COUGHASSIST CA-3000 User manual

COUGHASSIST
SERVICE GUIDE
Models CA-3000, CA-3200 Models CM-3000, CM-3200

TABLE OF CONTENTS
FRONT PANEL ASSEMBLY REMOVAL..............................................................................................................3
CIRCUIT BOARD REPLACEMENT......................................................................................................................4
PRESSURE GAUGE REPLACEMENT ................................................................................................................5
PADDLE SWITCH ASSEMBLY REPLACEMENT (CA MODELS ONLY) ............................................................5
FRONT PANEL LABEL REPLACEMENT.............................................................................................................6
VALVE ASSEMBLY REPLACEMENT..................................................................................................................6
VALVE ACTUATOR MOTOR REPLACEMENT (CA MODELS ONLY)................................................................7
MOTOR BLOWER REPLACEMENT....................................................................................................................8
PROPER GROUND WIRE ASSEMBLY...............................................................................................................9
FINAL TEST PROCEDURE................................................................................................................................10
COUGHASSIST SCHEMATICS MODELS CA-3000, CA-3200………………………..……………………………12
COUGHASSIST SCHEMATICS MODELS CM-3000, CM-3200………………………..………………………..…14
Page 2 J.H. Emerson Co.

This Service Guide is for use only by qualified technical personnel.
WARNING - Always unplug the CoughAssist from any electrical power before servicing.
FRONT PANEL PARTS REPLACEMENT - Including Front Panel, Circuit Board, Pressure Gauge, Paddle
Switch (CA models only), and Front Label
The only front panel parts that may be replaced without removing the Top Cover are the six control knobs (three
on the CM models), and the Manual Control Lever on the CM models only. Each control knob is held in place by
one setscrew. The Manual Control Lever (CM models only) may be carefully pried off of the valve shaft, as it is
held in place by an interference friction fit only.
In addition, the Pressure Gauge may be “zeroed” without removing the Top Cover. The access hole directly below
the gauge is covered by an adhesive sticker, which may be removed. Zero the gauge, with the unit turned off,
using a small straight blade screwdriver. NOTE: If the gauge cannot be set to “0”, it should be replaced.
Access to all other parts on the front panel require removal of the Front Panel Assembly as follows:
Front Panel Assembly Removal
1. Remove the two flat head screws from the rear of the housing and the two pan head screws from under the
front of the housing. See Figure 1.
J.H. Emerson Co. Page 3
1
2
3
4
Figure 1
Item Part No. Description
1 811-3110 SCREW, PAN HEAD 8-32x5/8
(2 EACH)
2 325-9204 HOUSING TOP ASSEMBLY
3 813-3110 SCREW, FLAT HEAD 8-32x5/8”
(2 EACH)
4 849-3600 TINNERMAN NUT #8 (2 EACH)
2. Lift the Top Cover off of the housing.
3. Remove the two control knobs labeled “Inhale Flow” and “Inhale Pressure” on the front panel by loosening
the setscrew on each.
4. On the CM models only, remove the Manual Control Lever by carefully prying it off of the valve shaft.
5. Unscrew the three “plastite” screws holding the panel assembly to the lower housing. See Figure 2. NOTE: A
long Phillips screwdriver is very helpful for access to the three screws.

Figure 2 Item Part No. Description
1 226-7001 PLASTIC TUBE, 1/8”ID x 8”
2 829-3108 SCREW, PLASTITE #8X1/2”
(3 EACH)
3 325-0252 KNOB, MANUAL (CM only)
4 632-3004 KNOB (2 EACH)
325-9202
1
2
3
4 5
FRONT PANEL ASSEMBLY
FOR CA-3000
325-9222
FRONT PANEL ASSEMBLY
FOR CM-3000
325-9226
FRONT PANEL ASSEMBLY
FOR CA-3200
5
325-9227
FRONT PANEL ASSEMBLY
FOR CM-3200
6. Slide the panel assembly towards the front, as shown in Figure 2.
7. To completely disconnect the panel from the unit, unplug the three white circuit board connectors (a 6-pin, a
3-pin, and a 2-pin connector), and disconnect the gauge tube from the Pressure Gauge fitting. Also, to
remove the ground wire on the panel, remove the hex nut holding it on the ground stud on the panel
bracket.
WARNING – If the ground wire is removed during servicing, be sure to replace it properly upon reassembly (see
“Proper Ground Wire Assembly”). Failure to do so could result in an electrical shock hazard.
CIRCUIT BOARD REPLACEMENT
1. To gain access to the Circuit Board, first remove the Top Cover and Front Panel Assembly as described
above.
2. Remove the four control knobs (only one on the CM models) by loosening the set screw on each.
3. On the CA models only, unplug the small black circuit board connector next to the Pressure Gauge.
4. Remove the 5 nylon screws holding the Circuit Board to the panel assembly, and slide the board out.
5. To install a new circuit board, first be sure the insulator is resting on the standoffs, as shown in Figure 3,
“Circuit Board Removal”. Slide the board up to the panel, reinstall the five nylon screws, and reconnect the
small black connector next to the Pressure Gauge (CA models only). Also, reinstall the four control knobs
so that the pointers point from 0 to 5 seconds.
Page 4 J.H. Emerson Co.
Figure 3
Item Part No. Description
1 325-0252 INSULATOR FOR CIRCUIT BOARD
2 632-3004 KNOB (4 EACH)
3 805-3604 SCREW, PAN HEAD, NYLON,
8X32-1/4” (5 EACH)
325-9206
6. Whenever a new circuit board is installed, the unit must be readjusted for pressure range, as described in
“Final Test Procedure”.
CIRCUIT BOARD ASSEMBLY
FOR CA-3000
325-9223 CIRCUIT BOARD ASSEMBLY
FOR CM-3000
325-9224 CIRCUIT BOARD ASSEMBLY\
FOR CA-3200
4
325-9225 CIRCUIT BOARD ASSEMBLY
FOR CM-3200
2 3
1
4

PRESSURE GAUGE REPLACEMENT
1. To replace the Pressure Gauge, first remove the Top Cover, Front Panel Assembly and Circuit Board, as
described above.
2. Remove the four 4-40 screws holding the Front Panel Spacer to the bracket, as shown in Figure 4.
1
4
2
7
3
6
5
Figure 4
Item Part No. Description
1 510-0106 BARBED ELBOW, 1/4FPT X 1/8”
2 325-9212 PADDLE SWITCH ASSEMBLY
3 901-8003 LABEL – COVER GAUGE ADJUST
HOLE
325-9228 FRONT PANEL SPACER WITH LABEL
FOR CA
4 325-9229 FRONT PANEL SPACER WITH LABEL
FOR CM
5 501-1011 PRESSURE GAUGE WITH BRACKET
6 811-0104
SCREW, PAN HEAD, 4-40 X 1/4”
(4 EACH)
7 325-0204 FRONT PANEL SUPPORT BRACKET
3. Loosen the two hex nuts holding the gauge bracket, slide the gauge bracket aside, and remove the gauge
from the front panel bracket. NOTE: On CA models only, take note of how the Paddle Switch Assembly
wires are routed around the Pressure Gauge so they can be placed properly when the gauge is replaced.
4. To install a new gauge, first remove the clear plastic lens from the new gauge by unscrewing it from the
gauge case. Position the gauge in the front panel bracket and install the gauge bracket, tightening the two
hex nuts. NOTE: Do NOT over tighten the gauge bracket nuts. Doing so can warp the front panel bracket.
5. Replace the Front Panel Spacer and Circuit Board Assembly.
6. On CA models only, reroute the Paddle Switch Assembly wires between the gauge and gauge bracket near
the bottom of the gauge, and then around and over the top of the gauge. Reconnect the switch assembly
wires to the small black connector on the circuit board next to the pressure gauge.
PADDLE SWITCH ASSEMBLY REPLACEMENT (CA MODELS ONLY)
1. To replace the Paddle Switch Assembly, first remove the Top Cover and Front Panel Assembly, as
described above. It is not necessary to remove the Circuit Board Assembly.
2. Unplug the small black connector on the circuit board next to the pressure gauge. Slide the wires out from
the gauge bracket. Press the switch out of the panel spacer from behind.
3. To install a new switch, slide the wires through the hole in the panel from the front and press the switch in
place. Be sure to orient the switch with the wires on the top row of switch contacts.
4. Route the switch wires between the gauge and gauge bracket near the bottom of the gauge, and around
the top of the gauge. Reconnect the small black connector to the circuit board near the pressure gauge.
5. Check that the wires on the switch assembly do not extend beyond the ends of the switch contacts, but lead
directly up towards the gauge. This is necessary to ensure that the wires do not interfere with the valve
assembly.
J.H. Emerson Co. Page 5

FRONT PANEL LABEL REPLACEMENT
1. To replace the Front Panel Label and spacer, first remove the Top Cover, Front Panel Assembly and Circuit
Board, as described above.
2. Remove the four 4-40 screws holding the Front Panel Spacer to the bracket, as shown in Figure 4. Replace
with a new spacer with label.
VALVE ASSEMBLY REPLACEMENT
1. To remove and/or replace a valve assembly, first remove the Top Cover and Front Panel Assembly as
described above.
2. Disconnect the three hoses attached to the sides of the valve (two on the left and one on the right). Also,
slide the black plastic elbow off of the lower right fitting on the valve. NOTE: The connector on the valve is
fragile: be careful when removing the black plastic elbow not to exert too much side pressure.
3. Disconnect the hose adapter from the patient outlet on the right side of the unit.
4. Disconnect the four push-on electrical connectors attached to the power filter on top of the Valve Assembly.
5. Turn the unit on its side and unscrew the four rubber bumpers attached to the Bottom Panel, as shown in
Figure 5, “Valve Assembly Removal”. Also, remove the “plastite” screw in the middle of the Bottom Panel.
Remove the Bottom Panel, leaving the two green/yellow ground wires attached.
6. Unscrew the four “plastite” screws holding the Valve Assembly, as shown in Figure 5, and carefully remove
the Valve Assembly from the lower housing.
1
8
2
3
4
5
6
7
Figure 5 Item Part No. Description
1 633-3011 RUBBER BUMPER (4 EACH)
2 829-3112 SCREW, PLASTITE #8x3/4” (4 EACH)
3 730-2028 O-RING (2-028)
4 740-1008 ADAPTER, 22mm x 22mm
325-9210 VALVE ASSEMBLY, CA
5 325-9211 VALVE ASSEMBLY, CM
6 223-1009 FLEX TUBE, 9”
7 829-3108 SCREW, PLASTITE #8 x1/2” (5 EACH)
8 325-0238 BOTTOM PANEL
TO REINSTALL A VALVE ASSEMBLY
7. First be sure the o-ring is seated in the groove in the lower housing under the valve. Position the valve so
the two large holes in the bottom of the valve body align with the two locating bosses on the housing.
Reinstall the four “plastite” screws to attach the valve to the lower housing. NOTE: Be sure to use the
longer, ¾” “plastite” screws to mount the valve, not the ½” screws used on the Front Panel Assembly and
the Bottom Panel.
8. Replace the bottom panel using the four rubber bumpers with screws, plus one screw in the middle of the
panel.
9. Reconnect the hoses and black plastic elbow to the valve assembly, as shown in Figures 2 and 6. Also,
reconnect the adapter leading to the patient outlet.
Page 6 J.H. Emerson Co.

J.H. Emerson Co. Page 7
Figure 6
10. Reconnect the power switch wiring harness wires to the terminals on the left side of the power filter, black
wire to the rear and white wire to the front. Also, reconnect the main power wiring harness wires to the
insulated terminals on the right side of the power filter, black wire to the rear and white wire to the front.
NOTE: Do NOT connect any wire to the unshielded terminal on the power filter.
VALVE ACTUATOR MOTOR REPLACEMENT (CA MODELS ONLY)
On the automatic CA models only, the valve actuator motor and associated drive components may be removed
and/or replaced without removing the valve from the bottom housing. To replace the valve assembly, however, it
must be removed, as described in the section, “Valve Assembly Replacement”. Since the valve is a precision
mechanism with close tolerances, it is recommended that it not be disassembled.
1. To replace the actuator motor or drive components, first remove the Top Cover and Front Panel assemblies
as described above.
2. Remove the Power Filter from the top of the valve by removing the two “plastite” screws, as shown in Figure
7. Also, remove the screws holding the bracket to the valve, two on top and one under the actuator motor.
Remove the bracket with actuator motor. Note: the cable chain will also be loose from the assembly at this
time.
3. Replace other drive components as necessary: cable chain, large sprocket, spacer or torsion spring. NOTE:
The small sprocket on the motor shaft is held in place using a set screw and an anaerobic adhesive, and is
not designed to be removed from the shaft.
4. To remove the actuator motor, first disconnect the two terminals from the motor capacitor. Then, remove
the four binding head screws holding the motor to the bracket, and remove the motor.
Item Part No. Description
1 325-9203 BOTTOM HOUSING ASSEMBLY
2 829-2110 SCREW, PLASTITE #6 5/8” (2 EACH)
325-9218 MAIN POWER WIRING HARNESS WITH
POWER INLET
621-2004 FUSE, 3 AMP (2 EACH)
628-1110 FUSE HOLDER (2 EACH)
3
628-1109 POWER ENTRY MODULE
4 223-1009 FLEX TUBE, 9” (4 EACH)
5 325-0231 CORD WRAP (2 EACH)
6 829-3708 SCREW, PLASTITE (BLACK) #8 x 1/2”
(4 EACH)
7 325-0201 TOP HOUSING
8 829-3108 SCREW, PLASTITE #8 x 1/2”
(2 EACH)
9 325-0242 PATIENT OUTLET CLAMP
10 325-0246 MANUAL KNOB AXLE (CM only)
11 325-0255 PATIENT OUTLET
325-9219 WIRING HARNESS WITH POWER
SWITCH
12 685-9015 POWER SWITCH
13 696-4002 POWER CORD WITH HOSPITAL GRADE
PLUG
696-4003 POWER CORD WITH SCHUKO PLUG
13
7
6
5
8
1
2
3
9
4
10
11
12

Item Part No. Description
1 325-0230 TORSION SPRING
2 633-2027 SPACER
3 414-2001 CABLE CHAIN
4 325-0281 SPROCKET, LARGE
5 805-3104 SCREW, BINDING HEAD 8-32 x1/4”
(4 EACH)
6 325-0217 BRACKET, MOTOR MOUNT
7 CAPACITOR (PART OF ITEM 9
ACUTATOR MOTOR ASSEMBLY)
801-3108 SCREW, 8-32 x 1/2”
840-3100 NUT, 8-32
8
854-3100 LOCKWASHER, #8
9 325-9209 ACTUATOR MOTOR ASSEMBLY
(WITH CAPACITOR AND SMALL
SPROCKET)
10 829-3108 SCREW, PLASTITE #8 x 12” (5 EACH)
11 646-2002 POWER FILTER, 6 AMP
12 325-9201 VALVE ASSEMBLY
13 720-5005 RIBBED BUSHING (3 EACH)
Figure 7
Page 8 J.H. Emerson Co.
5. To replace the actuator motor, position it on the bracket, install the four binding head screws, and reconnect
the two terminals to the motor capacitor. Hold the bracket on the valve, and place the cable chain over both
sprockets so that the splice in the chain is roughly ½ way between the sprockets. Reinstall two “plastite”
screws in the outer two holes on the top of the bracket, and one screw on the tab below the motor.
6. After assembly, check the cable chain tension: it should be loose enough so that the two sides of the chain
may be squeezed together roughly ½ way, but not touch. If adjustment is necessary, loosen the three
screws holding the bracket, move the bracket for proper cable tension, and retighten the three screws.
Alternately, the four screws holding the motor may be loosened and the motor moved.
7. Check that the valve assembly rotates freely without any binding to both extreme positions (with the Inhale
Flow mechanism out of the way), and that the torsion spring always returns the mechanism to the middle
position.
8. Replace the Power Filter using two “plastite” screws.
MOTOR BLOWER REPLACEMENT
The motor blower assembly may be removed and/or replaced without removing the Front Panel or Valve
Assemblies. To remove the blower:
1. Remove the two flat head screws from the rear of the housing and the two pan head screws from under the
front of the housing. See Figure 1.
2. Lift the Top Cover off of the housing.
3. Disconnect the 2-pin connector on the left side of the unit leading to the motor blower.
4. Slide the black plastic elbow off of the side of the valve assembly. See Figure 8. NOTE: The connector on
the valve is fragile: be careful when removing the black plastic elbow not to exert too much side pressure.
Also remove the hose connector from the large black cap on top of the blower.
10
1
2
3
4
5
6
7
8 9
11
12
13

Figure 8 Item Part No. Description
1 325-0282 DUCT, BLOWER EXHAUST
2 325-9205 MOTOR BLOWER ASSEMBLY
3 811-5110 SCREW, PAN HEAD, ¼ x 20-5/8”
(3 EACH)
4 852-5100 LOCK WASHER, SPLIT #8 (3 EACH)
5 659-1002 MOTOR BRUSH (2 EACH)
6 745-1003
6
5
4
3
2
1
J.H. Emerson Co. Page 9
VIBRATION CONTROL MOUNT
(3 EACH)
5. Unscrew the three large screws holding the blower housing to the vibration control mounts. Lift the motor
blower assembly up and out of the housing.
6. To reinstall or replace the motor blower, reverse the steps above. NOTE: When reattaching the hose
connector to the blower cap, BE SURE not to push the connector too far into the cap.
PROPER GROUND WIRE ASSEMBLY
The green wires with yellow striping inside of the CoughAssist are electrical ground leads and serve an important
safety feature. There are two such wires attached to the bottom panel, and one attached to the front panel
bracket. In order to meet IEC, UL and CSA electrical safety requirements for construction, these leads are
attached to the device in a very specific sequence. If any of the leads are removed during servicing, they must
be replaced in the proper order as follows:
Ground Lead to Front Panel Bracket
Reattach the front panel ground lead in the following sequence:
1. External tooth star lock washer, #8
2. Ring tongue from ground wire
3. Split lock washer, #8
4. Hex nut, #8
5. Tighten hex nut securely
Ground Leads to Bottom Panel
Normally these ground wires need not be removed for any servicing, except possibly to replace the bottom
panel. If so, reattach the two ground wires to the bottom panel in the following sequence:
1. External tooth star lock washer, #8
2. Ring tongue on ground wire leading directly to the Power Entry Module
3. Split lock washer, #8
4. Hex nut, #8
5. Align ring tongue parallel to the tab on the bottom panel, towards the screw on the tab
6. Tighten the hex nut securely
7. Ring tongue on ground wire leading to the front panel
8. Split lock washer, #8
9. Hex nut, #8
10. Align ring tongue parallel to the tab on the bottom panel, towards the screw on the tab
11. Tighten the hex nut securely.

FINAL TEST PROCEDURE
After any disassembly of the CoughAssist, the unit should be tested for proper operation before being put back into
service. This test can be done without the top cover on in order to gain access to the blower pressure adjustment
potentiometers. See figure 9. However, proper precautions should be taken to avoid electrical shock if this is done.
TEST SET-UP
1. Use a rubber plug or similar object to temporarily block the Patient Connection on the front of the unit.
2. Check that the Pressure Gauge is zeroed. If adjustment is needed remove the gray dot covering the
adjustment hole, adjust using a small flat blade screwdriver, and replace the dot.
3. On all models, set the Inhale Pressure knob fully clockwise, and Inhale Flow and Pressure knobs fully
counterclockwise. On the CA models, set the Manual/Auto switch to Manual, and set each time knob to
about 1 second.
4. Plug the CoughAssist into an appropriate electrical outlet.
FUNCTIONAL TESTS
1. Place the power switch to the “on” position and note that the green light in the switch comes on.
2. Turn the Pressure knob through the full range of blower speeds and be sure the speed of the motor
increases steadily. With the Pressure knob fully clockwise, allow the unit to warm up for 1 to 2 minutes.
3. With the Pressure knob set at the minimum speed (counterclockwise) move the Manual Control Lever to the
Inhale position (to the right) and note that the pressure on the gauge reads between 2 and 5 cmH2O. Move
the Manual Control Lever to exhale (to the left) and note that the gauge reads between -2 and -5 cmH2O.
Turn the Pressure knob to maximum (clockwise) and repeat inhale and exhale test noting that the reading
on the gauge is between 57 and 63 cmH2O. Release the manual control lever from the inhale and exhale
positions at maximum pressure and note that the lever moves to the center and pressure drops immediately
to 0 cmH2O.
4. If the correct pressures are not achieved the pressure control can be adjusted as follows. First, remove the
top cover. If the unit has not been on for a while, turn it on with the Pressure knob fully clockwise and allow
the unit to warm up for 1 to 2 minutes.
WARNING: To avoid electrical shock, take the normal precautions when working with the unit plugged in and the
cover off.
5. On the circuit board attached to the front panel locate the two trim potentiometers directly above the Patient
Outlet on the right. See figure 9. The top trim pot adjusts the minimum pressure (clockwise to increase),
while the bottom trim pot adjusts the maximum pressure (counterclockwise to increase). First adjust the
minimum pressure (2 to 5 cmH2O), then adjust the maximum (57 to 63 cmH2O), then check the minimum
again since the two adjustments interact somewhat. Repeat the adjustments a few times to be sure the
minimum and maximum pressures, positive and negative, are correct.
6. Inhale Pressure Test - with the Manual Control Lever in the inhale position (to the right) adjust the pressure
control knob to attain 40 cmH2O. Set Inhale Pressure knob all the way counterclockwise. Note the reading
on the gauge: it should be between 18 and 22 cmH2O. Turning the inhale pressure knob slowly clockwise
should increase the pressure gradually back to 40 cm H2O.
7. Inhale Flow Check - turn the Pressure knob fully clockwise, actuate the Manual Control Lever to Inhale (to
the right) and note the pressure reading on the gauge; release the control lever. Set Inhale Flow to
minimum (clockwise). Actuate Manual Control Lever to Inhale and verify that the pressure reading has
dropped less than 10 cmH2O below the previous reading (maximum flow).
Page 10 J.H. Emerson Co.

8. Remove rubber stopper from the patient outlet. Check the flow by actuating the Manual Control Lever to
Inhale and note the flow of air out of the unit. Release the Manual Control Lever. Set Inhale Flow to
maximum (counterclockwise), and repeat the test. Note that the flow out of the unit has increased markedly.
9. Automatic timing function test (CA models only) - Set the pressure to minimum. Move the switch from
manual to automatic (Inhale, exhale and pause should already be set to 1 second). Verify that the unit
immediately begins with the inhale pressure, followed by exhale (negative) pressure then drops to 0 cm H2O
and continues to repeat.
10. Set the switch back to manual and verify that the pressure drops to 0 cm H2O. Return to Auto.
11. One at a time set each of the timing knobs to 5 seconds and verify that the each knob affects the correct
phase, that is, inhale time varies the inhale pressure phase, exhale time varies the exhale pressure phase
and pause time varies the zero pressure phase.
12. Timing check (CA models only) - Set the inhale, exhale and pause time knobs to 5 seconds. Using a
stopwatch time each phase and verify that each one lasts between 4.8 and 5.2 seconds. Set the knobs to 1
second each and using a stop watch verify that each phase lasts between 0.9 and 1.1 seconds.
NOTE: These times are adjusted at the factory and usually do not need to be altered. However, if adjustment is
required, this is controlled by the three trim potentiometers at the top of the circuit board, to the left of the
Pressure Gauge, clockwise to increase the time. Left trim pot (R13) adjusts Inhale time. Middle trim pot (R10)
adjusts Pause time. Right trim pot (R16) adjusts Exhale time. See figure 9.
J.H. Emerson Co. Page 11
Maximum pressure (R33)
Minimum pressure (R34) Exhale time (R16)
Pause time (R10)
Inhale time
(
R13
)
Automatic time adjust potentiometers
Pressure adjust potentiometers
Fi
g
ure 9

Page 12 J.H. Emerson Co.

J.H. Emerson Co. Page 13

Page 14 J.H. Emerson Co.

J.H. Emerson Co. Page 15

J.H. Emerson Co.
22 Cottage Park Avenue
Cambridge, MA USA 02140-1601
Phone: [phone] or 617-864-1414
Fax: [phone]
Email: [email protected]
Web: www.coughassist.com
910-1114-2