Welch Allyn PneumoCheck 61000 User manual

Service Manual
PneumoCheck™
Spirometer Model # 61000,
Printer Charger #’s 76100 & 76106
Welch Allyn Medical Division
4341 State Street Road
P.O. Box 220
Skaneateles Falls, NY 13153-0220
Copyright 1997
Part 610132

Service Manual 610132 Rev. E Pneumocheck Handle and Printer/Charger 1
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DRAWINGS AND/OR ILLUSTRATIONS AND/OR PART NUMBERS CONTAINED IN THIS DOCUMENT
ARE FOR REFERENCE PURPOSES ONLY! FOR CURRENT REVISIONS CALL WELCH ALLYN.

2 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E

Service Manual 610132 Rev. E Pneumocheck Handle and Printer/Charger 3
Contents
General Information........................................................................................................... 5
1.1 Handheld Spirometer ................................................................................................................6
1.2 Printer .........................................................................................................................................8
Service ............................................................................................................................... 11
2.1 Bench Test Of Pneumocheck.................................................................................................12
2.2 Bench Test of Printer Charger................................................................................................17
2.3 Required Tools and Equipment .............................................................................................21
2.4 Test and Adjustment Procedures ...........................................................................................22
Theory of Operation ..........................................................................................................23
3.1 Spirometer Circuit Description ..............................................................................................24
3.2 Spirometer - Printer Circuit Description ...............................................................................30
3.3 Messages.................................................................................................................................33
Troubleshooting ................................................................................................................37
4.1 PneumoCheck Handle Technical Troubleshooting .............................................................40
4.2 Customer Service Questions and Answers.........................................................................43
Disassembly and Repair...................................................................................................49
5.1 Pneumocheck Handle Disassembly Procedures ................................................................50
5.2 Pneumocheck Printer/Charger Disassembly Procedures .................................................56
Pneumocheck Handle and Printer/Charger Spare Parts ...............................................65
List of Drawings and A Specs ..........................................................................................67

4 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E
Help Information:
•All service and repairs must be performed by authorized Welch Allyn personnel or
agents, using Welch Allyn replacement parts. Failure to do so will invalidate the
product warranty.
•If you have any questions about servicing the 61000 Pneumocheck or the 76100 or
76105 Printer Chargers, please call or write Welch Allyn:
Attn: Product Service Department
Welch Allyn, Inc.
4341 State Street Road
Skaneateles Falls, NY 13153-0220
U.S.A.
Telephone: [phone]
Fax: [phone]
• Troubleshooting assistance is contained in Section 4 of this manual.
•Please read and understand the PneumoCheck and Printer/Charger Operating
Instructions PN 610140-3.

Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 5
1.1 Basic Description - Handheld Spirometer
1.2 Basic Description - Printer
General Information
Section 1 - General Information

6 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E
Section 1 - General Information
6 Pneumocheck Handle and Printer/Charger
The handheld spirometer is a small, battery operated
device incorporating a laminar flow sensing pneumatic
liquid crystal display, and electronic circuitry in an
injection molded case.
The front panel of the handheld spirometer includes the
eight character, alphanumeric display, two push-button
keys labeled TEST and DATA, an ON/OFF slide switch
and a battery charge indicator light. The flow sensor is
housedinthetopportionofthedevice and isremovable
forcleaning and sterilization. The mouthpiece is atone
end of the flow sensor and fits disposable cups or
disposable cardboard tubes. There are two electrical
contacts on each side to the spirometers batteries. On
one side of the spirometer is a DC jack for battery
charging in case the operator chooses not to purchase
the optional printer base.
The main function of the handheld spirometer is to
gather data from two kinds of spirometry maneuvers by
patients: the FVC maneuver and the MVV maneuver.
TheTEST key is used toselectand perform thedesired
test. It is normally pressed when the spirometer is
displaying the word SELECT. It can also be pressed
during a maneuver or during the results display to
prematurely quit a test and begin another.
TheDATA key is used tocontinuewhenever the device
pauses to display some information. When the word
SELECT isbeingdisplayed,theDATA keycanbeused
to show the results of the test that is currently stored in
memory.
The general flow of usage of the device starts with the
selection of a test. The operator then waits for an
audible beep, indicating that it is ready to acquire data
fromthemaneuver. Thepatientputsthemouthpieceto
his mouth and performs the maneuver. Upon
completion indicated by another audible beep, there is
a brief delay while the results are calculated then the
result messages are displayed. This completes the
loop, and the machine goes back to SELECT and waits
for another keypress.
1.1 Handheld Spirometer
Refer to Owners Guide
P/N 610140-3

Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 7
When not in use, the handheld spirometer sits-in the
cradle of the printer base (or it is connected to an outlet
via a DC power adapter,) and the battery is charged.
The battery indicator light remains on whenever a
source of charge current is present. The spirometer
becomes operational when it is lifted from the printer
base or disconnected from the DC adapter. The
spirometer is functional only while disconnected from
the charger or printer base and the ON/OFF switch is
ON. The word SELECT appearson thedisplay and the
device waits for a keypress from the operator.
When the word SELECT is on the display, you can do
one to the following:
1. Press the test key which will start the sequence
for doing an FVC test, and MVV test, or a
calibration of the spirometer.
2. Press the DATA key which will display the test
values of the best test of a test is currently
stored in the spirometer’s memory.
3. Put the spirometer back into the printer cradle
which will start the sequence for transmitting
any test data in the spirometer’s memory to the
printer’s memory, and then resume charging
the battery.
4. Connect the spirometer to the DC power
adapter, which will resume charging the battery.
5. Turn the unit off using the ON/OFF slide switch.
A more detailed description of the operation of the
spirometer is contained in the Operator’s Manual.
Section 1 - General Information

8 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E
The printer base consists of a receptacle to hold the
spirometer, a battery charging circuit, a high speed
thermal line printer, and associated microprocessor a
power circuitry, all housed in an injection molded case.
The front panel of the printer includes 2 indicator lights,
and 3 push button keys marked STOP, FEED, and
PRINT. Also on the front panel are 5 numeric rotary
switches: 2 digits for AGE, and 3 digits for HEIGHT.
The are also 2 slide switches for selecting SEX and
RACE.
There is a set of 4 option switches located on the
underside of the unit.
The main function of the printer base is to print reports
of spirometry tests performed by the handheld
spirometer, and to charge the spirometer’s battery.
The general flow of usage is as follows:
Whenthe spirometer is placedin the cradleof the base,
it immediately begins sending data to the printer base
during which time the message SENDING appears on
the panel of the printer base. Once the data transfer is
complete, the printer base gives a compound beep and
continues to charge. The READY light on the printer
base turns on solidly, indicating that there is a test
storedin itsmemory. Theoperatorthensetsthepatient
demographic switches for the patient, then presses the
PRINT key to print the report.
There are two indicator lights on the front panel of the
printer base. One is labeled POWER and is on
wheneverthe unit ispluggedintoapowered outlet. The
other light is labeled READY, in the memory of the
printer base. When the device is receiving data from
the spirometer, this light flashes. Once the transfer is
complete and test is in memory, the light remains on.
1.2 Printer
Section 1 - General Information

Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 9
The READY light is also used to indicate an error
condition. Errors are numbered from one to three.
When an error occurs, an alarm sounds and the
READY light flashes in groups of 1, 2, or 3 flashes (at a
rate of times per second), corresponding to the error
thatwasdetected.Aonesecondpauseoccursbetween
these flashes. This continues until the error condition
has been cleared.
The PRINT key is used to print a report. If there is no
report to be printed and the PRINT key is pressed, a
short chirp will sound and no report is printed.
The FEED key is used to feed paper out of the printer.
The paper is fed as long as the key is held down. The
key is not operable while a report is being printed or
while the data is being transferred from the spirometer.
TheSTOP keyaborts the current task(reportprintingor
data transfer) and returns to the wait state of the base.
It is also used to clear the machine of any error
condition that it might be in. It does not clear the printer
base’s memory.
The demographic switches are used to indicate the
patient’s age, height, sex, and race. The AGE switch
consistsof two digits,each of whichcan range from 0 to
9. The range of valid values depends on the normal
being used.
The HEIGHT switches operate in the same manner as
the AGE switch, except that it has three digits. Either
inches or centimeters can be used for the height. As
was the case for AGE the range of valid values depend
on the normal being used.
Section 1 - General Information

10 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E
If the value for either age or height fails outside of valid
range, then the normal values are not calculated or
printed on the report.
The SEX switch is a slide switch. The up position
indicates the patient is a female, while the down
position indicates that the patient is male.
The RACE switch is also a slide switch. The up position
indicates race group 1 and the down position indicates
race group 2. Race group 1 is used if the patient is
Black, Oriental, East Indian, or Pakistani. Race group 2
is used for all other races.
Therearefour optionswitcheslocatedontheunderside
of the printer base. The switches are dip switches that
canbeineithertheON orOFFposition.Theseswitches
can be changed while the printer base is on. The
options specify certain aspects of the report printing.
They are:
1. OFF
2. OFF Knudson, 1983
1. ON
2. OFF Knudson, 1976
1. OFF
2. ON Morris, Crapo et al
1. ON
2. ON European
3. OFF: Short report form
3. ON: Long report form
4. OFF: Flow/Volume plot
4. ON: Volume/Time plot
These options are discussed in further detail in the
Operator’s Manual.
Section 1 - General Information

Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 11
2.1 BenchTestofPneumocheck
2,2 BenchTestofPrinter/Charger
2.3 RequiredToolsandEquipment
2.4 TestandAdjustmentProcedures
Service
Section 2 - Service

12 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E
1 Remove pneumotach if necessary.
2 Obtain a good set of batteries and insert in
pneumocheck.
3 Replacepneumotach. Turnpneumocheckon.If
unitpowersupcontinuetesting(steps3&
beyond).If unitdoesn’tpowerup,takeapart.
Referto troubleshootingguide.
4 Put into data mode (hold down white button,
turn unit on and release white button).
5 Observe LCD; all segments should be on.
6 Depress and release ‘test’ button. Unit should
step through a self diagnostic.
Testing > ROM OK > RAM OK > EEPRM OK>
ASLEEP
In ‘ASLEEP’ mode, the unit will stop and await
further instruction.
If unit stops before sleep mode, there is a
failure. Refer to troubleshooting guide.
7 Depress & release test button: ON reading
should be displayed. It should read
between 30 and 80. Continue testing whether
on reading is in range or not.
Calibration of this circuit will be covered in
SEC B, STEP 6.
8 Depress & release test button: Unit should give
BAT reading. This should be 815 +/- 1%
(807-823). Even if number is outside of range,
continue on to steps 9-12. Refer to
troubleshooting guide to diagnose after
completing step 12.
2.1 BENCH TEST OF
PNEUMOCHECK
SECTION A
Section 2 - Service
Caution: Adequate ESD protection
must be worn at all times when
working on the Pneumocheck,
handle or printer/charger.

Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 13
9 Depress&releasetestbutton:Ambient
temperature should be displayed.
20 degrees C = 68 degrees F
22 degrees C = 72 degrees F
24 degrees C = 75 degrees F
25 degrees C = 77 degrees F
27 degrees C = 81 degrees F
30 degrees C = 86 degrees F
If unit displays a reading outside ambient
temperature range, complete steps 10 thru 12.
Then, refer to troubleshooting guide. If unit
displays a reading of 390-400 degrees F,
check battery voltages. If battery voltage is
low, replace battery and repeat steps 4 thru
12.
10 Depress & release test button: Unit should
read FO = 55. This is a software coefficient.
11 Depress & release test button: Unit should
display a flashing ‘BAT OK’ message.
12 Depress & release test button: Unit should
display ‘DO DCV’ message.
13 Turn unit off. Depress test button and turn unit
on, release test button. Unit should read:
‘Test Mode’ >VER.3.5 >clear > select. The
latest software is VER 3.5: If unit reads VER
3.2, the software must be changed. The
PROM is part no 610102-535. It goes into
position U4 of the LCD digital PC board.
Section 2 - Service

14 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E
DisassembleUnit:
WearESD wriststrapwhenperformingthe
following operations.
1 Observe backplate; notice what must be
present:
If there is a raised surface where the ‘flat’
should be and/or if there is no recessed circle,
replace backplate (610015-503).Remove
battery holder before discarding old
backplate.
NOTE:Observe back of LCD board. If back of
LCD board does not have a metal bar, you
must replace this board.
2 Apply a moderate amount of force to the side
of each battery contact. Contact should hold
firm. If it does not, take battery contact off and
clean any dried epoxy off of metal conducting
surface on PC board.
Obtain a new battery contact (610067-1) and
solder to PC board, noting proper
positioning.
Before soldering, screw contact onto PC board
with appropriate hardware.
Lastly, tighten to specifications (approx. 12-16
in/oz.) or until moderately firm. Take note that
black fiber washer is not destroyed. Perform
this step whether epoxy was adequate or
contact had to be soldered.
SECTION B
Section 2 - Service

Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 15
3 Ifrequired,changeRedLEDtoorange
(230015-6).
4 If necessary, change software. You must
remove digital board from front plate to do
this. PROM is location U4 on digital board.
5 If necessary, reverse side contacts. To do this,
remove the two metal contacts from the black
plastic piece. Reverse the plastic piece so that
metal contacts will be raised outside of plastic
surface of main frame. Do this for each side.
6 Calibrate the transducer circuit: to get to ON
reading, see steps 4-7 section A. If ON
reading was in spec.(see step 7, section A),
set to 50 or as close as you can get (within
5 cts.), using R33 (pot at bottom of PC board).
Apply 58.8 DPA (60 mm of water with
manometer) to transducer via long hose.
Adjust R36 (pot just above R33) to 844 +/- 5
cts. Return to ODPA, reading should be 50 +/-
5 cts. Readjust if necessary.
If the transducer reading is outside of the 30-80
range, measure the transducer output ofpins 2 and 4
of the transducer. They are the two white wires
coming from the transducer. You should see no more
than approx. 300 micro volts (.3mv). If this is the
case, readjust ON reading to spec. as per sec. B,
step 6.
If you see more than 300 mcvolts (.3mv), replace
transducer.
If you cannot build pressure in transducer,
diaphragm is torn, replace transducer.
Section 2 - Service

16 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E
Oncetransduceris replaced, calibrate accordingto
Section B, step 6.
Oncetransduceriscalibrated,re-assembleunit.
7 With unit assembled and good batteries in,
without the pneumotach (top piece), insert
into working printer charger. With a DC
ammeter, measure current between the top
of each battery. You should see approx. 11 ma
recharge current.
If reading is outside of 10-12 ma, refer to
troubleshooting guide.
8 If reading is good, assemble pneumotach onto
handle. Obtain final test form.
Step through, test in ‘DATA’ mode as per
Section A, steps 4-12 .
Observe ‘ON’ reading . As you do this and
write down in appropriate place on form.
Continue to move forward until you see DO
DCV.
At this point throw switch on test printer to RXTX OK
position. This puts a short circuit between the RX and
TX communication lines. Insert handle. The following
messages should appear:
DCV SEEN > RXTX OK > CHARGE > screen blank.
If they do, remove handle, the message DO DCV
should re-appear. Return switch on test printer to RX
fail position.
These tests are taken from spec. A01943 Rev.F.
Get ready to calibrate w/3.0 liter syringe according to
spec. A01945 Rev.D.
Section 2 - Service

Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 17
1. ESDprotectionisrequired wheneverworkingwiththe
pneumocheckprinter.
2. Apply power to the unit. It should beep twice and the
“power LED” will light. The “data” light should not be
lit.
3. Note and record “dip” switch settings if customer
owned. These switches will have to be returned to
thesepositionswhen testing is complete.
4. Checkprinterwelltomakesurethereisnofoampad.
Ifthereisone, it must be removed. Makesureprinter
ispowereddown. Removepadbywalkingandrolling
back pad from ends. Move slowly as to not tear the
padifpossible.Continueuntilpad is removed. Clean
remainingadhesivewithanadhesiveremoversolution.
Try to avoid scratchingtheprinterwell plastic piece.
5. Completethefollowingtests: A .
WithaDVMsetonthe200VDCrange,measure14vdc
acrosscontacts asshownbelowthatare markedwith
an(**).
14 vdc
** ##
gnd
## **
B. Checkvoltagebetween ground contactinprinter
wellandpin8oftheJ2connector.TheJ2 connectoris
the longer of the two groups of pins in front of the
printhead.Pin 1 isat the leftend of thelonger group,
countinglefttoright. Thevoltageshouldbebetween
4.75and 5.75 vdc.
C. Checkvoltagebetween ground contact inprinter
welland pin1oftheJ2connector. Thevoltageshould
be24vdc+/-.5volts.
2.2 Bench Test of the
PneumocheckPrinter/charger
Section 2 - Service

18 Pneumocheck Handle and Printer/Charger Service Manual 610132 Rev. E
D. Installapaperroll if one is notinstalled.Measurethe
dcvoltagebetweentheground contact in printer well
andpin3 of the J1connector.TheJ1 connector is the
smaller of the two groups of pins in front of the
printhead. Pin 1 is on the left, counting left to right.
Thevoltageshouldbe 3.00 vdc orless.
6. Makingsuretheredcapped lever atrightofprinthead
is pushed all the way toward the back of the printer,
holddownthefeedbutton.Thepapershouldadvance
steadilyforward.
7. Hold down feed button, then press and release the
stop button. The paper should automatically feed in
thereversedirection.Release the feed button. Paper
willstopfeeding.
8. Pushtheprintbutton.Theunit should beep,
indicatingthatithas no data. The datalightshould
remainunlit.
9. Download data into printer by placing spirometer
handle,inonstate,with data in it, into the printer well.
The data light should flash repeatedly for several
seconds.Afterthis,the data light should belit.
10.Make sure all dip switches on bottom of printer are
set to the “off” position. On top of printer, set the
following: Age: 36; Height: 159; Race: 2; Sex: F.
Depress and release the print button to obtain a
printout. Theprintout shouldagreewiththesettings.
Also, the standard printed should be Knudson 1976
(dip switches 1 and 2 in off position), short form (dip
switch3inoffposition),andtheflowovervolumegraph
(dip switch 4 in off position).
Section 2 - Service

Service Manual 610132 Rev. E Pneumocheck Handle Printer/Charger 19
11.Setdip switches on bottom ofprinterto“on” position.
On top of printer, set the following: Age: 59; Height:
96; Race: 1; Sex: M.
Depress and release the print button to obtain a
printout. Observeprintout.The printout should agree
with the settings. Also, the standard should be Euro
CCS (dip switches 1 and 2 in on position), the long
form, which is a questionnaire (dip switch 3 in on
position), andthevolume over timegraph(dipswitch
4in on position).
12.Return dip switches to position they were when unit
cameinfromcustomer.Ifunitisaloaner,oranewunit
being returned to stock, set all dip switches to off
position.
13.Holddowntheprintbuttonandpress/releasethestop
button.Releasetheprintbutton.Atestprintoutshould
print. At right side of top line, check the version of
software.ItshouldbeV3.2. If it is V3.1,itneedstobe
changed.The“PROM”thatcontrolsthisisinposition
U5onthe mainpcboard. Replace existing Prom with
part number 610102-506. This Prom is software
versionV3.2.
14.Perform agency tests on printer. These include the
groundcontinuitytestand the leakage current test.If
the main pcboard, transformer or line filter was
replaced,performthehypot test. Observe standards.
Theyare:
Ground continuity test: .2 ohm maximum
resistancewith10amperesofcurrentflowthroughthe
earthgroundlinefromthewall plug to a distant metal
point on the unit, probably the transformer screw
oppositewherethe ground wire isconnected;
Leakage current test: 100 microamps or less
from any dead metal part on printer to earth ground,
withtheprinterungroundedandpoweredup.
Hypot test: 1200 vac across the hot and neutral
(tiedtogether)andearthgroundforonesecondwithout
breakdown(voltagereduction).
Section 2 - Service