Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure G - Spout Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure H - Regulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure I - Spout Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure J - Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure K - Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure L - Heating Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure M - Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure N - Intake Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure O - Electronics Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure P - Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure Q - Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Safety precautions
Warning - Improper application, adjustment or servicing can result in serious injury.
Always disconnect power source before servicing.
Warning - Do not lean on the unit. Sink structure is not designed to support human weight.
Caution - To avoid the risk of burns do not adjust the storage tank temperature control above
120 deg. Fahrenheit.
Caution - Prevent from freezing. Purge system before storage to prevent damage to lines or
pump.
Caution - To avoid damage to heating components, operate the unit only in the upright
position

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Introduction
Purpose
The ADU-40CF Command Air Portable Field Sink provides a practical water source for mobile
medical and dental operations. Both warm and cold water are available for washing and instrument
cleansing. Hands free operation makes surgical scrubs simple. The rigid stainless steel basin is
durable and is easy to disinfect. And the accessory tray allows sink-side consolidation of all instru-
ments. Light weight and compact size make the ADU-40CF easy to set-up and transport. To receive
the best service and longest life from your Aseptico product, follow the instructions detailed in this
manual.
Performance characteristics
Weight: 48 lb.
Size: 19 x 19 x 14 in. (external)
Sink flow rate: 0.68 gpm (2.2 lpm)
Max. pump discharge head: 8.3 ft (2.5 meters)
Pump self priming limit: 48 in. (1.2 meters)
Heating capacity: 1500 Watts
Tank capacity: 0.75 Gal. (2.9 Litre)
Peak water temp.: 106° F, ±7°F (41°C, ±4°C)
Items furnished
Sink unit, surgical, 120/230 Volt, 50/60 Hz, single phase.
Aluminum legs (4).
Intake and waste hoses.
Cold water, manual pump.
ON/OFF foot switch.
120V and 230V power cords.
Instrument tray (6 1/2 x 10 in.).
Grounding lug.
Alternate source regulator.
2 copies Operations/Service Manual.
Items not furnished
Jerry cans or alternate water supply.
Waste water Jerry can.
120/230, 50/60Hz, single phase electrical power supply.
Storage and handling precautions
Avoid freezing. To protect internal components, purge the sink’s tank and lines prior to
unattended periods in sub freezing conditions.

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Preparations for use and installation instructions
After removal from its original packaging the ADU-40CF will include the following items:
Component Locations:
Figure A - Open Case
Pouch 3 (plumbing pouch, in basin)
Intake hose assembly
Waste hose assembly
Cold water pump assembly
Alternate source regulator assembly
Pouch 1 (leg pouch, in lid)
Legs (4)
Pouch 2 (electronics pouch, in basin)
120V power cord
230V power cord
Foot switch
Instrument tray
1 Sink assembly
1 MIL-Spec carry case
2 Operation & Service Manuals
3 Accessory pouches
1
2
3
4
1
2
3
4
1
2
3
4
12
Figure B - Legs
Figure C - Pouch 2
Figure D - Pouch 3

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Assembly
1. After removing the ADU-40CF Command Air Field Sink from its original packaging, unfasten all
perimeter latches and remove the cover. Locate the three accessory pouches and lift the sink from
the carry case. Reference figure A
2. Remove the four collapsible legs from the leg pouch and unfold. Make sure the locking dowel
engages completely. Insert the legs into the guide tubes on the underside of the sink chassis and
twist to engage the lock-pin and secure.
3. Raise the sink spout to the fully extended
position.
4. Remove the contents of the plumbing pouch. Attach the intake hose assembly to the quick
connect, labeled “WATER IN” on the underside of the sink. Immerse the hose weight in the
source jerry can (not provided) to the preset distance and secure the line using the attached push-
on cap. Reference figure F
5. Attach the waste hose to the underside of the sink. Place the
opposite end in a waste water jerry can (not provided). Secure
the line using the push on cap. Reference figure F
6. If desired, attach the components of the cold water pump
assembly to dispense cold water.
a) Unpack the manual foot pump and tubing assembly.
b) Attach the adapter spout to the sink spigot. Reference figure G
c) Place the foot pump on a level section of ground and attach the
quick connect to the Y-connector of the intake hose assembly.
Prime the lines by depressing the foot pump several times, until
water flows into the sink. Reference figure D
7. Remove the contents of the electronics pouch. Attach the
electric ON/OFF foot switch to the foot switch connector,
labeled “FOOT CONTROL”, on the underside of the sink.
Reference figure F
8. Select the appropriate power cord for the power source. Connect
the cord on the underside of the sink and secure it using the
retaining clip connector. Plug the other end into the power
source. The sink will operate on either a 120V or a 230V power
supply. The green L.E.D. by the spout will light indicating power.
Reference figure F
9. If desired, attach the instrument tray to either side of the sink.
Secure the tray with the thumbscrews.
10. The ADU-40CF is constructed with full electrical protection;
however, provisions have been made to attach an external ground
rod (not provided) to a grounding stud on the underside of the
sink. Reference Figure F
Figure E - Spout Position
Figure G - Spout Connection
Storage Position Operation Position
Figure F - Connections

Page 6
Water Source Information
The ADU-40CF is designed to operate from jerry cans and from a variety of alternate water
sources. If the ADU-40CF is to be used with an alternate water supply, the source will determine
the required intake configuration. For operation from either a jerry can or a bladder water supply
having a pressure between -2 psi and 10 psi (a supply height ranging from 4 ft. below to 23 ft.
above the sink basin) appropriate flow rates can be generated by the sink’s internal pump.
Connection to this type of source can be made using the existing intake tube or, if required, by
disconnecting the lower section of the intake hose at the Y-connector and replacing it with the
male end of a garden hose from the source. For connection to an established water source with an
operating pressure above 5 psi, the regulator assembly is recommended. Attachment is performed
by disconnecting the lower section of the intake hose at the Y-connector and replacing it with the
regulator assembly. Reference figure H
A line from the water supply having male
garden hose threads can then be attached to
the female side of the regulator assembly.
Note: The cold water foot pump should not
be used in conjunction with a pressurized
water source.
Principles Of Operation
Water Delivery System
The water delivery system consists of the main pump, the solenoid valve, the cold water foot pump
and the alternate source regulator assembly. When the ON/OFF foot switch is depressed, the
internal electric pump moves water through the tank where it is warmed. The solenoid valve serves
as the flow control mechanism when the sink is operated from a pressurized water source. The
solenoid valve is normally closed and is actuated by depressing the foot switch. The cold water foot
pump manually delivers water from the source to the basin without warming. If required, the manual
pump may be used to partially prime the intake line. To use a pressurized water supply the regulator
assembly should be connected between the sink and the source. The regulator will reduce the water’s
flow to match the sink’s heating capacity and will dampen the effects of system pressure fluxuation.
Heating System
The Heating System is composed of the tank, the extendible spout, the level switch, the control
circuitry and the heating element. The tank is the reservoir for the water to be heated. The spout
position determines the volume of water stored in the tank. And the level switch, located at the top
of the tank, activates the heating element. To allow the level switch to actuate and begin the water
warming process, the spout must be in the extended position. The orange L.E.D. by the spout will
light to indicate that the tank is full and the warming processes is active. The control circuitry will
stop the heating process when the water temperature reaches 106 deg. Fahrenheit (41 deg.
Centigrade). Heating will resume when the water temperature falls below 97 deg. Fahrenheit (36
deg. Centigrade).
Note: Operation with the tank in a position other than its intended upright position, can cause the
level switch to give a false water level indication. A dry run condition may result, potentially
damaging the heating element. Only operate the unit with the tank upright and the spout in the
extended position.
Figure H - Regulator Assembly

Page 7
Operating instructions
Start-up procedure
Once the Set-Up is complete, prime the system by depressing the foot switch. Allow one and a half
minutes for the internal tank to fill. Release the foot switch when water begins to flow from the
spout. The orange L.E.D. by the spout will light when the tank has filled indicating that the heating
element is active. The orange L.E.D. with go out when the tank water is warmed. If desired, prime
the cold water line by depressing the foot pump several times until water flows into the sink.
To operate the sink depress the ON/OFF foot switch for warm water or the foot pump for cold water.
Water will automatically be warmed as it flows through the internal water tank. The outlet temper-
ature will vary with consumption and source temperature. As a general rule, a full tank of room
temperature water will take two and a half to three minutes to warm to the shut off temperature of
106 deg. Fahrenheit (41 deg. Centigrade).
Waste Water Management
Fluid level in the waste container should be managed in such a way as to avoid overflow. This risk is
minimal when operating from a jerry can. When operating from a source greater than the waste jerry
can, care should be taken to monitor waste water level carefully.
Shut down procedures
1. Drain all water from the sink basin and clean the drain catch. Dry components before storage.
2. Drain and disconnect the cold water supply line and the drain hose. Use the manual pump to assist
in draining the cold water supply line.
3. Disconnect the intake hose from the quick connect labeled “WATER IN” and reattach it to the
quick connect labeled “PURGE”. If the water in the reservoir is to be reclaimed, leave the
weighted end of the intake hose in the source jerry can. Otherwise, purge the water in the tank to
a waste water jerry can or the ground. NOTE: To avoid contamination, minimize intake hose
contact with waste water.
4. When water stops flowing from the tank, depress the foot switch briefly while intermittently
pressing upward on the nub of the “WATER IN” quick disconnect. This process will purge the
pump and the internal supply lines. Release the foot switch when water ceases to flow from the
intake hose.
5. Drain and disconnect the intake hose. Disinfect all hoses which have come into contact with waste
water using a dilute bleach solution.
6. Store the intake, cold water and drain hoses along with the alternate source regulator in the
plumbing pouch. Be sure to coil tubing carefully to avoid kinking. Dry components as thoroughly
as possible before storage.
7.Disconnect the ON/OFF foot switch, power cord, and instrument tray. Store these items in the
electronics accessories pouch.
8. Twist loose and remove the four sink legs. Fold and store them in the leg pouch.
9. Place the sink into the case with the sink sides aligned with the case handles. Store the plumbing
and electrical pouches in the sink basin. Lower the sink spout.
10.Store the leg pouch in the lid. Place the lid and secure all perimeter latches. Reference figure A

Page 8
Daily cleaning
All hoses which have come in contact with waste water during operation must be disinfected with a
dilute bleach or equivalent solution, prior to storage. Disinfect exposed sink parts in accordance with
conventional medical/dental practice.
Daily functional checklist
Observation of the following conditions will ensure that the ADU-40CF is functioning normally.
1. The green L.E.D. by the spout lights when the unit is connected to a power source.
2. The pump can be heard running when the ON/OFF footswitch is depressed.
3. The spout is fully extended.
4. When the tank is filled the orange L.E.D. lights indicating the heating element is operating.
5. Once primed the intake lines retain their water level when the pump is not operating.
Environmental Conditions
This laboratory equipment has received UL approval for use in the following
range of environmental conditions:
Altitude: up to 2000 m
Temperature: 0 to 40°C
Maximum relative humidity: 80% for temperatures up to 31°C decreasing linearly to 50% at 40°C
Mains supply voltage fluctuations: not to exceed ±10% of the nominal voltage
Transient overvoltages: according to installation categories I, II, and III.
Transient overvoltages for mains supply: minimum and normal category is II
Pollution degrees: 1 and 2 in accordance with IEC 664.

Page 9
Maintenance and
Servicing Instructions
Cleaning and lubrication
The external surfaces of the ADU-40CF’s chassis, spout, basin and accessory tray can be cleaned
with a commercial dental disinfectant. Sink hoses contacting waste water must be disinfected after
each session. To minimize the risk of corrosion, chlorine based cleaners should not be used to clean
the interior of the water storage tank or the sink’s legs. After a time the clear lines used in the
plumbing may develop a milky mineral deposit. This scale can be reduced by flushing the lines with
a dilute bleach or ammonium solution. External components will be sufficiently maintained by a
cleaning regiment consistent with standard medical and dental practice. Internal components do not
require lubrication or have special cleaning instructions.
Performance verification and Inspection
No specific inspection schedule needs to be maintained for this unit. Components have been
selected for their maintenance free service life. The drain catch should be cleaned after each use.
The particulate filter in the Y-connector should be checked and rinsed when water flow seems
restricted or when pump operation is labored. Verifying that the following conditions are satisfied
during operation will ensure proper function. These conditions should be verified as the final step
of any major repair.
1. The green L.E.D. by the spout lights when the unit is connected to a power source.
2. The pump can be heard running when the ON/OFF footswitch is depressed.
3. The tank fills when the footswitch has been depressed for two minutes and the orange L.E.D.
lights to indicate the heating element is operational.
4. The orange L.E.D. goes out when the peak water temperature of 106 degrees Fahrenheit (41
degrees Centigrade) is reached.
5. The orange L.E.D. relights and heating resumes when the heated water falls below a temperature
of 97 degrees Fahrenheit (36 degrees Centigrade).
6. Once primed the intake lines retain their water level when the pump is not operating.

Page 10
Troubleshooting
Problem Cause Action
Not drawing water, pump operating No water source/intake tube Add water to source/adjust intake hose
above water line.
Inline filter clogged Rinse or replace filter
Solenoid valve closed Replace
Pump seals Replace pump
Not drawing water, pump not operating Fuse blown Inspect pump, replace if required
Diode Inspect control board, replace
components or board as required
Reduced water flow rate Clogged filter Rinse filter
Not heating water, orange LED lit Heating element fuse blown Inspect control board and heating
element, replace components as
necessary
Heating element damaged Replace element
Not heating water, orange LED not lit Spout not raised Raise spout
Circuit board, thermal sensor Inspect control board and
components, replace as required
Level sensor Replace level sensor
Not heating water, green L.E.D. not lit No system power Check electrical source and connections.
Leak at spout Seal failure Replace seal
Water leak from sink bottom Internal leak Remove basin and search for leak
Tighten or replace clamps or tubing
Tank Tighten fittings