Keeler Cryomatic 2509-P-1000-JPN User manual

‘Cryomatic’ Console
Service Manual for:
2509-P-1000-JPN
2509-P-1000 September 2011 onwards

KCU401-2 Keeler Cryomatic Service Manual
Contents
Introduction
…………………………………………………………………
…
.
4
About this Manual ……………………………………………………….. 4
Good Working Practices ………………………………………………… 4
Scheduled Maintenance
……………………………………………………...
5
Enclosure & Fittings
…………………………………………………………
.
6
Programming Port Cover ……………………………………………….. 6
Removal of Cover ……………………………………………………….. 6
Rubber Feet ……………………………………………………………… 6
Electrical Sys
tem …
……………………………………………………………
7
Replacing Mains Fuses …………………………………………………. 7
Mains Cord ……………………………………………………………….. 7
Mains Inlet ………………………………………………………………… 8
Power Supply Sub-assembly …………………………………………… 9
Pneumatic System ……………………………………………………………
.
10
Pneumatic Module Sub-assembly ……………………………………… 10
Replacing the Inlet Filter ………………………………………………… 11
Solenoid Valves ………………………………………………………….. 11
Electronic System
……………………………………………………………
.
1
2
Footswitch ………………………………………………………………… 12
Controller PCB Assembly ………………………………………………. 12
LCD Panel ………………………………………………………………… 13
Firmware Upgrades
……………………………………
………………………
1
4
Programming Adaptor …………………………………………………… 14
Download Utility ………………………………………………………….. 14
ISP Procedure ……………………………………………………………. 15
Spare Parts and Accessories ……………………………………………….
1
6
Faultfinding Chart
………………………………………………………
……..
1
7
Warranty …………………………………………………………………………
1
8
Disposal …………………………………………………………………………
1
8
Technical Data ………………………………………………………………
…
19
Appendix 1 – Console General Arrangement ……………………………….. 20
Appendix 2 – Pneumatic Module General Arrangement …………………… 23

KCU401-2 Keeler Cryomatic Service Manual
Safety Considerations
The system has been designed to comply with the following regulatory standards for
Safety and Electromagnetic Compatibility:
EN60601-1, UL60601-1 & CAN/CSA-C22.2 No 601.1
EN60601-1-2
Although compliant with applicable EMC directives, this equipment may still be
susceptible to excessive emissions and/or may interfere with other more sensitive
material.
For your own safety and the safety of the equipment, always take the following
precautions:
Keep the console away from sources of liquids and do not spray with water.
Switch off the electrical supply and disconnect from the mains supply before
cleaning and inspection.
Do not use hypercarbonate or phenolic based cleaning solutions or
disinfectants containing cationic surfactants (e.g. Dettox) to clean the console.
Ensure that the system is clean and dry prior to storage.
Observe the usual safety precautions, associated with the use of medical gases,
at all times. Copies of these guidelines will be available from the gas supplier.
Ensure the correct disposition of gas exhausted from the system so as to
minimise the exposure to nitrous oxide. This is the responsibility of the user.
Ensure that the system is inspected by properly trained personnel once per
annum for performance and safety checks.
SAFETY WARNINGS
Electrical equipment may be hazardous if misused. The equipment
covers should only be removed by authorised technical personnel.
Do not use the system in the presence of flammable gases such as
anaesthetic agents.

KCU401-2 Keeler Cryomatic Service Manual
1. Introduction
About this Manual This manual covers all aspects of servicing the Cryomatic
System (models from June 2011 onwards).
This manual is for use only by properly trained Keeler
service engineers.
This manual assumes that the Cryomatic system has been
correctly installed following the guidelines in the Cryomatic
Instructions For Use.
Good Working Practices
Potentially dangerous voltages are present inside the
equipment – care should be observed when operating the
equipment with the front cover removed.
The Cryomatic contains several components/sub-assemblies
which are sensitive to electrostatic discharge (ESD) and
relevant precautions should be taken when handling such
components.

KCU401-2 Keeler Cryomatic Service Manual
2. Scheduled Maintenance
The Cryomatic system should ideally be inspected and
serviced annually by Keeler trained personnel.
The following service points should be covered:
a) General inspection of console for any signs of
damage.
b) Inspection of mains cord for signs of damage –
replace if necessary.
c) Inspection of high pressure gas hose for signs of
damage – replace if necessary.
d) Inspection of footswitch for signs of damage –
replace if necessary.
e) Inspection of exhaust hose assembly for signs of
damage – replace if necessary.
f) Replace gas inlet filter.
g) Check probe couplings for signs of wear or damage.
h) Check probe coupling electrical contacts – clean if
necessary.
i) Performance check using test probe.

KCU401-2 Keeler Cryomatic Service Manual
2. Enclosure & Fittings
Programming Port Cover
The programming port cover may need to be removed in
the event of a firmware upgrade (see Section 6). This is
secured at the rear of the unit by 2 small screws.
Removal of Front Cover
Almost all of the servicing and/or rectification will require
the removal of the front cover. This can be carried out as
follows.
a) Remove the cryoprobe (if fitted).
b) Switch off and disconnect gas supply.
c) Disconnect Cryomatic from the mains electrical
supply.
d) Disconnect footswitch.
e) Remove 4 tamper-proof fixings at the rear of the
enclosure using the appropriate tooling.
f) Withdraw the front cover and carefully disconnect
all connections to the Controller PCB Assembly.
g) Completely withdraw the front cover.
h) Re-fitting is the reverse of removal.
Rubber Feet
The rubber feet are secured to the base of the enclosure by
an adhesive layer. They are very robust. If they should
become detached due to rough handling they should be
replaced. Any residual adhesive should be removed using
an alcohol based cleaner before the new foot is firmly
pressed into the square locating recess on the base of the
enclosure.

KCU401-2 Keeler Cryomatic Service Manual
3. Electrical System
Replacing Mains Fuses
The Cryomatic must be disconnected from the mains before
attempting to replace the mains fuses.
The mains fuses are housed in the small drawer below the
rocker switch on the side of the unit. A screwdriver (or
similar) should be used to unlatch the drawer to gain access
to the fuse compartment.
Fuses should only be replaced with the same type and
rating.
Mains Cord
The mains cord should be replaced if there are any signs of
damage upon inspection. The mains cord is of medical
grade and replacements should be obtained from the
manufacturer.

KCU401-2 Keeler Cryomatic Service Manual
Mains Inlet
The mains inlet unit can be removed in the following
manner.
a) Remove the crimped electrical connections from the
rear of the unit (make a note of the correct
orientation).
b) Remove the 2 countersunk screws which are
accessed from the outside of the unit.
c) Carefully withdraw the mains inlet unit from the
enclosure.
d) Re-fitting is the reverse of removal.

KCU401-2 Keeler Cryomatic Service Manual
Power Supply Sub-assembly
Disconnect the power connection from CN3 on the
Controller PCB. Use a digital multi-meter to check the
output of the power supply. Verify that the following dc
voltages can be measured with respect to the black
connection (pin 4):
red (pin 1) +5 V
yellow (pin 2) +24 V
white (pin 3) -12 V
The entire power supply sub-assembly can be removed as
follows.
a) Remove the inlet connection from the power supply.
b) Remove the 3 pan head screws which secure the
component plate. Note that these fixings also
provide secure protective earth points.
c) Carefully remove the sub-assembly from the
enclosure.
d) Re-fitting is the reverse of removal (ensuring that
earth connections are re-instated correctly).

KCU401-2 Keeler Cryomatic Service Manual
4. Pneumatic System
Pneumatic Module Sub-assembly
The complete pneumatic module sub-assembly can be
removed as follows.
a) Loosen and remove the bezel from the probe
connector.
b) Push back the collar and remove the flexible exhaust
connection from the module.
c) Remove the pneumatic module support bracket.
d) Carefully remove the cap-head screws that secure
the module to the rear enclosure.
e) Withdraw the pneumatic module from the enclosure.
f) Re-fitting is the reverse of removal.

KCU401-2 Keeler Cryomatic Service Manual
Replacing the Inlet Filter
The inlet filter is included to prevent any minute particulate
debris from entering the pneumatic system. This component
should be inspected and replaced as part of the routine
maintenance schedule.
The inlet filter is situated within the manifold block. It can
be accessed by removing the inlet adapter (refer to GA in
Appendix 2). Once the adapter has been removed, the filter
can be unscrewed using a flat bladed screwdriver. Re-fitting
is the reverse of removal. A new ‘Dowty’ seal should be
fitted when the inlet adapter is replaced.
Solenoid Valves
Should the need arise, solenoid valves can be replaced
without removing the pneumatic module from the
enclosure.
Remove the electrical connector (noting orientation) by
undoing the central retaining screw. Remove the solenoid
valve coil (noting orientation). Remove the 2 countersunk
fixing screws. The solenoid valve can now be removed.
Care must taken to note the orientation of the valve as they
have an arrow on the body denoting the direction of flow.
Re-fitting is the reverse of removal taking care to install the
valve in the correct orientation (refer to GA in Appendix 2).

KCU401-2 Keeler Cryomatic Service Manual
5. Electronic System
Footswitch
The footswitch is connected to the Cryomatic at the rear of
the console. The footswitch is not a serviceable item and if
it is faulty then it should be returned to the manufacturer for
replacement.
Controller PCB Assembly
Observe proper precautions for the prevention of damage
to static sensitive devices.
The Controller PCB Assembly can be removed in the
following manner.
a) Unlatch the connection for the LCD panel in
position CN1. Carefully withdraw the flexible cable
assembly.
b) Unplug the front panel membrane connector in
position CN13.
c) Remove the 6 pozi pan-head screws that secure the
PCB to the enclosure (being careful to retain all
washers).
d) Withdraw the PCB from the enclosure.
e) Re-fitting is the reverse of removal. Care should be
taken when re-connecting the LCD flexible cable
assembly as this is easily damaged. Ensure that the
latch is closed properly.

KCU401-2 Keeler Cryomatic Service Manual
LCD Panel
Observe proper precautions for the prevention of damage
to static sensitive devices.
It is unlikely that the LCD panel will fail but should the
need arise, the LCD panel can be removed in the following
manner.
a) Remove the Controller PCB Assembly (see previous
section).
b) Remove 4 pan-head screws which secure the LCD
retaining bracket. Ensure that the 4 spacers are
retained.
c) Carefully remove the LCD Panel.
d) Re-fitting is the reverse of removal – ensure that the
panel is centred correctly before finally tightening
the retaining bracket.

KCU401-2 Keeler Cryomatic Service Manual
6. Firmware Upgrades
Firmware upgrades can easily be performed using the In System Programming (ISP)
facility which is incorporated in the Cryomatic.
Programming Adaptor
A special programming adaptor is required to connect a PC
or laptop to the Cryomatic. This can be obtained from the
manufacturer. The programming port is accessed at the rear
of the equipment and is located behind a small removable
cover.
Download Utility (‘FLIP’)
The ‘FLIP’ programming application from Atmel is
available as shareware. This is available as a free download
from the Atmel website or alternatively a copy can be
obtained from the manufacturer. This application software
is required to control the communication between the
PC/laptop and the Cryomatic.
The software can be downloaded by the using the following
link:
http://www.atmel.com/dyn/products/tools_card.asp?tool_id
=2767

KCU401-2 Keeler Cryomatic Service Manual
ISP Procedure
The exact procedure may vary slightly depending on the
version of ‘FLIP’ that is being used.
The following procedure should be followed when
performing a firmware upgrade in the field.
a) The Cryomatic should be powered up.
b) Launch the FLIP application.
c) Press F2 for Device Selection. Select T89C51AC2
from the list then select OK.
d) Connect the ribbon cable connector into the ISP
programming port on the Cryomatic.
e) Press F3 for Communication Settings. If using the
computers serial port select COM1 and 19200 baud
from the drop down lists. Check the manual sync
box.
f) OR if using the USB adapter, select COM3 and
19200 baud from the drop down lists. Check the
manual sync box.
g) Press Connect then press the reset button on the ISP
adapter. Press the Sync button (the system will
respond by automatically filling in the device
information).
h) Select the Device drop down menu and select
Erase.
i) On the Erase dialogue box select Full Chip Erase
and press Erase. Wait until this action has been
completed.
j) On the File drop down menu select Load Hex. Use
the browser to select the appropriate file and select
Open to load the program into the buffer. Wait until
this action has been completed.
k) Select the Device drop down menu and select
Program.
l) When this has completed remove the ribbon cable
connector from the ISP header port on the target
system.
m) If accessible press the reset button on the target
system to start the application, alternatively turn the
machine off at the main switch and then back on
again.
Occasionally, as with any RS232 communication system, the data transfer fails. A
time-out message usually results. If any operation fails, simply try again until proper
communication is established. Consult the FLIP User Manual if problems persist.

KCU401-2 Keeler Cryomatic Service Manual
7. Faultfinding Chart
Problem/Fault
Possible Cause
Corrective Action
Section
1
system does not
power up
a mains fuse in plug blown replace with correct rating
and type
b inlet fuse(s) replace with correct rating
and type
3
c mains inlet module faulty check for mains voltage on
output terminals – replace if
necessary
3
d power supply faulty Check for correct voltages
on output connector –
replace if necessary
3
2
system appears to
power up but LCD
screen is blank
a contrast setting incorrect adjust contrast level to
correct setting
5
b LCD module faulty check that LCD flat ribbon is
connected properly –
replace if necessary
5
3
system appears to
power up but
nothing happens
a firmware corrupted re-install firmware 6
b faulty controller PCB replace controller PCB 5
4
no gas supply
indicated on LCD
screen
a gas cylinder not connected
or valve not open
connect cylinder and open
valves
b insufficient cylinder pressure replace cylinder
c inlet filter clogged replace inlet filter 4
d faulty pressure sensor replace pneumatic module 4
5
system will not
recognise probe
a faulty memory IC in probe
coupling
replace/re-program
b possible damage to
electrical contacts of
console or probe - dirty or
oxidised probe contacts
inspect contacts and clean
carefully if necessary
6
probe does not
freeze properly
(low or zero flow)
a residual moisture in probe
following sterilisation
re-purge probe
b probe blocked with
particulate matter
replace/repair probe
c gas supply insufficient check cylinder, connection
and valve – replace cylinder
if necessary
d faulty/blocked control valve replace pneumatic module 4
e exhaust hose is blocked or
occluded.
check the exhaust hose for
blockages or occlusions -
replace if necessary
f faulty pressure sensor replace pneumatic module 4
g faulty controller PCB replace controller PCB 5
7
probe defrosts
slowly
a probe fault – possible
internal leak
replace probe
b faulty/leaking control valve replace valve or pneumatic
module
4
c leak internal to console check for internal gas leaks
– repair leak(s) or replace
pneumatic module
4
8
excessive flow rate
from exhaust
a faulty/leaking control valve replace valve or pneumatic
module
4
9
gas leaks from
coupling when
probe is
disconnected
a faulty ‘o’ rings in QR
connectors
replace pneumatic module 4
10
mute control does
not function
a faulty membrane label replace enclosure front 2

KCU401-2 Keeler Cryomatic Service Manual
8. Spare Parts Listing
The following spare parts are available from the distributor.
Description Part Number
Controller PCB Assembly KCU050
Pneumatic Module Assembly MCU051
Power Supply Assembly MCU054
High Pressure Hose Assembly MCU065
Mains Inlet CST261
Case Front Assembly MCU068
Case Rear MCU301
Cover Plate MCU302
LCD Panel MCU204
Solenoid Valve N/C 0.8mm Orifice 24V/10W MCU205
Solenoid Valve N/O 0.5mm Orifice 24V/14.5W MCU206
Footswitch Assembly MCU217
2A Anti-surge Fuse MIS094
Rubber Foot MCU213
1/8” Dowty Seal FAS014
Inlet Filter MCU219
M4 x 10 Tamperproof Pan-head Screw FAS055
M3 x 16 Pozi Countersunk Screw FAS044
M3 x 6 Pozi Pan-head Screw FAS031
M3 x 8 Pozi Pan-head Screw FAS054
M3 Shake-proof Washer FAS033
M3 Plain Washer FAS032
Mains Cord various
Exhaust Hose (5m) CST267
Exhaust Silencer MIS104
Cryomatic Console Carton PKG015
Cryomatic Probe Carton PKG004/S
Cryomatic Instructions For Use KCU400
Cryomatic Service Manual KCU401
Programming Adapter

KCU401-2 Keeler Cryomatic Service Manual
9. Warranty
The Cryomatic and its components are covered by warranty that they meet their
performance standards and are free from any defects in materials or workmanship.
Within 12 months from delivery by Keeler, the manufacturer shall at no charge to the
customer, upon written notice from the customer, repair or replace any components
which are defective in material or workmanship.
The customer agrees that it shall have no remedy in the event of any breach of the
foregoing warranty other than as provided above. This warranty is exclusive and in
lieu of all other warranties, expressed or implied, and all implied warranties of
merchantability or fitness for a particular purpose are expressly disclaimed.
The obligations of the manufacturer as set forth in this warranty are expressly
conditioned on the following:-
(i) No alterations or repairs of any malfunction of the system shall be made to the
system except by the manufacturer or his authorized representative, without the prior
written approval of the manufacturer or his authorized representative (and in no case
will the manufacturer assume responsibility for repairs or alterations made by those
other than the manufacturer or his authorized representative).
And
(ii) The customer shall give notice to the manufacturer or their authorized
representative of any malfunction of the system and shall not use the system in any
surgical operation after they are aware of any malfunction.
(iii) The customer complies with manufacturer’s recommended Preventative
Maintenance (see Section 8) and can provide proof of such action.
10. Disposal
Ensure that this equipment is disposed of in accordance with local regulations. Please
contact the supplier if in doubt.

KCU401-2 Keeler Cryomatic Service Manual
11. Technical Data
Cryogen
ic System
Gas Specification: Medical Grade Nitrous Oxide (N
2
O) or Carbon Dioxide
(CO
2
) in non-syphon cylinders.
Operating Pressure Range: 3100 – 5860 kPa (450 – 850 PSI)
Maximum Pressure 8275 kPa (1200 PSI)
Freeze Control Footswitch (press to freeze, release to defrost)
Electrical Ratings
Input Voltage Range: 110-240Vac (50/60Hz)
Power Rating: 100VA
Fuses: T2AH 250V
Dimensions
Width: 305mm (12”)
Depth: 200mm (8”)
Height: 190mm (7.5”)
Weight: 2.5kg (6lbs)
Classificati
on
&
Safety Standards
Complies with: EN60601-1, UL60601-1 & CAN/CSA-C22.2 No 601.1
Equipment Classification: Class 1, Type BF (Applied Part)
Mode of operation: Continuous
Protection against ingress: Console IPx0
Footswitch IP68
Environmental Cond
itions
Storage Operating
Temperature Range -20°C to +50°C +10°C to +40°C
Relative Humidity 10% to 80% 30% to 70%
Atmospheric Pressure 500hPa to 1060hPa 700hPa to 1060hPa
Symbols used on the equipment
All symbols used are in accordance with BS EN60417-2:1999 (Graphical Symbols for
use on Equipment).
BF (Applied Part) Fuse rating
Refer to the User Manual Footswitch connection
Dangerous voltages present
inside the equipment
Exhaust connection
AC voltage input Gas inlet connection

Appendix 1 – Console General Arrangement