Frontiermedical toto Operating instructions

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
1Version 1 - August 2019
Service, Maintenance and Repair Manual

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
2Version 1 - August 2019
CONTENTS
Introducon ......................................................................................................................................... 3
Alarms and Alerts................................................................................................................................. 4
Service Procedure ................................................................................................................................ 5
Service Procedure - Problem Diagnosis ............................................................................................... 6
Spare Parts List………………………………………………………………………………………………………………………………..7
Checking and Replacing the Fuse......................................................................................................... 8
Tesng for a Faulty PCB and ‘piggybacking’ a Working Spare ............................................................. 9 - 10
Replacing a Faulty PCB......................................................................................................................... 11
Standard Pressure Test ........................................................................................................................ 12
Replacing a Faulty Compressor............................................................................................................ 13 - 14
Synchronous Motor Replacement ....................................................................................................... 15 - 17
Quick Release Connector Replacement............................................................................................... 18
Bed Hook Replacement ....................................................................................................................... 19 - 20
Air Cell Replacement............................................................................................................................ 21
CPR Deaon Valve Replacement ....................................................................................................... 22
Plaorm Cover Replacement............................................................................................................... 23
Troubleshoong................................................................................................................................... 24
Electrical Safety Test and Test aer Repair ......................................................................................... 25
General safety, disposal Informaon................................................................................................... 26
Technical Specicaons ....................................................................................................................... 27

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
3Version 1 - August 2019
INTRODUCTION
This service and repair manual outlines the steps to carry out a service and the procedures to follow if there is a suspected fault
with the Toto system. Malfuncon of the control unit may be due to the failure of one of the replaceable electrical components.
If a repair seems unmanageable or the issue falls outside the scope of serviceable repairs, please return the control unit to Froner
Therapeucs Inc.
The electronically controlled control unit provides the air supply to the Toto plaorm. A digital touch membrane operates the
control unit on the front display panel. Features include membrane lockout to prevent accidental changes to the sengs, several
alarms, LED indicators and an alarm mute compleng the operator controls.
On the side of the unit are two air outlets for quick connecon to the Toto plaorm via an air hose assembly.
The mains power supply to the unit can be easily disconnected and is designed to detach if pulled too rmly – protecng the
internal wiring from damage.
The quality of the control unit underpins the reliability and pressure redistribuon capabilies of the system. At the centre of the
control unit lies the compressor, which runs at a rapid and connuous rate whenever the unit is operaonal. The connuous rapid
movement places compressor materials under high stress and heat condions, which can make the unit suscepble to wear and
tear over an extended period.
The compressor housing is a sturdy metal cage, secured on all sides by rubber mounts. These mounts serve to insulate the rest of
the unit from the vibraon of the compressor.
Should the control unit fail to operate, or system pressure fails to reach nominal operang status, please follow the steps to isolate
the cause of the problem and make the appropriate repair.

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
4Version 1 - August 2019
Alarms and Alerts Indicated by an Audible Alarm and:Reference
‘Inialisaon Failure’
Control unit fails to start.
Five ‘Inate me’ LEDs and Five ‘Rest me’ LEDs
ashing (when acvated).
Alarm Mute Buon
Present alarm has been muted. A solid blue LED.
Lock Signal
Control unit is locked. A solid orange LED.
Power loss
Power to the control unit has been interrupted. A solid yellow LED.
High-Pressure Alarm
Airow between the control unit and the plaorm is
prevented, i.e. a blocked air hose.
A solid yellow LED.
Low-Pressure Alarm
The pressure in the system has fallen below the
minimum operaonal requirements, i.e. an air leak.
A solid yellow LED.
Service interval
Service required; default at one-year use. A solid orange LED (No audible alarm).
ALARMS AND ALERTS
Toto Touch has several low priority alarms to ensure paent safety and ecacy.
5
6
7
8
9
56
78
910
1
10
3
42
34

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
5Version 1 - August 2019
SERVICE PROCEDURE
The following checks should be completed to determine whether or not there is system fault or failure that may require part
replacements as part of the roune service procedure. To conduct these checks, you’ll require the apparatus specied below:
1. UNBOXING
a. Please wear suitable PPE before handling the unit.
b. Unbox the control unit.
c. Using appropriate cleaning products, clean down the unit, power lead and work surface.
d. Place the unit on the clean work surface.
2. FILTER REPLACEMENT
a. Remove the filter from the back of the unit and clean using cold water.
b. Dry the filter thoroughly and replace.
3. FUNCTIONALITY TEST
a. Connect the control unit to the mains power supply.
b. Switch the unit on by holding the power button for approximately 5 seconds.
c. The unit should now be on, and air should be flowing from the female connector.
d. Connect the flow & pressure test rig to the female connector.
e. Test the flow; the reading should be between 5LPM & 10LPM.
f. Now test the pressure, the reading should also be between 110mmHg & 130mmHg.
g. Test that the LEDs and buttons on the membrane are working correctly by cycling through tilt/rest time settings.
h. To test the alarm LEDs, carry out the following high and low-pressure tests:
•Allow the unit pump air from the female connector for approximately 5 minutes until the low-pressure alarm sounds, and
the LED illuminates.
•With the low-pressure alarm still sounding, use the female connector bung to prevent any air from escaping.
•The low-pressure alarm and LED should now be off and the high-pressure alarm and LED should be active.
•Use this opportunity to test the mute alarm button and LED, pressing the button should mute any alarm sound and
illuminate the blue LED.
•Switch the unit to pump air out of the male connector and repeat the high and low-pressure tests.
•To turn the service LED off, simultaneously hold the ‘inflate time’ and ‘rest time’ buttons for five seconds.
4. ELECTRICAL SAFETY TESTING
a. If the unit passes step 3, the unit now requires a safety test per IEC 62353: 2014.
b. Perform the safety test using a Rigel 288+ tester or similar device (Equipment leakage must produce a value <100μA).
c. If the unit passes the above test, then the service is complete.
d. Log the results, date, time and personal details of the engineer.
NOTE - If the unit fails step 3 or 4, follow the problem diagnosis procedure on the next page.
Tamperproof Label Air Flow Bungs (Male & Female) Air Flow Meter Air Pressure Gauge

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
6Version 1 - August 2019
SERVICE PROCEDURE - PROBLEM DIAGNOSIS
If the control unit does not pass the funconality test, use the ow diagram below to diagnose the problem.
5. OPENING THE CONTROL UNIT
a. Once you’ve diagnosed the problem, source the appropriate replacement parts (full list on next page).
b. Remove tamper-proof sticker, unscrew the unit and open it carefully.
c. After the unit is open check for any visible signs of damage, loose wiring or tubing, dirt and contamination.
d. Perform repair using appropriate replacement part.
e. Tighten all internal screws.
f. Close the unit up and re-place screws
g. If a repair procedure has taken place, re-conduct section 3 (functionality test) to check for correct function and operation.
h. If you no longer require to re-open the control unit, put a new tamper-proof sticker over the screws
6. ELECTRICAL SAFETY TESTING (POST REPAIR)
a. If the unit passes step 3, the unit now requires a safety test per IEC 62353: 2014
b. Perform the safety test using a Rigel 288+ tester or similar device. (Equipment leakage must produce a value <100μA)
c. If the unit passes the above test, then the service is complete.
d. Log the results, date, time and personal details of the engineer
NOTE - If the unit fails step 6, return to the manufacturer.

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
7Version 1 - August 2019
SPARE PARTS LIST
In order to conduct the service and repair procedures that follow, dierent kits are available for replacing certain parts. Below is a
complete list of the kits available.
To order any of the following, contact Froner Therapeucs Incorporated, Bualo, NY 14221 (Tel. [phone]).
Stock
Code Descripon Kit Contents
010300
Bed Hook
Assembly LH/RH
Assembly
Screw PB 4 x 12
Screw M3 x 8 P200
Hook Bend Square Premium
φ6 x 56mm
Hook Generic 10 DS
Generic 10DS
Generic 10DS
φ10.7 x 14.3
Hook Safety Plate
010301
Male QR Air Hose
Connector
Assembly
Male QR Connector Body
O-ring Quick Release
Connector P7
010302
Female QR Air
Hose Connector
Assembly
Female QR Connector Body
Spring Quick Release
Connector
Connector quick release grey
010303 IEC Mains
Connector Single Item
010304 Air QR Connector
Panel Single Item
010305 Cap Sponge Filter Single Item
010306 Sponge Filter Single Item
010307 Rear Case Handle
and Fixings
Hand case
Screw PB 4 x 12
010308 Rear Case
Assembly
Screw Hole Scker
Label Scker PET Blue
Stand Rubber 4244 N.R.H
Screw Hole Rubber Stopper
Screw PB 4 x 18
Case Rear
010328 110V Motor and
Fixings
Motor Synchronous 110V VAM
-2.5/3rpm
Screw M3 x 16
Stock
Code Descripon Kit Contents
010310 Micro Switch
Assembly
Micro Switch 1
Micro Switch 2
Screw PA 3 x 30
010311 Diverter Valve
Assembly
R-clip 1mm D20mmL
φ38.8 x 7
Spring R.V Analogue
Two Tube Valve Assy
Exhaust Valve
Screw M2 x 5 P200
010312 3-way Air Hose
Assembly
Connector 3-way T-type PA Black
Hose Silicon Rubber
010313 Compressor Air
Hose Assembly
Connector L-shaped Tube 18mm
x 8mm
Tube PVC Clear 4.5 x 8 PVC
010327
110V
Compressor
and Mounng
Assembly
CU Compressor
Rubber Compressor Mounng
010315
Compressor
and Fixings
Assembly
Screw PB 4 x 8
Compressor Case Housing
Foam EVA black 90 x 10 x 4mm
010323 110V PCB
Assembly
PCB Support Fixing
CU PCB Assembly Toto 10DS
Film Isolang PCB
010324
Front Case and
V3 Membrane
Assembly
Label Membrane
Case Front
010318 Buzzer
Assembly
Alarm Buzzer
Buzzer Seat
010325 Alarm Speaker Single Item
010326
Speaker
Bracket
Assembly
Speaker Frame
Screw

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
8Version 1 - August 2019
CHECKING AND REPLACING THE FUSE
Control unit failures may be a result of a blown fuse. To replace, follow the steps below.
Note: When replacing, only use the same fuse rang (T1AH/250V).
1. Prepare the Control Unit
Switch o the power supply to
the control unit, disconnect the
air hoses and remove the power
cord from the electrical socket in
the side of the unit.
Using a so cloth to protect the
unit from damage, place the
control unit on a level work
surface with the back facing
upwards.
2. Remove the Fuse
Insert the at headed
screwdriver into the fuse holder
and lever out of posion.
Remove the fuse from the
holder and safely discard.
3. Insert New Fuse
Insert a new fuse into the fuse
holder and replace.
Ensure the holder is secure.
4. Reconnect and Test
Reconnect the power cord to the
control unit and switch on the
power supply. If the control unit
sll fails to operate, the problem
may be due to a faulty circuit
board. Proceed to the PCB
(printed circuit board) check
procedure.
If the unit switches on but the
fuse “blows” again, repeat the
steps to replace the damaged
fuse but do not reconnect power
as damage may be due to a
faulty compressor.
Required Tools:
Flat Head Screwdriver
Required Parts:
1x T1AH/250V Fuse

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
9Version 1 - August 2019
1. Prepare the Control Unit
Switch o the power supply to
the control unit, disconnect the
air hoses and remove the power
cord from the electrical socket in
the side of the unit.
Using a so cloth to protect the
unit from damage, place the
control unit on a level work
surface with the back facing
upwards.
2. Remove the Tamper Proof
Label
Using a heat gun (80°C / 176°f),
remove and discard the tamper-
proof label.
3. Remove Screws
Remove white screw caps.
Use a Phillips Head Screwdriver
to remove the seven screws that
secure the housing.
Place the screws in a safe place
(such as small container or jar)
to prevent loss.
4. Separate the Housing
Gently loosen the top and
boom housing. Once loose,
hold the power socket (IEC
connector) to prevent from
catching while liing the top
cover and leaning it back on your
work surface.
Be careful not to drag the
internal wires and tubing during
this process.
5. Disconnect the PCB (i)
Disconnect the six electronic
leads by cung the cable es
that secure the leads to the PCB.
Carefully pull away the plasc
cases (not the wiring) to
disconnect.
6. Disconnect the PCB (ii)
Disconnect the two remaining
at digital leads and one air
tube.
Be sure to note the locaon of
all eight connecons on the
circuit board for easy
replacement.
Leave the disconnected PCB in
the control unit during tesng.
TESTING FOR A FAULTY PCB (PRINTED CIRCUIT BOARD) AND ‘PIGGYBACKING’ A WORKING SPARE
To determine if the PCB has failed, always test the Control unit using a working spare. When handling the PCB, an-stac gloves (or
other an-stac precauons) should be used to protect the PCB from stac.
Required Tools:
Phillips Screwdriver
Wire Clippers
Heat Gun
Required Parts:
1x 110V PCB Assembly
REF - 010323

SERVICE AND REPAIR PROCEDURES
Toto® Plaorm & Control Unit (110V)
10 Version 1 - August 2019
7. Piggybacking the Spare
PCB
Take the spare PCB and connect
all eight leads into the
corresponding connectors
Six electronic leads; two digital;
one air pipe.
8. Test
Reconnect mains power, switch
on the control unit and check
the display panel.
If the unit now operates, the
internal PCB has failed and
needs replacing. Proceed to the
printed circuit board
replacement procedure for the
next steps.
NOTE: If the control unit sll
does not operate, return to
Froner Therapeucs Inc. for
further repair or
replacement.
TESTING FOR A FAULTY PCB AND ‘PIGGYBACKING’ A WORKING SPARE CONTINUED
Required Tools:
Phillips Screwdriver
Wire Clippers
Heat Gun
Required Parts:
1x 110V PCB Assembly
REF - 010323