Tyco Healthcare KENDALL 6060 Novamedix A-V Impulse System User manual

SERVICE MANUAL
MODEL 6060

Contents
1. WARRANTY DECLARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Controller functionality tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Computer based test method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Preventative maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. FAULT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Liquid crystal display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Impulse control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4. COMPONENT REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . 18
4.1 Opening and closing the controller case . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Replacing an air hose socket ‘O’ ring seal . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Replacing an air hose socket body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Replacing the membrane fascia label . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Replacing the membrane switch panel . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.6 Replacing the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.7 Replacing the reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.8 Replacing a fill or vent valve piston . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.9 Replacing a valve coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.10 Replacing the fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.11 Replacing the valve driver PCB assembly . . . . . . . . . . . . . . . . . . . . . . . 28
4.12 Replacing the processor PCB assembly . . . . . . . . . . . . . . . . . . . . . . . . 28
4.13 Replacing display components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.14 Replacing the EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.15 Replacing the power supply assembly . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.16 Replacing the power cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.17 Replacing the power inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.18 Replacing a fuseholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.19 Replacing the power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5. UPGRADE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6. LIST OF SUPPORTING ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FIGURES
Figure 1 View of the front of the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2 View of the rear of the controller and the bed hook / handle . . . . . . 2
Figure 3 Compressor user serviceable parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 4 View of opened case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 5 View of the processor PCB assembly and liquid crystal display . . . . 21
Figure 6 View of compressor and valve driver PCB assembly showing
the pneumatic and electrical connections . . . . . . . . . . . . . . . . . . . . . . 24
Figure 7 Diagram of valve driver PCB assembly showing pneumatic
and electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 8 Exploded view of both display assemblies . . . . . . . . . . . . . . . . . . . . . . 29
Figure 9 View of power supply assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 10 Arrangement of wires on the power inlet . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 11 View of fuseholders and ground test screw . . . . . . . . . . . . . . . . . . . . . 33
Figure 12 Arrangement of wires on the power switch . . . . . . . . . . . . . . . . . . . . . 34
Figure 13 Electrical schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 14 Pneumatic schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Contents

1
1. LIMITED WARRANTY AND FACTORY SERVICE
Kendall Healthcare Products Company hereafter called Kendall warrants that your
A-V Impulse System® controller does not contain defective materials or workmanship.
This warranty is for one year from the delivery of the controller to the original purchaser.
If within the first year of purchase there is a fault on the unit, the controller should be
returned to the Kendall Service Center at the address shown below, and Kendall will free
of charge, inspect the unit and replace any part which upon their examination, appears to
be defective provided that there is no evidence that the unit has been tampered with, or
mistreated. This warranty does not apply to the air supply hoses or to the disposable
ImPad® inflation pads or to equipment damaged through shipping, tampering,
negligence, or misuse, including liquid immersion, autoclaving, or ETO sterilization.
If, within the first year of purchase the controller is serviced by personnel other than those
expressly authorized by Kendall, the warranty becomes void, and the company cannot be
held liable for any consequential damage caused as a result.
Some states do not allow the exclusion or limitation of accidental or consequential
damages, so the foregoing limitation or exclusion regarding damages may not apply. Also,
this Limited Warranty gives you specific legal rights, and you may also have other rights,
which vary, from state to state.
This Service Manual is intended as a guide to technically qualified personnel when
evaluating instrument malfunctions, it is not to be construed as authorization to perform
warranty repairs. Unauthorized service will void the warranty.
The Kendall Healthcare Products Company maintains service facilities with the capability
to promptly repair an A-V Impulse System® controller. Controllers requiring repairs must
be shipped fully assembled, prepaid and insured to -
The Service Manager,
Building 2,
Kendall Healthcare Products Company,
5 Hampshire Street,
Mansfield, MA 02048.
Telephone: [phone].
If possible, the original packaging should be used to ensure safe arrival. Before shipping
your unit please call the above number first to obtain a return materials authorization
number.
If you have any service maintenance problems, contact the Service Manager at Kendall.

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Bed hook/handle
Membrane
switch panel
Membrane
fascia label
Power
switch
Case front
Liquid crystal display
Patient left air
hose socket
Communication port Patient right air
hose socket
Case
screws
Ground test srew
Instruction
label
Figure 1: View of the front of the controller
Figure 2: View of the back of the controller and the bed hook/handle.
Fuseholders
Tamper
label
Power cord retainer

3
2. MAINTENANCE
2.1 INTRODUCTION
Personnel servicing this equipment should be familiar with the Operator’s
Instruction Manual and the operating principals of the A-V Impulse System®
Controller. The alarm indicators displayed by the controller are useful in diagnosing
problems. If a controller needs to be returned to Kendall for service, it should be
accompanied by a description of the problem and any fault or error codes that are
displayed along with a return materials authorization number.
This manual conforms with the Kendall policy of restricting service procedures to
board level. In accordance with this policy circuit diagrams, repair and test
information are not available for service personnel to attempt component level
repair. Kendall maintains a stock of replacement boards if one is needed.
Throughout this manual user serviceable items are shown in italic type. The
descriptions used are identical or abridged versions of items listed in Section 6.
THE CONTROLLER SHOULD ALWAYS BE DISCONNECTED FROM LINE
VOLTAGE BEFORE ATTEMPTING ANY MAINTENANCE OR SERVICING
PROCEDURE.
2.2 CONTROLLER FUNCTIONALITY TESTS
The functionality tests specified are the same as that used to verify correct operation of
the controller prior to product release. Throughout this document reference is made to
part or all of these tests to provide an effective means of verifying controller function.
2.2.1 Ensure that the controller is not connected to line voltage.
Release each fuseholder and confirm that the fuses are 1A and T speed rated.
Replace the fuses and confirm that the fuse holder locks correctly.
2.2.2 Switch ON the controller and check that the start up routine and displays are
clearly shown as described in the Operator’s Instruction Manual model 6060.
2.2.3 Check that all of the backlight LEDs are illuminated.
2.2.4 Check that the compressor and fan are running.
2.2.5 Press the patient right and patient left PRESETS 1-2-3 buttons, and check
that the pressure and impulse duration for each preset are correct.
2.2.6 Press the RUN . STOP Patient LEFT and the RUN . STOP Patient RIGHT
buttons until the air hose and foot icons appear. The buttons should not need
to be pressed more than twice.
2.2.7 Press the patient left and patient right '+' and '-' buttons twice each and
check that the displayed pressure value changes.
2.2.8 Press the CYCLE button once. The cycle icon and cycle value should be
displayed for five seconds.

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2.2.9 Connect the Standard test load (1 litre) to the patient left and patient right channels.
Check the pressure displayed is 130 mm Hg and the hold time is 3 seconds. Press
the RUN . STOP Patient LEFT and the RUN . STOP Patient RIGHT buttons.
Confirm that the check marks appear within 4 impulses on each channel.
2.2.10 With the cycle time set to 20 seconds, use a stopwatch to measure the time
between impulses. The interval should be 20 seconds +/- 1 second.
2.2.11 Use an Electrical Safety Analyzer to check that the resistance of the power
cord is less than 0.2 ohms. The analyzer test lead must be connected to the
ground screw on the power cord retainer.
2.2.12 With the power switch in the ON position, use an Electrical Safety Analyzer
to check that the leakage current is less than 0.1 mA. The analyzer test lead
must be connected to the ground screw on the power cord retainer.
2.3 COMPUTER BASED TEST METHOD
The Service Solutions CD-ROM contains an audio visual presentation illustrating
service techniques and the extensive FrontLite® PC based test program suitable for
inspection and preventative maintenance purposes.
This program is used to verify compressor output and impulse pressure using the
Standard test load (1 litre) and controller cycle and inflation times through the
controller communication port using the controller to computer interface cable. The
controller can also be connected to a modem for remote interrogation through the
communication port using the controller to modem interface cable.
2.4 REGULAR MAINTENANCE
The only regular maintenance necessary is to clean the outer case of the controller
when required, and to check the air supply hoses and connectors for damage.
Remove external fluff from the fan inlet and outlet grills by gently vacuuming them
and then remove fluff from the fan blades by blowing them with low-pressure air,
without over-speeding the fan.
POSITION THE CONTROLLER TO REDUCE LINT ENTRY AND DO NOT
COVER WITH BEDDING.
The controller case should be cleaned with a soft cloth dampened with water. If
necessary the unit can be wiped with a mild disinfectant and/or detergent, but excess
fluid should be avoided. The controller should be wiped dry with a clean cloth.
Caution: Avoid the use of commercial cleaning solutions that contain
Ammonium Chloride as the active ingredient. Such solutions are not compatible
with the case materials.
NEVER IMMERSE THE CONTROLLER IN WATER, SPRAY LIQUID INTO THE
CONTROLLER GRILLS OR STERILIZE BY ETO OR STEAM AUTOCLAVING AS
IRREPARABLE DAMAGE WILL BE CAUSED.

5
2.5 PREVENTATIVE MAINTENANCE
To maintain optimum functional performance and electrical safety it is
recommended that after one year’s operation, and then every year, the controller be
removed from use and checked.
Carry out all of the procedures contained in Sections 2.5.1 through 2.5.8 inclusive,
referring to the recommended service schedule throughout.
When a controller is opened for service or repair, remove accumulated dust from
inside the case halves, especially around the fan blades and fan housing area.
2.5.1 Labeling
Examine the labels on the controller and ensure they are legible and intact.
If any of the information on a label cannot easily be read, the label should
be replaced.
2.5.2 Power Cord
Examine the power cord assembly and replace the power cord if there are any
signs of damage (see Section 4.16).
As a quick check use a digital ground tester, and check that the resistance
between the ground pin on the power cord, and the power cord retainer screw
is 0.2 ohms or less.
If this value is greater than 0.2 ohms, remove the power cord and test the
power cord separately.
If the resistance of the power cord is greater than 0.1 ohms, then it should be
replaced.
If the resistance of the power cord is less than 0.1 ohms, measure the
resistance between the ground pin of the controller power inlet, and the
ground test screw. If the value of this resistance is greater than 0.1 ohms, the
controller should be returned to the Kendall Service Center for repair.
Connect the controller, via the power cord, to an Electrical Safety Analyzer
and confirm the ground resistance and leakage current (see Sections 2.2.11
and 2.2.12). If the test values exceed these limits the controller should be
returned to the Kendall for repair.
Ensure that the power cord retainer screw is securely fastened for this test.
2.5.3 Cooling Fan
Check that the cooling fan is running smoothly and there is no vibration or
other noise that might indicate the fan is damaged or obstructed. If the
cooling fan is not operating at normal speed and efficiency, open the case to
inspect it more closely. Beware of metal parts at higher than line voltage.
For greater access to the fan, the power supply assembly should be removed
(see Section 4.15).
Use a vacuum cleaner or low pressure air to remove dust or debris from the
cooling fan and grill.
Refit the power supply.

6
2.5.4 Membrane Switch Panel and Display
Switch ON the controller and check the Liquid Crystal Display (LCD) for
sharpness, legibility and brightness. If the display appears dim or segments
are missing, dismantle the display assembly and clean the contacts to the LCD
(see Section 4.13). If after reassembling the controller the display is still
defective, then replace the zebra elastomer and the LCD bezel (snap fit) only.
Use the following tests to check that the buttons on the membrane switch
panel are working effectively. If a button has to be pressed hard or more than
once in order to get a response, then replace the switch panel (see Section 4.5).
Press the RUN . STOP Patient LEFT and the RUN . STOP Patient RIGHT
buttons and check that the air hose and foot icons appear. Ensure the
controller delivers an impulse to each channel. Stop the impulsing by
pressing the RUN . STOP buttons.
Use the PRESETS 1-2-3 button to select each setup in turn, and check that the
information displayed matches the description in the Operator's Instruction
Manual.
Use the "+" and "-" buttons to alter the impulse pressure.
Press the CYCLE button, then use the "+" and "- " buttons to alter the cycle time.
2.5.5 Air Hose Sockets
Replace the ‘O’ ring seals within the air hose sockets (see Section 4.2).
Examine the socket face for damage such as chips and cracks. If there is any
visible damage replace the socket (see Section 4.3).
2.5.6 Compressor
Service Interval
Compressors should be tested and maintained at 3000-hour intervals, except
for compressors identifiable by a green dot on the air filter plate, which have a
6000-hour interval.
A compressor service kit is available containing all necessary parts to upgrade
to a 6000-hour service interval.
Compressor Performance
PC test method
The compressor output pressure may be tested by using the Service Solutions
CD –ROM FrontLite® test program and a PC connected through the
controller communication port using the supplied cable and Standard test
load (1 litre), following the supplied instructions.
Manual test method
To manually test the compressor output pressure open the controller case
front approximately one inch and carefully remove the 7 way flat flexible
cable from the processor PCB assembly. Position the controller onto its
handle, on a flat surface. Disconnect the compressor supply tube at the

7
reservoir nipple and connect it to a pressure meter. Reinstate the controller to
the upright position. Turn the controller power switch ON and read the
pressure output.
Controller test method
For controllers with version 16 software the compressor output pressure can
be tested directly on the controller using a Standard test load (1 litre)
connected to the patient right channel.
Turn the controller power switch ON and during the 5 second countdown
press the patient right "-" button twice in quick succession to start the test. A
60-second countdown is displayed in the top left of the LCD and a flashing "P"
in the top right. When the countdown is complete the controller will impulse
once from the patient right channel into the test load. The compressor output
pressure is displayed in the top right of the LCD for 20 seconds, or until any
button is pressed, after which the controller will revert to normal operation.
If the compressor output pressure is less than 16 psi then the compressor
should be replaced with a new item, or removed from the controller and
returned to the Kendall Service Center for a compressor exchange,
alternatively the complete controller can be returned to Kendall for repair.
If required, the compressor may be serviced in-situ as follows.
Compressor Overhaul
Reference should be made to the Recommended Service Schedule table for
guidance into compressor component replacement intervals.
The compressor specification is subject to a policy of continuous
improvement and in accordance with this policy particular parts are available
as upgrade items. This procedure is sequentially structured and assumes that
latest upgrade parts are used throughout.
ENSURE THAT THE CONTROLLER IS NOT CONNECTED TO LINE
VOLTAGE.
Air filter replacement
Undo the center screw at the top end of the compressor, and remove the
plate. Lift out the air filter element and discard. Wipe clean the air filter
recess and replace the air filter element. Apply one drop of Loctite 242 to the
screw thread. Replace the plate and screw down securely.
Compressor disassembly
Without putting stress on the rubber mounting feet, unscrew the four screws
securing the cylinder head using a Phillips #2 screwdriver. Carefully pull the
cylinder head and front cover gasket away from the compressor body.
Remove the front cylinder housing.
Loosen the screw holding the exhaust valve in place on the front cylinder
housing, and rotate the valve to one side. Use an Isopropyl Alcohol (IPA)
swab to carefully wipe the cylinder housing and the rubber seal in the exhaust

8
valve. Align the rubber seal, metal valve, and over extension stop accurately
over one another and 0.25mm from the edge. Tighten the screw and confirm
their position.
OBSERVE HEALTH AND SAFETY PRECAUTIONS WHEN HANDLING
CHEMICALS.
Remove the piston assembly, complete with spring and spring seat. Clean out
the inside of the compressor body by blowing with compressed air.
If the piston can not be removed then the compressor may be out of
alignment. The compressor should be replaced with a new item, or removed
from the controller and returned to the Kendall Service Center for a
compressor exchange, alternatively the complete controller can be returned
to Kendall for repair.
Compressor disassembly if it is out of alignment
With access to a compressor alignment tool the compressor may be re-
aligned on site.
Remove the compressor from the controller (see Section 4.6).
Undo the two screws holding the rear cover to the compressor body and
lift the cover off the wiring grommet.
Slacken the two screws holding the rear cylinder housing to the compressor
body and carefully withdraw the piston assembly, complete with spring and
spring seat.
Remove the two screws holding the rear cylinder housing to the
compressor body, separate the parts and work the housing out from
between the coils.
Inspect the rear cylinder housing bearing insert for wear. The insert must
be hemispherical in shape. If the insert is worn, remove the old bearing
and press in a replacement. If the rear bearing is serviceable wipe off all
grease residue with an Isopropyl Alcohol (IPA) swab.
Remove the laminations and coils from the compressor body.
Compressor re-alignment
Clean off all residual adhesive from the rear cylinder housing,
laminations and compressor body. Blow all compressor parts and the
compressor body with low pressure compressed air
Stand the compressor alignment tool upright on a flat surface, with the
small diameter upwards.
Place the compressor body over the alignment tool with the rear end
uppermost and the feet toward you, ensuring that it locates correctly in
the front cylinder housing recess.
Apply Loctite 454 (or 410) evenly around the lamination mating surface

9
of the compressor body. Apply Loctite 454 to the rear cylinder housing
mating surface of the compressor body adjacent to the fixing screw holes.
Place the laminations and coils, with the wire grommet facing towards
you, on top of the compressor body. With one hand keep the
laminations elevated above the adhesive.
Position the rear cylinder housing with screws and washers between the
coils and on the alignment tool. Insert and tighten the rear cylinder
housing retaining screws.
Place the rear cover onto the upper surface of the laminations. Lower
the laminations and rear cover onto the adhesive on the compressor
body. Insert and tighten the rear cover retaining screws. Wipe off any
excess adhesive.
Remove the alignment tool.
Compressor body
Rear cylinder housing
Rear cylinder housing
bearing insert
Rear cover
Front cover gasket
Plate
Air filter
element
Cylinder
head
Outlet
port
PTFE
gasket front
Rubber mounts
Spring seat
Spring
Piston assembly
Sealing ring
PTFE gasket rear
Front cylinder housing
Exhaust valve assembly
Figure 3: Compressor user serviceable parts

10
Recommended Service Schedule
PART DESCRIPTION SERVICE INTERVAL HOURS
NUMBER 3000 5-6000 8-9000 11-12000
COMPRESSOR
AV6534-00 Air filter element MMMM
AV6531-00 Piston assembly MMMM
AV6532-01 Front cylinder housing U1 M U1 U1 M U1
AV6708-01 Rear cylinder housing U2 M U2 U2 M U2
AV6710-00 Rear bearing insert DDDD
AV6533-00 Spring MMMM
AV6538-00 Spring seat MMMM
AV6709-01 Compressor lubricant U3 U3 U3 U3
AV6536-00 PTFE gasket, front DDDD
AV6537-00 PTFE gasket, rear DDDD
AV6535-00 Front cover gasket DDDD
COMPRESSOR Extended life
AV6534-00 Air filter element N M N M
AV6531-00 Piston assembly N M N M
AV6532-01 Front cylinder housing N M N M
AV6708-01 Rear cylinder housing N M N M
AV6710-00 Rear bearing insert N D N D
AV6533-00 Spring N M N M
AV6538-00 Spring seat N M N M
AV6709-01 Compressor lubricant N M N M
AV6536-00 PTFE gasket, front N D N D
AV6537-00 PTFE gasket, rear N D N D
AV6535-00 Front cover gasket N D N D
GENERAL PARTS
AV6555-00 ‘0’ ring seal LLLL
AV6540-00 Case foot set AAAA
AV6541-00 Case and handle grip set AAAA
AV6598-01 Tamper seal grey MMMM
AV6547-00 Reservoir assembly U4 D M D
AV6564-16 EPROM U5 U5 U5 U5
AV6517-02 Fan assembly U6 N D N
AIR HOSE
AV6801-04 Connector inflation pad end DDDD
AV6802-02 Connector unit end DDDD
5007 Air hose blue DDDD

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Key to Recommended Service Schedule
M Mandatory Replacement
U1 Upgrade Possible: Replacement of Front cylinder housing AV6532-00 with AV6532-01 to
extend compressor service interval to 6000-hours
U2 Upgrade Possible: Replacement of Rear cylinder housing AV6708-00 with AV6708-01 to
extend compressor service interval to 6000-hours
U3 Upgrade Advised: Replacement of Compressor lubricant AV6709-00 with AV6709-01 for
improved lubrication.
U4 Upgrade Possible: Replacement Reservoir. Please call the Kendall Service Center for details.
U5 Upgrade Possible: Replacement EPROM available for upgrade to the latest software version.
U6 Upgrade Recommended: Replacement Fan AV6517-00, or –01 with AV6517-02 for
improved durability.
D Replace on discretionary basis
L Lubricate with ‘O’ ring lubricant AV6545-00
A Replace using Loctite 401 after cleaning off all residual adhesive from molding.
N No action
Compressor assembly
Fit a replacement spring and spring seat to the piston by twisting and pushing
and check that they are both secure.
Apply a 2-mm diameter sphere of compressor lubricant to the spring seat and
insert the piston; spring first, into the compressor body.
Carefully place the front cylinder housing over the piston, locating the boss in
the front cylinder housing recess and orientated to align the exhaust valve
above the outlet port.
Check that the front cover gasket is undamaged and supple. If it is not,
replace it. Fit the gasket over the pins on the underside of the cylinder head.
Carefully place the cylinder head and the gasket onto the compressor body
(with the serial number label uppermost), being careful to locate the pins in
the cylinder head in their corresponding holes in the compressor body.
Insert the cylinder head screws into the holes and tighten them up evenly using
a Phillips #2 screwdriver. DO NOT EXCEED 4.5lb/in (5.2kg/cm) TORQUE.
Apply the green dot to the air filter plate to identify the compressor has been
fitted with upgrade parts.
WHEN CONNECTING TO THE POWER SUPPLY, BEWARE OF
EXPOSED METAL PARTS AT HIGHER THAN LINE VOLTAGE.
Refit the compressor back into the controller.
Connect the controller to line voltage.
Test the compressor according to any method detailed in compressor
performance at the start of this sub-section.

12
2.5.7 Alarms
Kinked air supply hose.
Connect the Standard test load (1 litre) to the patient right outlet. Switch ON
the controller and press the RUN . STOP Patient RIGHT button, wait for the
check mark to appear.
Kink the air supply hose to the test load. At the next impulse the controller
will detect that the air hose is kinked, the air should be dumped immediately
through the vent valve and the check mark will disappear.
After another three impulses the display should show the icon for a kinked air
hose and a flashing fault code of 2, the audible alarm should sound and the
controller should continue with short impulses. If the air is not dumped
through the vent valve after the next cycle, then unkink the air hose and
replace the valve driver PCB assembly (see Section 4.11).
After the audible alarm sounds, unkink the air hose. At the next impulse the
controller should detect that the kink has been removed, the audible alarm
should stop and the icon for the kinked air hose should no longer be displayed.
Allow the controller to continue impulsing until the check mark is displayed.
Repeat this test procedure for the patient left channel.
Detached air supply hose
Connect the Standard test load (1 litre) to the patient left outlet. Do not
connect the patient right outlet.
Switch ON the controller, press the RUN . STOP Patient LEFT and the RUN .
STOP Patient RIGHT buttons. After the first impulse to the patient right
channel the controller should detect that the patient right air hose is
detached. The display should show an arrow between the icon for the
controller and the icon for the patient right air hose, and display a flashing
fault code of 1. The audible alarm should sound, and the controller should
continue to impulse to both channels.
Without stopping the impulses, disconnect the test load from the patient left
channel and connect it to the patient right channel. Do not connect the
patient left outlet. At the next impulse to the patient right channel, the
controller should detect that an air hose has been connected, and the fault
code for the patient right channel will no longer be displayed. After four
impulses to the patient left channel, the display for this channel should show
the icons for a detached air supply hose.
If the controller does not alarm correctly the controller should be returned to
the Kendall Service Center.

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2.5.8 Functionality and safety tests
Close the case.
Perform the controller safety tests to confirm the ground resistance and
leakage current (see Sections 2.2.11 and 2.2.12).
Perform the complete controller functionality tests (see Section 2.2 or 2.3).

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3. FAULT DIAGNOSIS
THE CONTROLLER SHOULD ALWAYS BE DISCONNECTED FROM LINE
VOLTAGE BEFORE ATTEMPTING ANY MAINTENANCE OR SERVICING
PROCEDURE.
Before undertaking any fault diagnosis, check the fuses. If, when the controller is switched
ON, a replacement fuse blows immediately, the controller should be returned to the
Kendall Service Center for repair.
The diagnostic procedures specified assume that the controller is connected to line voltage
and switched ON. When diagnosing any fault, check the power supply output voltages first.
3.1 POWER SUPPLY
WHEN CHECKING THE POWER SUPPLY VOLTAGES, BEWARE OF EXPOSED
METAL PARTS AT HIGHER THAN LINE VOLTAGE.
See the table below for the power supply assembly test points.
CONNECTOR/PIN (-) CONNECTOR/PIN (+) VOLTAGE (±5%)
PL3/1 PL3/2 +5V DC
PL3/1 PL3/3 +24V DC
PL4/1 PL4/2 +5V DC
PL4/1 PL4/3 +24V DC
PL5/1 PL5/3 <10V DC
PL5/1 PL5/3 120V AC see note
(Line Voltage)
NOTE:Link PL4/4 to PL4/2 Via a 1K resistor. Disconnect the connector from the
valve driver PCB assembly at PL3, and insert the legs of the resistor into the
socket.
Use standard antistatic precautions when handling the electronic PCB’s.
3.2 LIQUID CRYSTAL DISPLAY
(Including the LED backlighting and Liquid Crystal Display)
If the Liquid Crystal Display (LCD) is not backlit or only partially lit check the power
supply output voltages.
Confirm the power supply voltages conform to the table (see Section 3.1).
If the voltages are correct then replace the processor PCB assembly. If the voltages are
not correct then replace the power supply assembly.

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If the LCD elements are incomplete dismantle the display and clean the zebra
elastomer and contact surfaces (see Section 4.13).
If the LCD is entirely blank check the power supply output voltages.
Confirm the power supply voltages conform to the table (see Section 3.1).
If the voltages are correct then check the fit of the EPROM into the socket. If this
does not correct the fault, then replace the processor PCB assembly. If the voltages
are not correct then replace the power supply assembly.
Alternatively the whole controller may be returned to the Kendall Service
Center for repair.
3.3 COMPRESSOR
If the compressor is not operating check that the controller is not in the standby
condition by pressing either the RUN . STOP Patient LEFT or the RUN . STOP
Patient RIGHT buttons.
Confirm the power supply for the compressor is at line voltage.
If the line voltage is correct then remove the compressor from the controller and
return it to the Kendall Service Center for a compressor exchange. If the line voltage
is not correct then replace the power supply assembly.
Alternatively the whole controller may be returned to the Kendall Service
Center for repair.
3.4 IMPULSE CONTROL VALVES
If the controller is not impulsing air from either air hose socket, press both the RUN .
STOP Patient LEFT and the RUN . STOP Patient RIGHT buttons, check that the
LCD shows that the controller is impulsing and listen for air issuing from the patient
outlets. If air is not heard check the compressor performance (see Section 2.5.6).
Additionally the valve function can be checked by switching the controller OFF and
ON, and listening for the sequence of multiple clicks as the valves are cycled during
the start up routine.
If the clicks are not heard, check that the electrical connections to the valve driver
PCB assembly and from the valve driver PCB to the valve coils are secure. If the valves
still do not operate, disassemble the valves and clean them (see Section 4.8).
Alternatively the whole controller may be returned to the Kendall Service
Center for repair.

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3.5 ERROR CODES
See the table below for controller error codes.
CODE DESCRIPTION CAUSE REMEDY
E01 RAM error Failure on processor Replace the processor
PCB assembly PCB assembly
E02 ADC error ADC output is not zero Check that there is no
at switch ON pressure on the transducer
at switch ON
Replace the valve driver
PCB assembly
E03 NVR error Failure on processor Replace the processor
PCB assembly PCB assembly
E04 Membrane switch Buttons depressed at Do not depress buttons at
panel error switch ON switch ON
Defective membrane Replace defective
switch panel membrane switch panel
E05 Left fill Left fill valve not Dismantle and clean
closing properly valve components
Replace the fill valve piston
E06 Left vent Left vent valve not Dismantle and clean
closing properly valve components
Replace the vent
valve piston
E07 Right fill Right fill valve not Dismantle and clean
closing properly valve components
Replace the fill valve piston
E08 Right vent Right vent valve not Dismantle and clean
closing properly valve components
Replace the vent
valve piston
E09 Hardware version The software and Check with the Kendall
hardware versions are Service Center
not compatible
E10 High pressure trip The high pressure trip Check that there is no
line is not zero pressure on the transducer
at switch ON
Replace the valve driver
PCB assembly

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CODE DESCRIPTION CAUSE REMEDY
E11 NVR setup A new software version Switch OFF and ON
has failed to update
Non-Volatile RAM
E12 Over Temperature Over Temperature Check the fan grills are not
Cutout Cutout exceeded obstructed
113°F (45°C)
Check the fan is operating
at normal speed and
efficiency
Replace the fan