Stryker Neptune 2 ROVER ULTRA User manual

2014/12 0702-002-619 Rev C www.stryker.com
Stryker®and Neptune®are trademarks and/or registered trademarks of the Stryker Corporation.
Service and Installation Manual
Domestic/ International
Neptune
®
2
Waste Management System
120V/230V ROVER - ULTRA
REF 0702-001-000
0702-002-000
120V/230V DOCKING STATION
REF 0702-014-000
0702-015-000
0000026959, Rev. C Effective Date: Dec 16, 2014 3:43:21 PM
Print Date: Dec 16, 2014 04:03:57 PM

0000026959, Rev. C Effective Date: Dec 16, 2014 3:43:21 PM
Print Date: Dec 16, 2014 04:03:57 PM

2014/12 0702-002-619 Rev C www.stryker.com
Stryker®and Neptune®are trademarks and/or registered trademarks of the Stryker Corporation.
Service and Installation Manual
Domestic/ International
Neptune
®
2
Waste Management System
120V/230V ROVER - ULTRA
REF 0702-001-000
0702-002-000
120V/230V DOCKING STATION
REF 0702-014-000
0702-015-000
0000026959, Rev. C Effective Date: Dec 16, 2014 3:43:21 PM
Print Date: Dec 16, 2014 04:03:57 PM

0000026959, Rev. C Effective Date: Dec 16, 2014 3:43:21 PM
Print Date: Dec 16, 2014 04:03:57 PM

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0000026959, Rev. C Effective Date: Dec 16, 2014 3:43:21 PM
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How to Use the Neptune 2 Service Manual
The Neptune 2 service and installation manual is comprised of 8 chapters that each covers a
separate service topic. While a table of contents is provided to aid in quickly locating the
desired material, the contents of each chapter are outlined below.
Chapter 1 –Operational Description
Here you will find a brief overview of how the Neptune 2 Waste Management System works.
Included topics are:
The components in each subsystem (i.e. vacuum subsystem, or fresh water subsystem)
The specific function of those components and how they operate in the system.
Illustration of the user interface panel to familiarize the technician with the indicators and
controls of the Neptune 2 Ultra Rover.
Chapter 2 –Ultra Rover Disassembly
The Neptune 2 Waste Management System is comprised of a docking station (a stationary
device; also referred to as a Docker) to remove waste fluid, and a mobile device called a Rover
to collect surgical fluid. The Neptune Ultra is Stryker’s two canister model Rover, which also
provides a motorized IV Pole and smoke evacuation in the same compact footprint. Chapter 2
outlines the procedures necessary to remove and replace components in the Ultra Rover.
Reference the disassembly examples for a detailed description of how the procedures are
structured.
Chapter 3 –Docker Disassembly
The docking station, or Docker, is a stationary unit centrally located to a power source
(standard wall outlet), a fresh water source, and a drain. It is responsible for removing the
surgical fluid from the Rover through an automated sequence that requires little interaction
from the user, as well as rinse the Rover with detergent after use. The procedures to remove
and replace components for the Docker are outlined in chapter 4. Reference the disassembly
examples for a detailed description of how the procedures are structured.
Warning Indicators and Disassembly Procedure Example
The following examples illustrate how the disassembly procedures are structured as well as
the warning indicators used when performing maintenance in the field. The disassembly
procedures apply to chapters 2, 3, and 4, although each chapter will cover the steps necessary
to perform maintenance on a specific product.
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Warning Indicators
First and foremost, it is crucial that the technician be familiar with the indicators used
when performing maintenance on the Neptune Waste Management System. The words
WARNING, CAUTION, and NOTE each carry a special meaning.
WARNING: Disregarding WARNING information may compromise the
safety of the patient and/or health care staff and may
result in injury.
CAUTION: Disregarding CAUTION information may compromise
product reliability and may result in damage.
NOTE: NOTE information supplements and/or clarifies procedural
information.
A triangle with an exclamation point alerts the technician
to read and understand the accompanying instructions,
especially the operating, maintenance, and
safety information.
A triangle with water droplets alerts the technician that the
associated repair step may potentially expose the technician
to fluids. (fresh water or surgical waste) A fluid warning poses
a potential hazard to both personnel and equipment.
Disassembly Basics
The disassembly procedures provide a step-by-step illustration of how the Neptune
Waste Management system is disassembled. As a general rule, each product’s
disassembly section begins with the steps required to remove the covers. It is important
for the technician to understand that the subsequent procedures begin with the
assumption that the covers have been removed to gain access to the system. Certain
procedures are longer than others and therefore include the steps to remove the
necessary covers. The disassembly procedures outline the steps necessary to remove
all of the subsystems and circuit boards in each product.
For the most part the process starts with the covers and proceeds through removing
each component, one at a time. The technician should ensure that the equipment is
unplugged and turned off during disassembly!! Power should not be applied when
removing components or subassemblies. Components are assembled in reverse order
of assembly and therefore reassembly of the equipment is not covered.
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Disassembly Diagram
Assembly Title
The assembly title consists of the name and the part number of the component to be
removed. If an assembly has additional parts that can be removed, the technician
should refer to the procedure for that part. For example, page 2-7 outlines the steps to
remove the top cover assembly. There are also removal procedures for two
components on the top cover assembly. (These are the main control board on page 2-
12 and the volume display assembly on page 2-19) Each of the two subassemblies of
the top cover begins with taking off the top cover. Always verify that the procedure being
followed is for the part you intend to replace. The number of steps involved and the
order they are performed may vary depending on which part is being replaced.
Front Panel Assembly P/N 0702-001-070
ASSEMBLY TITLE
Assembly Name Assembly
Part Number
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Warning Indicators
Certain steps in the disassembly process will require the technician to take special
precaution. In this case the step, or sometimes even the whole procedure, will be
preceded by a warning indicator. The message contains an indicator, a warning level,
and the message.
Indicator: Used to identify a warning message. (water or precautionary)
Warning Level: Used to indicate the severity of the message. (Note, Caution, or
Warning)
Message: Communicates a potential hazard or clarifies the disassembly step.
WARNING
INDICATOR
Indicator Warning
Level
Make sure to dock the rover before removing the front cover. To prevent
accidental leaks, the canisters must be empty prior to removing them!
Note
Message
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vii
Disassembly Step
Each step in the removal process outlines the following:
Component: The component name is always in bold.
Part Number: The part number for the component being removed.
Reference Designator: A visual reference to the component to remove.
Required Tool: Lists the tool needed to perform the listed action
Sometimes a component may be listed in a procedure without a part number. For example, the
technician may be directed to remove the connector labeled main control board. In this case
there will not be an accompanying reference designator or illustration. Items such as
connectors (and some wire harnesses) are referenced as plugs (i.e. P2) and do not have a
part number other than that of the physical connector. These types of items are simply referred
to by the label near the connector end.
DISASSEMBLY
STEP
Remove two strikeplates (p/n 0702-001-323) (BN) on the bottom of front cover assembly
using 3/16” allen wrench.
Required Tool
Component to
be removed Component part number Reference designator
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Disassembly Diagram
The diagram provides the technician with a visual reference of the components to be
removed. The reference designators shown help the technician to correspond each part
in the diagram to the one listed in the disassembly step. Dashed lines indicate a motion
path for parts to be removed. It is important to understand that any parts mentioned in
the removal step will be shown in bold, immediately followed by the part number and
reference designator. However, only the part being removed in each step will have a
corresponding reference designator in the diagram. This allows the technician to clearly
indentify which part is being removed while also still providing the part number
information for all parts in the Neptune system.
DISASSEMBLY
DIAGRAM
Indicates a
removal path
for components
Reference
designator
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Chapter 4 –Troubleshooting
This chapter provides the technician with the information required to troubleshoot the
Neptune 2 Waste management system. Chapter 5 provides:
Troubleshooting Overview
Ultra Rover Block Diagrams
Docking Station Block Diagrams
System Troubleshooting Chart
System Settings Overview
Technician Menu Overview
Error Codes
Troubleshooting Overview
This section outlines how troubleshooting is accomplished using the half-split bracketing
method. A complete example is provided which guides the technician through a
troubleshooting example from start to finish. Included here are how to diagnose a
symptom, where to initiate troubleshooting, how to determine if a check is good or bad,
and where to proceed once that decision has been made. Ultimately the troubleshooting
process will lead a technician to the faulty assembly or component.
Ultra Rover Block Diagrams
This section builds on the knowledge gained in the troubleshooting overview. It provides
a block diagram for each of the subassemblies in the Ultra Rover. (The Solo Rover will
be included after it has been released.) Since the IV pole was used in the overview
example, it has not been included in the block diagram listing. The example for the IV
pole used actual data. The example can be used as a real-life troubleshooting aid.
Docking Station Block Diagrams
Similar to the Ultra Rover block diagrams section, here the technician can find a
troubleshooting aid for the docking station.
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System Troubleshooting Chart
This section provides data for each subsystem in the Ultra Rover. Proper
troubleshooting requires the technician to be able to determine whether the equipment
is performing as it should. The chart provides voltage and resistance measurements for
the subassemblies in the Rover. This should enable the technician to check the
resistance between points to verify continuity, measure for the correct voltage at a
connector, and ultimately to check for proper operation at each subassembly.
System Setting Menu
The system settings menu lists what options the user can change, and explains how to
access those options. This information is also provided to the user in the Instructions for
Use.
Technician Menu Overview
The technician menu is provided exclusively to the technician. Here the technician will
find information on how to manually control the docking sequence, perform calibrations,
reprogram software, and more. It is important to note that the information listed
here is meant for a Stryker certified trained technician only. This information should
be considered sensitive material. It is possible for someone to adversely affect the
operation of the Neptune Waste Management System if they are unaware. The
technician should understand how their menu choices in the technician menu will affect
the system.
Neptune Error Codes
The error messages in the Neptune Waste Management System are categorized into
17 different groups. Each category relates to a specific subsystem in either the Rover or
the Docker. Messages are displayed on the Vacuum display on the Rover user interface
panel and can be identified by a specific number. Each error code is generated for a
specific failure.
This should aid the technician in narrowing the search for a faulty component or
assembly. In some cases, a fault will generate multiple error codes. For instance, if a
wire harness fails, it may prevent a circuit board from communicating with several
subassemblies. This would result in multiple communication errors. This section
describes what each fault means, what components could generate that fault, and what
the initial troubleshooting steps should be.
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Chapter 5 –Technical Procedures
The disassembly procedures listed in chapters 2 and 3 provide a step-by-step process to
remove components in the Neptune Waste Management System. The procedures in
chapter 5 are provided to outline the steps necessary in a process other than removal.
Each process guides the technician from start to finish through procedures that mostly
require navigation through the Rover’s software menus. Included in this chapter are:
Field calibration
Electrical safety and testing
Detailed description of how to manually control the docking station
Multiple procedures designed to help the technician troubleshoot
Chapter 6 –Installation
This section provides the technician with the information required to install a Neptune 2
Waste Management System.
Chapter 7 –Appendices
The appendices section provides information for the technician that falls outside of the
information provided in each of the previous chapters. Appendix A is the section on the
230V Ultra Rover/ Docker troubleshooting and component removal/replacement. This
provides the international technician with instruction to remove/replace components,
troubleshooting, as well as electrical safety and functional testing information.
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2014/12 0702-002-619 Rev C www.stryker.com
Chapter 1 - Operational Description........................................................................................................1-1
General Description .............................................................................................................................1-1
Small Canister......................................................................................................................................1-1
Large Canister......................................................................................................................................1-1
Vacuum................................................................................................................................................1-1
Pre-Fill .................................................................................................................................................1-2
Smoke Evacuator.................................................................................................................................1-2
Docking Mechanism............................................................................................................................1-2
Docking Functions...............................................................................................................................1-2
IV Pole .................................................................................................................................................1-2
User Interface.......................................................................................................................................1-3
Chapter 2 –Ultra Rover Disassembly .....................................................................................................2-4
Front Panel Assembly P/N 0702-001-070...........................................................................................2-1
Rear Panel Assembly P/N 0702-001-060............................................................................................2-4
Lower Panel Assembly P/N 0702-001-030 .........................................................................................2-7
Bumper Assembly P/N 0702-001-940; 0702-001-950........................................................................2-8
Top Cover Assembly P/N 0702-001-090Q..........................................................................................2-9
Main Control PCBA P/N 0702-001-800Q.........................................................................................2-13
Volume Display Assembly P/N 0702-001-840Q ..............................................................................2-20
Removing Large and Small Canisters P/N 0702-001-320Q & 0702-001-300Q...............................2-26
Separation of Large & Small Canister Assemblies............................................................................2-32
Small Canister Assembly P/N 0702-001-300Q.................................................................................2-36
Power Transformer Assembly P/N 0702-002-830 ............................................................................2-39
Coupling Block Assembly P/N 0702-001-600Q ...............................................................................2-42
Exhaust Plenum Assembly P/N 702-001-930....................................................................................2-44
IV Pole Assembly P/N 0702-001-500Q ............................................................................................2-46
Prefill Tank P/N 702-001-370Q.........................................................................................................2-48
Prefill Pump Assembly 0702-001-380...............................................................................................2-49
Fluid Diverter Assembly P/N 0702-001-350Q..................................................................................2-50
Smoke Evacuator Assembly Removal P/N 0702-001-400Q.............................................................2-53
Vacuum Manifold Assembly P/N 0702-001-110Q ...........................................................................2-59
Fluid Suction HEPA Housing Assembly P/N 0702-001-110Q.........................................................2-63
Vacuum Pump Assembly P/N 0702-001-100Q.................................................................................2-65
Silencer Manifold Assembly P/N 0702-001-160Q............................................................................2-68
Caster Assembly P/N 0702-001-012Q; 0702-001-013Q.....................................................................2-1
Figure 4. Position of nut on caster stemManifold Receptacle Assembly P/N 0702-001-230Q ..........2-3
Rover Power Coupler Circuit Board Assembly P/N 0702-001-806Q.................................................2-5
Power Entry Module P/N 0702-001-862.............................................................................................2-6
Power Distribution PCBA P/N 0702-001-035Q..................................................................................2-7
AC Power PCBA P/N 0702-001-802Q................................................................................................2-9
Chapter 3 –Docker Disassembly.............................................................................................................3-1
Chassis Top Cover Removal P/N 0702-014-011.................................................................................3-1
Actuator Assembly P/N 0702-014-100................................................................................................3-2
Docker Power Coupler Assembly P/N 0702-014-114.........................................................................3-6
Extend Hall Sensor P/N 0702-014-119................................................................................................3-8
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1-2
(Retract) Hall Sensor P/N 0702-014-906.............................................................................................3-8
Stepper Motor P/N 0702-014-123 .....................................................................................................3-10
Offload Pump P/N 0702-014-201......................................................................................................3-12
Electromagnet P/N 0702-014-920 .....................................................................................................3-14
Injector Pump Assembly P/N 0702-001-380.....................................................................................3-14
Docker Isolation Transformer P/N 0702-014-520.............................................................................3-17
Water Inlet Assembly P/N 0702-014-400..........................................................................................3-19
Docker Power Coupler PCBA P/N 0702-014-510 ............................................................................3-20
Docker Main Controller PCBA P/N 0702-014-500...........................................................................3-21
Power Switch P/N 0700-001-412 ......................................................................................................3-23
Power Plug Module P/N 0702-014-019.............................................................................................3-25
Chapter 4 –Troubleshooting ...................................................................................................................4-1
Troubleshooting Overview ..................................................................................................................4-1
Rover System Block Diagrams –Ultra Rover.....................................................................................4-5
Vacuum System...............................................................................................................................4-5
Fresh Water System......................................................................................................................... 4-6
Waste System................................................................................................................................... 4-7
Docking Station Block Diagram..........................................................................................................4-8
System Troubleshooting Chart ............................................................................................................4-9
Main Control Board......................................................................................................................... 4-9
AC Power Board, Volume Display Board, & Tank Valve Motor.................................................4-11
IV Pole, Fluid Diverter, Power Coupler, Prefill Pump, & Canister Calibration Board.................4-12
System Settings Menu Overview.......................................................................................................4-13
Adjusting System Settings.............................................................................................................4-13
System Setting Options..................................................................................................................4-15
Technician Menu Overview...............................................................................................................4-16
To Access the Technician Menu (Away from the Docker)...........................................................4-17
To Access the Technician Menu (At the Docker) .........................................................................4-18
Neptune 2 Error Messages.................................................................................................................4-25
Chapter 5 –Technical Procedures .........................................................................................................5-38
Technical Procedures Overview..........................................................................................................5-1
Procedure 5.0 –Running with Errors ..............................................................................................5-1
Procedure 5.1 –Priming the Detergent Pump .................................................................................5-4
Procedure 5.2 –Manually Filling the Detergent Tube ....................................................................5-8
Procedure 5.3 –Reprogramming Rover Software...........................................................................5-9
Procedure 5.4 –Performing the Canister Calibration....................................................................5-12
Procedure 5.5 –Testing .................................................................................................................5-22
Procedure 5.6 –Clearing a Clog in the Small Canister ................................................................. 5-35
Procedure 5.7 –Finding a Missing Magnet...................................................................................5-40
Procedure 5.8 –Manually Raising & Lowering Docker Couplers................................................5-48
Procedure 5.9 –Preventive Maintenance....................................................................................... 5-52
Procedure 5.10 –Cleaning the Fluid Collection Canisters............................................................5-72
Chapter 6 –Installation..........................................................................................................................6-91
Chapter 7 –Appendices...........................................................................................................................7-1
Appendix A –230V Ultra Rover/ Docker...........................................................................................7-1
Appendix B –List of Materials .........................................................................................................7-21
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Appendix C –Power Distribution Block Diagram............................................................................7-34
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