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CompoMat G5 Service Manual Edition: 3/11.10 Part. no.: M67 599 1 0123
Table of Contents 1
Index
2
Important Information
3
2.1
How to use the Service Manual................................................................................................ 2-1
2.2
Significance of the warnings.................................................................................................... 2-1
2.3
Significance of the note ............................................................................................................ 2-2
2.4
Significance of the tip ............................................................................................................... 2-2
2.5
Technician's qualification......................................................................................................... 2-2
2.6
Instructions to be observed when servicing the system....................................................... 2-2
2.7 2.7.1 2.7.2 2.7.3 2.7.4 2.7.5
Warnings .................................................................................................................................... 2-3 Basic warnings ............................................................................................................................ 2-3 Warnings regarding electric hazards ........................................................................................... 2-4 Warnings regarding mechanical hazards .................................................................................... 2-5 Warnings regarding risk of burning.............................................................................................. 2-5 Warnings regarding biological hazards ....................................................................................... 2-6
2.8
Addresses .................................................................................................................................. 2-7
Installation 3.1
Preface........................................................................................................................................ 3-1
3.2
Important information on initial start-up ................................................................................. 3-1
3.3 3.3.1
Installing the optional scales ................................................................................................... 3-3 Installing the PLS scales ............................................................................................................. 3-4 3.3.1.1 Mounting the PLS scales ............................................................................................. 3-4 Installing the RCC scales ........................................................................................................... 3-5 3.3.2.1 Mounting the RCC scales............................................................................................. 3-6
3.3.2
4
3.4
Connector layout ....................................................................................................................... 3-8
3.5
Initial start-up........................................................................................................................... 3-10
3.6
Decommissioning / removal from service / recommissioning............................................ 3-19
Specifications
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5
Service mode 5.1
Accessing service mode when the device is switched off .................................................... 5-1
5.2 5.2.1 5.2.2 5.2.3
Accessing service mode from standby ................................................................................... 5-1 Self-test........................................................................................................................................ 5-2 Entering the password ................................................................................................................. 5-2 Main menu (Service).................................................................................................................... 5-2 5.2.3.1 Entering the serial number ........................................................................................... 5-3 5.2.3.2 Entering an E-code....................................................................................................... 5-4 5.2.3.3 Update/Init ARM7 ......................................................................................................... 5-5 5.2.3.4 Update/Init Trinamic ..................................................................................................... 5-5 5.2.3.5 Calibrating ADC & Heads............................................................................................. 5-6 Special functions (extended menu) ............................................................................................. 5-8 Application service mode............................................................................................................. 5-8 Program selection........................................................................................................................ 5-9 5.2.6.1 Display and operation of a service program ............................................................... 5-10
5.2.4 5.2.5 5.2.6 5.3 5.3.1 5.3.2
Seal & weighing (program-independent)............................................................................... 5-11 Program-independent sealing.................................................................................................... 5-12 Program-independent weighing................................................................................................. 5-12
5.4 5.4.1
5.4.5 5.4.6
Calibration ................................................................................................................................ 5-13 Calibrating top press.................................................................................................................. 5-13 5.4.1.1 Top press (calibrating press force)............................................................................. 5-14 5.4.1.2 Top press (calibrating press stroke) ........................................................................... 5-16 Calibrating the upper press........................................................................................................ 5-16 5.4.2.1 Upper press (calibrating the press force) ................................................................... 5-17 5.4.2.2 Upper press (calibrating press stroke) ....................................................................... 5-19 Calibrating the lower press ........................................................................................................ 5-19 5.4.3.1 Lower press (calibrating the press force) ................................................................... 5-20 5.4.3.2 Lower press (calibrating the press stroke) ................................................................. 5-22 Calibrating the scales ................................................................................................................ 5-22 5.4.4.1 Calibrating the press scales ....................................................................................... 5-22 5.4.4.2 Calibrating the RCC scales ........................................................................................ 5-23 5.4.4.3 Calibrating the PLS scales ......................................................................................... 5-24 Calibrating detector A ................................................................................................................ 5-25 Calibrating ADC & Heads (see chapter 5.2.3.5 on page 5-6).................................................... 5-26
5.5 5.5.1 5.5.2 5.5.3
Cleaning the press area .......................................................................................................... 5-26 Cleaning the upper press........................................................................................................... 5-27 Cleaning the lower press ........................................................................................................... 5-28 Cleaning the slide ...................................................................................................................... 5-29
5.6 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5
Setup......................................................................................................................................... 5-30 Language selection.................................................................................................................... 5-30 Process data.............................................................................................................................. 5-31 Software update......................................................................................................................... 5-31 Barcode test............................................................................................................................... 5-33 System information .................................................................................................................... 5-34
5.4.2 5.4.3 5.4.4
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6
7
8
TSC / TMC / MA 6.1
Important information for the procedure ................................................................................ 6-1
6.2
Test report - annual maintenance ............................................................................................ 6-2
6.3
Checking the electrical safety ................................................................................................ 6-12
6.4 6.4.1 6.4.2
Explanations on the reports ................................................................................................... 6-14 Explanations on the reports "Initial start-up" and "Annual maintenance" .................................. 6-14 Explanations on electrical safety checks ................................................................................... 6-36
Error Messages 7.1
CompoMat G5 Error Codes ...................................................................................................... 7-1
7.2 7.2.1 7.2.2 7.2.3 7.2.4
Actuator, action and error codes ............................................................................................. 7-4 Example....................................................................................................................................... 7-4 Error codes .................................................................................................................................. 7-4 Actuator codes............................................................................................................................. 7-6 Action codes ................................................................................................................................ 7-8
Calibration / adjustment 8.1
9
Calibration (see chapter 5.4 on page 5-13) ............................................................................. 8-1
Servicing / repair 9.1
Description / warnings .............................................................................................................. 9-1
9.2
Electrical hazards ...................................................................................................................... 9-2
9.3
Mechanical hazards................................................................................................................... 9-3
9.4
Risk of burning .......................................................................................................................... 9-3
9.5
Biological hazards..................................................................................................................... 9-4
9.6 9.6.1 9.6.2 9.6.3 9.6.4 9.6.5 9.6.6 9.6.7 9.6.8 9.6.9 9.6.10 9.6.11 9.6.12 9.6.13 9.6.14 9.6.15
Replacements / Repairs ............................................................................................................ 9-5 Replacing the Application Board bought-in assembly (M68 137 1)............................................. 9-5 Replacing the Display G5 printed circuit board bought-in assembly (M68 115 1)....................... 9-7 Replacing the Trinamic Board bought-in assembly ..................................................................... 9-8 Changing the top press silicon mat G5 (M68 129 1) ................................................................... 9-9 Replacing the BG-CompoFlow Opener Top and door............................................................... 9-10 Replacing the BG-CompoFlow Opener RCC ............................................................................ 9-14 Testing the BG-CompoFlow Opener ......................................................................................... 9-16 Replacing the Heads ................................................................................................................. 9-18 Replacing Head 3 (PLS scales)................................................................................................. 9-22 Replacing the weighing cell RCC (M63 526 1).......................................................................... 9-24 Testing the weighing cell RCC .................................................................................................. 9-27 Replacing the weighing cell PLS (M63 526 1)........................................................................... 9-27 Testing the weighing cell PLS ................................................................................................... 9-30 Replacing the scales 3 (M68 109 1) .......................................................................................... 9-30 Testing scales 3......................................................................................................................... 9-33
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9.7 9.7.1 9.7.2 9.7.3 9.7.4
Tests after the replacement of components ......................................................................... 9-34 BG-CompoFlow Opener height measurement .......................................................................... 9-34 BG-CompoFlow Opener installation .......................................................................................... 9-35 BG-CompoFlow Opener opening .............................................................................................. 9-35 BG-CompoFlow Opener height assembly ................................................................................. 9-35
10 Passwords 10.0.0.1 Service password ....................................................................................................... 10-1 10.0.0.2 Default settings for passwords in CompoMaster Net G5 .......................................... 10-1 10.0.0.3 Defining individual passwords in CompoMaster Net G5........................................... 10-1
11 Functional Description 11.1
Description of the therapy ...................................................................................................... 11-1
11.2
Physical Description ............................................................................................................... 11-1
11.3 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.3.6
Functional description ............................................................................................................ 11-1 Application Board bought-in assembly (M68 137 1) .................................................................. 11-1 Display G5 printed circuit board bought-in assembly (M68 115 1) ............................................ 11-1 HF generator 24V bought-in assembly (M66 178 1).................................................................. 11-2 Relay box G5 (M68 107 1)......................................................................................................... 11-2 Sealing Head El.Mag. Drive assembly (M68 144 1) .................................................................. 11-2 Trinamic Board bought-in assembly (M68 138 1)...................................................................... 11-2
11.4
Block diagram .......................................................................................................................... 11-3
11.5 11.5.1 11.5.2 11.5.3 11.5.4
Component layouts ................................................................................................................. 11-4 Application Board bought-in assembly ...................................................................................... 11-4 Display G5 printed circuit board bought-in assembly ................................................................ 11-5 LP1361 ...................................................................................................................................... 11-5 Trinamic Board bought-in assembly .......................................................................................... 11-6
11.6
Flow diagram (Service Menu) ................................................................................................. 11-7
12 Spare parts catalog 12.1
0-iv
Tools and accessories .......................................................................................................... 12-21
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Chapter 1: Index
1
Index
A
R
Accessories and tools 12-21
Replacing Application Board bought-in assembly 9-5
B
Replacing Display G5 printed circuit board bought-in assembly 9-7
Biological hazards 9-4 Block diagram 11-3
Replacing the Trinamic Board bought-in assembly 9-8
C
Risk of burning 9-3
Calibration / adjustment 8-1 Checking the electrical safety 6-12
S Scales, installing 3-3
D
Sealing seam, test criteria 6-30
Default passwords 10-1
Service mode 5-1 Service password 10-1 Servicing / repair 9-1
E Electrical safety inspections (explanation) 6-36 Error messages 7-1
F Functional description 11-1 Fuses 6-36
Spare parts catalog 12-1 Specifications 4-1
T Test report - annual maintenance 6-2 Test report explanation 6-14 Tools and accessories 12-21 TSC / TMC / maintenance 6-1
H Hazards (electric) 9-2 Hazards (mechanical) 9-3 Head 3, replacing (PLS scales) 9-22
W Warning description 9-1
Heads, replacing 9-18
I Important information 2-1 Initial start-up report 3-10 Installation 3-1
P Passwords 10-1
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Chapter 2: Important Information
2
Important Information
2.1
How to use the Service Manual
2.2
Identification
The document can be identified by the following information on the title page and on the labels, if any: – Edition of the technical document – Part number of the technical document
Page identification
The page identification 1-3, for example, refers to Chapter 1, page 3.
Editorial information
The editorial information 3/11.10, for example, refers to: 3rd Edition, November 2010.
Organization of the chapters
To facilitate the use of documents from Fresenius Kabi, the organization of the chapters has been standardized in all manuals. There may therefore be chapters within this document without any content. Chapters without content are identified.
Illustrations
The illustrations used in the documents (e.g. screens, photos, etc.) may differ from the original if this does not have any influence on the function.
Document changes
Changes to the technical document will be released as new editions or supplements. In general, this manual is subject to change without notice.
Reproduction
Reproduction, even of extracts, may only be performed with written authorization.
Significance of the warnings Warning Advises the operator that incorrect operation can result in personal injury. Caution Advises the operator that incorrect operation can cause damage to the equipment.
2-1
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Chapter 2: Important Information
2.3
Significance of the note Note: Information alerting the operator to the fact that failure to follow the steps as specified may result in the specific function not being executed correctly, not being executed at all, or not producing the desired effect.
2.4
Significance of the tip Tip Information providing useful tips for easy handling.
2.5
2.6
Technician's qualification Purpose
This technical document is intended for service technicians and can be used for first studies (to acquire a basic knowledge) and for reference purposes (for TSC, maintenance and repair). The study of this document, however, does not replace the training courses offered by the manufacturer.
Requirements
Knowledge of the current Operating Instructions of the respective device. Background experience in mechanics, electrical and medical engineering.
Instructions to be observed when servicing the system Authorized persons
Assembly, extensions, adjustments, modifications or repairs may only be undertaken by the manufacturer or any person authorized by the manufacturer.
Test equipment and accessories
The activities described in this technical document require the availability of the necessary technical measuring equipment and accessories.
Specifications
Observe the information on the specifications.
Precautions
Before turning power on, repair any visible damage. Prior to opening the device and when working on the open device, the following precautions have to be observed:
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Chapter 2: Important Information
– Protect the components against ingress of fluids. – Do not touch live parts. – Disconnect and connect all jacks, connectors and components only when the device is turned off.
2.7
Warnings
2.7.1
Basic warnings
Caution The CompoMat G5 may only be opened by qualified and skilled staff. Caution Operators are wholly responsible for any processes that they create in CompoMaster Net G5 and which are executed by the CompoMat G5. This applies in particular to possible loss of blood and blood products by incorrect programming. See the User Manual for CompoMaster Net G5 for information about using the CompoMaster Net G5 to program the CompoMat G5. Caution Operators are wholly responsible for preparatory tasks, such as storage, centrifuging, transport to the CompoMat G5, suspending on the pins and snapping any possible rated break points, all of which can have a significant influence on the quality of separation of the blood components. For these reasons, Fresenius Kabi does not provide information in advance concerning the quality of results as regards blood components obtained using CompoMat G5 processes. Fresenius Kabi only claims that there is a relatively high reproducibility of results for processed blood components within a relatively short preparation time. Please refer to the relevant literature for specific quality results for blood components processed with the CompoMat G5 in daily practice at a blood bank.
2-3
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Chapter 2: Important Information
2.7.2
Warnings regarding electric hazards
Warning Risk of injury caused by electrical voltage. When connecting the CompoMat G5 to a mains supply, the local regulations that apply have to be observed. Warning Risk of injury caused by electrical voltage. Improper commissioning and use of the electrical equipment can result in injuries, such as burns and electrical shocks. Warning Risk of injury caused by electrical voltage. When using safety class I systems, the quality of the protective ground of the installation is of particular importance. It must be taken into consideration that in many countries regulations have been enacted by the national authorities. The rear panel of the CompoMat G5 is provided with a connection for a grounded power cable. Warning Risk of injury caused by electrical voltage. If the power cable needs to be replaced, use only the original power cable listed in the spare parts catalog. If additional equipment, which is not included in the accessories, is connected to the device, there will be a danger that the permissible leakage currents will be exceeded. Warning Risk of injury by burning The devices are not suitable for use with flammable mixtures or nitrous oxide. Caution Loss of the preparation when disconnecting the power plug or in the event of a power failure. If there is a loss of power while processing a program in the CompoMat G5, all sealing heads/clamps will open and the presses will stop. This may cause a loss of the preparation.
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Chapter 2: Important Information
2.7.3
Warnings regarding mechanical hazards
Warning Risk of injury caused by parts moving autonomously. To avoid injury, operators must ensure to keep a sufficiently large distance to all moving parts of the CompoMat G5 . Moving parts are: – – – – – –
Door upper press lower press slide Top press CF-Opener
Warning Risk of injury by crushing Keep hands clear of the inside of the CompoMat G5 during operation of the device.
2.7.4
Warnings regarding risk of burning
Warning Risk of burning by touching the sealing electrodes – Do not touch the sealing electrodes of Heads 1-6 during the sealing process. – Do not place any live parts into the Heads. – Maintain a sufficient distance from the sealing electrodes in the Heads.
2-5
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Chapter 2: Important Information
2.7.5
Warnings regarding biological hazards
Warning Risk of infection by leaking blood bags It is always possible that donated blood could be infected by germs of contagious diseases. The blood must therefore always be treated as being potentially infectious. – Wear surgical or similar gloves when processing blood products. – Immediately clean and disinfect work surfaces that are contaminated with blood or blood products. Local laws and regulations concerning the handling of potentially infectious material must be observed at all times. Warning Risk of infection by leaking tubes – The operator should not exert any force on tubing, which is currently being sealed.
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Chapter 2: Important Information
2.8
Addresses Please address any inquiries to: Manufacturer
Fresenius Kabi AG 61346 Bad Homburg v.d.H. Germany Phone: +49 (0)6172 / 608 - 0
Service Central Europe
Fresenius HemoCare GmbH Technischer Service Pfingstweide 53 D-61169 Friedberg Germany International Service Hotline (08:30 - 17:00) Tel: +49 (0)6172 / 608 8469 Fax: +49 (0)6172 / 608 8539 Email: [email protected]
Service International
Responsible Regional Organization (Technical Service)
Local Service
2-7
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Chapter 3: Installation
3
Installation
3.1
Preface Instructions for all technicians authorized to commission our systems We, as manufacturers, permanently aim at delivering systems of highest quality. To reach this aim, we need your support. Please commission our devices uniformly using the enclosed "initial start-up report" and enter the values determined in the columns provided. The following applies: Corrections are necessary only if the measured values are outside of the specified tolerances!
3.2
Important information on initial start-up For initial start-up only
This technical document is intended for initial start-up only.
Environmental conditions
Variations in temperature during transport may lead to condensation water developing on conducting parts. In the event of major variations in temperature, the device must be given enough time to adapt to the ambient temperature before start-up.
Tester's qualification
The initial start-up must be performed by the Technical Service of Fresenius Kabi or a person authorized by them. The initial start-up procedure may only be performed by persons qualified to properly perform the specified checks on the basis of their educational background and training, as well as knowledge and experience gained in practice. Furthermore, the persons performing the tests must not be bound by any directives when performing this activity.
Test equipment and accessories
The activities described in this technical document require the availability of the necessary technical measuring equipment and accessories.
Specifications
Observe the information on the specifications.
Precautions
Before turning power on, repair any visible damage. Prior to opening the device and when working on the open device, the following precautions have to be observed: – Protect the components against ingress of fluids. – Do not touch live parts. – Disconnect and connect all jacks, connectors and components only when the device is turned off.
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Chapter 3: Installation
TSC/TMC/MA intervals TSC
Technical safety check Note: There is no TSC obligation for the CompoMat G5.
TMC
Technical measurement check Note: There is no TMC obligation for the CompoMat G5 .
MA
Servicing In order to avoid personal injury and damage to property, an annual maintenance must be carried out. (see chapter 6 on page 6-1) Once the CompoMat G5 has been opened, the Electrical Safety Check must be carried out before recommissioning the device. (see chapter 6.3 on page 6-12)
3-2
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Chapter 3: Installation
3.3
Installing the optional scales Warning Risk of injury when assembling the scales and when tilting the CompoMat G5. Electric shock – Turn CompoMat G5 off and disconnect the power plug. Caution Risk of damaging the CompoMat G5 when assembling the scales. Overvoltage and/or short-circuit – Turn CompoMat G5 off and disconnect the power plug. Note: Improperly-mounted scales can lead to incorrect weighing results. – A visible air gap must be present between the CompoMat G5 housing and the scales housing. – The connection cable must not touch the scales housing. Note: To ensure correct weighing results, the scales must be calibrated after mounting. (see chapter 5.4 on page 5-13) CompoMat G5 Tilting the
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To facilitate mounting, the CompoMat G5 can be placed on its back (see the following illustrations).
3/11.10
3-3
Chapter 3: Installation
3.3.1
Installing the PLS scales PLS scales kit
Unpack the PLS scales Kit (902 552 1) and check that it is complete and has not been damaged in transit: 1 x PLS scales 3 x Allen screws 3.3.1.1
Mounting the PLS scales
CompoMat G5 being positioned on its rear.
1
– Place the PLS scales flush with the housing and use the three Allen screws supplied to secure them to the mounting points (1). Laying the connection cables 1 2
3
– Connect the BNC plug (1) for Head 3 to the BNC port (2). – Secure the scales connecting cable using the cable clip (3).
3-4
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Chapter 3: Installation
Caution Damage to the scales connecting cable caused by incorrect routing. Crushing hazard – The scales connecting cable must be passed through the brackets (see following illustration).
4
– Connect the PLS scales to the Balance A (4) connector. – Calibrate the PLS scales (see chapter 5.4 on page 5-13). – Check calibration of the PLS scales. – Check Head 3.
3.3.2
Installing the RCC scales RCC scales kit
Unpack the RCC scales Kit (902 551 1). Check that it is complete and has not been damaged in transit. 1 x RCC scales 3 x Allen screws
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Chapter 3: Installation
3.3.2.1
Mounting the RCC scales
CompoMat G5 being positioned on its rear.
1
– Place the RCC scales flush with the housing and secure it with the three Allen screws (1) provided. – Route the scales connecting cable (1) and secure it using the two cable clips (2) (see following illustration). Routing the connecting cable 1
2
Caution Damage to the scales connecting cable caused by incorrect routing. Crushing hazard – The scales connecting cable must be passed through the brackets (see following illustration).
3-6
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Chapter 3: Installation
5
– Connect the RCC scales to the Balance B (5) connector. – Calibrate the RCC scales (see chapter 5.4 on page 5-13). – Check calibration of the RCC scales. – CF-Opener Check RCC scales.
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Chapter 3: Installation
3.4
Connector layout Caution Damage to the device when connecting the scales. Short circuit and/or overvoltage – Scales must only be connected when the device is switched off. View: CompoMat G5 from below
4/5
3/6
2
1
The allocation of the numbers complies with the following schematic view. Schematic view (from below): To rear 5
6
4
3
2
1
To front
(1) Network connection (LAN) (2) Two equal-priority USB ports (3) Scanner port (4) Connector for PLS scales (5) Connector for RCC scales (6) RFID scanner (pre-allocated, see following note) Note: The RFID (6) Scanner interface is allocated for future applications. At the moment no RFID scanner has been approved for use.
3-8
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Chapter 3: Installation
View: CompoMat G5 tilted 90° to the rear, with front facing up
1
2
3/6
4/5
The allocation of the numbers complies with the following schematic view. To front 1
2
3
4
6
5
To rear
(1) Network connection (LAN) (2) Two equal-priority USB ports (3) Scanner port (4) Connector for PLS scales (5) Connector for RCC scales (6) RFID scanner (pre-allocated, see following note) Note: The RFID Scanner (6) interface is allocated for future applications. At the moment no RFID scanner has been approved for use.
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Chapter 3: Installation
3.5
Initial start-up Note: A detailed description of the individual items can be found under chapter Explanations of reports (see chapter 6.4 on page 6-14)
CompoMat G5
Initial start-up report
Technician's name:
Customer/customer no.:
Version:
Optional:
Device no.:
Service report no.:
RCC scales: Serial number: PLS scales: Serial number:
Equipment code:
No.
Description
1
Unpacking (only for initial start-up!)
1.1
Unpack the device.
–
1.2
Check that all parts of the device have been accounted for.
–
1.3
Device without visible shipping damage.
–
2
Visual inspection
2.1
Check the fuses on the power input panel jack. Melting point of the fuses (2x) T 10 A / 230/240 V ~AC.
2.2
Labels and inscriptions are present and legible.
2.3
Mechanical condition permits safe use.
2.4
No contamination or damage.
2.5
The power cable is not damaged.
3-10
Correct.
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Chapter 3: Installation
No.
Description
Correct.
3
Device-related inspections
3.1
Calibration of ADC and the head sensors Main menu (Service) / Cal. ADC & Heads
Meas. value
Yes No
Calibration value Head 1: Desired value 10-50
________
Calibration value Head 2: Desired value 10-50
________
Calibration value Head 3: Desired value 10-50
________
Calibration value Head 4: Desired value 10-50
________
Calibration value Head 5: Desired value 10-50
________
Calibration value Head 6: Desired value 10-50
________
3.2
Calibrating the top press position Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Top Press
Yes No
3.3
Calibrating the upper press position Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Upper Press
Yes No
3.4
Calibrating the lower press position Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Lower Press
Yes No
3.5
Calibrating the top press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Top Press
Yes No
3.6
Calibrating the upper press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Upper Press
Yes No
3.7
Calibrating the lower press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Lower Press
Yes No
3.8
Calibrating the press scales Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Press Scale
Yes No
3.9
Calibrating the RCC scales Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / RCC Scale
Yes No
3.10
Calibrating the PLS scales Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / PLS Scale
Yes No
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Chapter 3: Installation
No.
Description
Correct.
3.11
Calibrating the A1-A8 detectors Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Detector A
Yes No
Calibration value det. A1: Desired value 50-200
________
Calibration value det. A2: Desired value 50-200
________
Calibration value det. A3: Desired value 50-200
________
Calibration value det. A4: Desired value 50-200
________
Calibration value det. A5: Desired value 50-200
________
Calibration value det. A6: Desired value 50-200
________
Calibration value det. A7: Desired value 50-200
________
Calibration value det. A8: Desired value 50-200
________
3.12
Testing the barcode scanner, barcode test (see chapter 5.6.4 on page 5-33) Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Setup / Barcode test
Yes No
3.13
Testing the network functionality
Yes No
3.14
Testing the WLAN functionality (n.v. = not available)
Yes No n.v.
3.15
Door / Door locks Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. door
Yes No
3.17
Top press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. TP force
Yes No
Press stops at a target value of 500 N (±30 N) 3.18
_______N
Upper press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. UP force
Yes No
Press stops at a target value of 500 N (±30 N) 3.19
_______N
Lower press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. LP force
Yes No
Press stops at a target value of 500 N (±30 N)
3-12
Meas. value
_______N
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Chapter 3: Installation
No.
Description
3.20
Test of press scales / PLS scales / RCC scales Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. X Scale
3.21
Correct. Yes No
PLS scales unladen target value: 0 g (±3 g)
_______g
PLS scales loaded with 500 g target value: 500 g (±3 g)
_______g
RCC scales unladen target value: 0 g (±3 g)
_______g
RCC scales loaded with 500 g target value: 500 g (±3 g)
_______g
Press scales unladen target value: 0 g (±3 g)
_______g
Press scales loaded with 500 g target value: 500 g (±3 g)
_______g
Slide occlusion Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Slide occl. or Serv. Slide occl. no PLS
Yes No
Target value 0 g (±15 g) 3.22
Meas. value
_______g
Test of CF-Opener top press / door / RCC scales (see Re: 3.22 on page 6-24) Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. CompoFlow
Yes No
Empty CF-Opener top press ⇒ Error message empty CF-Opener Place test tool 3.6 mm in CF-Opener top press ⇒ Error message ERROR CODE 0x0401 Empty CF-Opener door ⇒ Error message empty CF-Opener Place test tool 3.6 mm in CF-Opener door ⇒ Error message ERROR CODE 0x0401 Empty CF-Opener RCC scales ⇒ Error message empty CF-Opener Place test tool 3.6 mm in CF-Opener RCC scales ⇒ Error message ERROR CODE 0x0401
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Chapter 3: Installation
No.
Description
Correct.
3.23
A1 - A8 detectors Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Detector A
Meas. value
Yes No
Lower press stops / retracts when det. A1 is covered Lower press stops / retracts when det. A2 is covered Lower press stops / retracts when det. A3 is covered Lower press stops / retracts when det. A4 is covered Lower press stops / retracts when det. A5 is covered Lower press stops / retracts when det. A6 is covered Lower press stops / retracts when det. A7 is covered Lower press stops / retracts when det. A8 is covered 3.24
Opening / closing the Heads Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. O./C. heads or Serv. O./C. heads no PLS
Yes No
Close Head 1 Close Head 2 Close Head 3 (optional, only if PLS scales present) Close Head 4 Close Head 5 Close Head 6 Open Head 1 Open Head 2 Open Head 3 (optional, only if PLS scales present) Open Head 4 Open Head 5 Open Head 6 Close all Heads Open all Heads
3-14
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No.
Description
Correct.
3.25
Testing the Heads Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Check heads or Serv. Check heads no PLS
Meas. value
Yes No
All Heads empty Tubing requested for all Heads. Head 1, tubing inserted Tubing requested for all remaining Heads Head 2, tubing inserted Tubing requested for all remaining Heads Head 3, tubing inserted (optional, only if PLS scales present) Tubing requested for all remaining Heads Head 4, tubing inserted Tubing requested for all remaining Heads Head 5, tubing inserted Tubing requested for all remaining Heads Head 6, tubing inserted Tubing requested for all remaining Heads All Heads with tubings inserted No error message 3.26
Sealing behavior of the Heads Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Seal heads or Serv. Seal heads no PLS
Yes No
Head 1: Sealing seam and separation at the sealing seam are correct Head 2: Sealing seam and separation at the sealing seam are correct Head 3 (optional, only if PLS scales present): Sealing seam and separation at the sealing seam are correct Head 4: Sealing seam and separation at the sealing seam are correct Head 5: Sealing seam and separation at the sealing seam are correct Head 6: Sealing seam and separation at the sealing seam are correct
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Chapter 3: Installation
No.
Description
Correct.
3.27
Head sensors Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Head det. or Serv. Head det. no PLS
Meas. value
Yes No
Head 1: At 30% visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70% visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 2: At 30% visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70 % visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 3: At 30% visual sensitivity (optional) Release at grey scale tone 4 (Tolerance: ±1) At 70% visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 4: At 30 % visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70 % visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 5: At 30 % visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70 % visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 6: At 30 % visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70 % visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) 3.28
Behavior during bag press-out Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Empty bag
Yes No
Bag is emptied (from the lower press) Bag is emptied (from the upper press) Bag is emptied (from the top press) 3.30
Expanded test CF-Opener
Yes No
CF-Opener Top CF-Opener Door CF-Opener RCC
3-16
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No.
Description
Correct.
3.31
System information Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / System information
Meas. value
Yes No
Serial number
________
E-Code
________
Release
________
4
Checking the electrical safety (see chapter 6.4.2 on page 6-36) For Germany: in accordance with DIN EN 62353. In other countries, observe the local regulations!
4.1
Visual inspection performed.
4.2
Protective earth resistance max. 0.3 Ω (with power cable)
4.3
Leakage current measurement (device leakage current) max. 500 µA
______ Ω
Differential current measurement acc. to DIN EN 62353, Figure 5
_____ µA
Direct measurement acc. to DIN EN 62353, Figure 4
_____ µA
or
4.4
Insulation resistance measurement > 2 MΩ
_____ MΩ
Test equipment used: Force measuring device (Type, serial number): ________________________________________________________________________________________ Protective earth resistance, leakage current, insulation resistance (Type, serial number): ________________________________________________________________________________________ Comments:
Date:
Fresenius Kabi
Signature:
CompoMat G5
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Stamp:
3-17
Chapter 3: Installation
The device has been released for its intended use.
Yes No
Next check: Comments:
Date:
Signature:
Confirmation of the test
Stamp:
Test equipment used: Type and serial number of the test equipment used. Comments: Any irregularities which occurred during the test are documented in this section. Date, signature, stamp Performance of the test has to be confirmed with date, tester's signature and stamp.
Assessment of the test
The device has been released for its intended use. During the intended use of the device it must be ensured that the device does not present a hazard to patients, employees or other third parties. As part of overall evaluation, testers are obliged to give their official approval for the use of the device. If defects are identified, then the device owner must be informed of these without delay. Date of next inspection: The next inspection date has to be entered in the report. The intervals specified by the manufacturer have to be observed. Comments: Any irregularities which occurred during the assessment are documented in this section. Date, signature, stamp: Assessment of initial start-up must be confirmed by the tester including the date, tester's signature and stamp.
3-18
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3.6
Decommissioning / removal from service / recommissioning Note: For information regarding this chapter see: CompoMat G5 Operating Instructions
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Chapter 4: Specifications
4
Specifications Note: For information regarding this chapter see: CompoMat G5 Operating Instructions
4-1
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Chapter 5: Service mode
5
Service mode Tip The display has a yellow background when service mode is active.
Tip To help you find your way around the Service Menu, a flow diagram is available for this menu (see chapter 11.6 on page 11-7).
5.1
Accessing service mode when the device is switched off Accessories
– USB stick service G5 (M67 482 1)
Procedure
1. Insert the USB stick service G5. 2. Turn on the CompoMat G5 via the main switch. Service mode is activated after approx. 2 min. The two-part self-test is then executed. (see chapter 5.2.1 on page 5-2)
5.2
Accessing service mode from standby Accessories
– USB stick service G5 (M67 482 1)
Procedure
1. Insert the USB stick service G5. (see chapter 3.4 on page 3-8) 2. Wait at least 10 s (USB stick is initialized). 3. Press the menu key
(On/Off).
The two-part self-test is then executed. (see chapter 5.2.1 on page 5-2)
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Chapter 5: Service mode
5.2.1
Self-test The following components are tested: – – – – – – – –
5.2.2
System files Network IO communication Slide CF-Opener Top CF-Opener Door CF-Opener RCC Head
– – – – – – –
PLS Scale RCC scales Press Scale Upper Press Lower Press Top Press Door
Entering the password
Note: Passwords (see Passwords on page 10-1) Once the self-test has been passed, the screen message Password request will be displayed (shown here on the left). The password is entered as follows: – Select the input position using the function keys.
(yellow) and
(green)
– Use the (Up) and (Down) menu keys to select the required numerical value for the highlighted input position. The password is “1462”. – Confirm the input using the menu key
5.2.3
.
Main menu (Service) Once the password has been entered, the screen message Main menu (Service) will be displayed (shown here on the left). The following menu options are available: – – – – – – –
5-2
Set serial number Set E-Code Set MAC-Address Update/Init ARM7 Update/Init Trinamic Cal. ADC & Heads Special functions
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Chapter 5: Service mode
5.2.3.1
Entering the serial number
Note: The serial number must be entered again after the replacement of the Display G5 printed circuit board bought-in assembly. Requirements
The menu Main menu (Service) must be selected. (see chapter 5.1 on page 5-1) to (see chapter 5.2.3 on page 5-2) – Use the (Up) and (Down) menu keys to select the menu option Set serial number. – Confirm the selection using the menu key
.
The screen message Set serial number will be displayed (shown here on the left). The serial number is entered as follows: – Select the input position using the function keys.
(yellow) and
(green)
– Use the (Up) and (Down) menu keys to select the required numerical value for the highlighted input position. – Confirm the input using the menu key
.
The screen message Advice will be displayed (shown here on the left). – Accept the message using the
(green) function key.
The CompoMat G5 will be rebooted. A screen message will be displayed, requesting password entry. (see chapter 5.2.2 on page 5-2)
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Chapter 5: Service mode
5.2.3.2
Entering an E-code
Note: The E-code must be entered again after the replacement of the Display G5 printed circuit board bought-in assembly. Requirements
The menu Main menu (Service) must be selected. (see chapter 5.1 on page 5-1) to (see chapter 5.2.3 on page 5-2) – Use the (Up) and option Set E-Code.
(Down) menu keys to select the menu
– Confirm the selection using the menu key
.
The screen message Set E-Code will be displayed (shown here on the left). – Note the E-code from the rear of the CompoMat G5 and enter as follows: – Select the input position using the function keys.
(yellow) and
(green)
– Use the (Up) and (Down) menu keys to select the required numerical value for the highlighted input position. – Confirm the input using the menu key
.
The screen message Advice will be displayed (shown here on the left). – Accept the message using the
(green) function key.
You will be returned to the Main menu (Service) screen.
5-4
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Chapter 5: Service mode
5.2.3.3
Update/Init ARM7
Note: The firmware for the Application Board bought-in assembly (M68 137 1) is installed automatically during installation of the G5 procedure software (see Software update on page 5-31). Manual installation normally is not required. Note: After the update/init on the Application Board bought-in assembly (M68 137 1) the CompoMat G5 must be fully calibrated (see chapter 6.2 on page 6-2). The calibration process is started automatically.
Requirements
The menu Main menu (Service) must be selected. (see chapter 5.1 on page 5-1) to (see chapter 5.2.3 on page 5-2)
Accessories
The subsequent calibration requires the use of the following accessories: – Calibrated force measuring device incl. pressure sensor (M67 499 1) – Tool for force measurement G5 (M67 961 1) – Synthetic block G5 (M67 851 1) – Use the (Up) and (Down) menu keys to select the menu option Update/init ARM7. – Confirm the selection using the menu key
.
The update is carried out without safety prompt. The following screen messages will be displayed in sequence: – – – – –
5.2.3.4
Wait... Reset IO board... Wait... Erase IO software... Wait... Install IO software... Restart... Please wait... Selftest...
Update/Init Trinamic
Note: The procedures for the Trinamic Board bought-in assembly (M68 138 1) are installed automatically during installation of the G5 procedure software (see Software update on page 5-31). Manual installation of the Trinamic board normally is not required.
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Chapter 5: Service mode
Requirements
The menu Main menu (Service) must be selected. (see chapter 5.1 on page 5-1) to (see chapter 5.2.3 on page 5-2) – Use the (Up) and (Down) menu keys to select the menu option Update/init Trinamic. – Confirm the selection using the menu key
.
The Application Board bought-in assembly (M68 138 1) update is carried out automatically without safety prompt.
The screen message Init motor control will be displayed (shown here on the left). The CompoMat G5 will be rebooted once the progress bar is complete.
Note: All presses must be re-calibrated following an update/init on the Trinamic Board bought-in assembly (M68 138 1). The calibration process is started automatically.
5.2.3.5
Calibrating ADC & Heads Requirements
5-6
The menu Main menu (Service) must be selected. (see chapter 5.1 on page 5-1) to (see chapter 5.2.3 on page 5-2)
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– Use the (Up) and (Down) menu keys to select the menu option Cal. ADC & Heads . – Confirm the selection using the menu key
.
The screen message Calibrate ADC & Head Detectors... will be displayed (shown here on the left).
After successful calibration, the screen message Advice will be displayed (shown here on the left). – The calibration data displayed must be documented in the report. (i.e. values for Heads 1 to 6) – Confirm the end of calibration using the
(green) function key.
The CompoMat G5 will be rebooted.
Note: The calibration values must be in the range between 10 and 50.
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Chapter 5: Service mode
5.2.4
Special functions (extended menu) Requirements
The menu Main menu (Service) must be selected. (see chapter 5.1 on page 5-1) to (see chapter 5.2.3 on page 5-2) – Use the (Up) and Special functions.
(Down) menu keys to select the menu option
– Confirm the selection using the menu key
.
The screen message Special functions will be displayed (shown here on the left). The Special functions menu expands the Main menu (Service) to include the following options: – – – – – –
5.2.5
Appl. Service mode Download files Unittest screenshots Unittest network stress Create Production Stick Production state
Application service mode Requirements
The extended menu Special functions must be selected in the Main menu (Service). (see chapter 5.2.3 on page 5-2) – Use the (Up) and (Down) menu keys to select the menu option Appl. Service-Mode. – Confirm the selection using the menu key
5-8
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Chapter 5: Service mode
The screen message Ready to use will be displayed (shown here on the left). The program selected (here, 30 Demo no heads) may differ from the actual program shown. – Press the
(green) function key.
The program displayed will be executed. Or – Press the
(yellow) function key.
The screen message Main menu will be displayed (shown here on the left). The following menu options are available: – – – – – –
Special features in service mode
Programm selection Seal & weighing Calibrate Cleanup Setup System information
– All passwords are deactivated – The language is English throughout and cannot be modified. – Process data are deactivated
5.2.6
Program selection Requirements
The sub-menu Appl. Service-Mode has been selected in the extended Special functions menu. (see chapter 5.2.5 on page 5-8) – Use the (Up) and (Down) menu keys to select the menu option Program selection. – Confirm the selection using the menu key
Special features for service menu "Program selection"
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.
In the Program selection service menu, a fixed set of service programs are available that are not provided by CompoMaster Net G5.
3/11.10
5-9
Chapter 5: Service mode
The screen message Program selection will be displayed (shown here on the left). – Use the program.
(Up) and
(Down) menu keys to select the desired
– Confirm the selection using the menu key
.
The screen message Ready to use will be displayed (shown here on the left). – Press the
(green) function key.
The selected program (here, 30 Demo no heads) will be executed. Or – Press the
(yellow) function key.
The display switches back to the Main menu
5.2.6.1
Display and operation of a service program The program step currently running is shown in field 1. 1
– To stop the service program: Press the – To interrupt the service program: Press the
5-10
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Chapter 5: Service mode
– The corresponding parameters are shown in field 1 during execution of the program step.
1
5.3
Seal & weighing (program-independent) Requirements
The sub-menu Appl. Service-Mode has been selected in the extended Special functions menu. (see chapter 5.2.5 on page 5-8) – Use the (Up) and (Down) menu keys to select the menu option Seal & weighing. – Confirm the selection using the menu key
.
The screen message Seal & weighing will be displayed (shown here on the left).
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Chapter 5: Service mode
5.3.1
Program-independent sealing
Note: Only Head 2 can be used for program-independent sealing. Tip The number of sealing processes is not limited. – Insert the tubing into sealing head 2. – Press the
(green) function key.
The inserted tubing will be sealed. – Press the
(blue) function key.
The display switches back to the Main menu
5.3.2
Program-independent weighing
Note: Only the RCC scales can be used for program-independent weighing. Tip The number of weighing processes is not limited. – Tare the RCC scales using the
(yellow) function key.
The weighing process can be carried out. – Press the
(blue) function key.
The display switches back to the Main menu
5-12
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Chapter 5: Service mode
5.4
Calibration Warning Risk of injury from actuators moving automatically. Crushing hazard – Do not reach into the press area when the presses are active. Requirements
The sub-menu Appl. Service-Mode has been selected in the extended Special functions menu. (see chapter 5.2.5 on page 5-8) – Use the (Up) and option Calibrate.
(Down) menu keys to select the menu
– Confirm the selection using the menu key
.
The screen message Calibrate will be displayed (shown here on the left). The following actuators can be calibrated: – – – – – – –
5.4.1
Top press upper press lower press Press scales RCC scales PLS scales Detector A
Calibrating top press Requirements
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The menu Calibrate must be selected in the Main menu. (see chapter 5.4 on page 5-13)
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Chapter 5: Service mode
– Use the actuator.
(Up) and
(Down) menu keys to select the desired
– Confirm the selection using the menu key
.
The screen message Calibrate Top Press will be displayed (shown here on the left). Two calibration functions are available: – Calibrate press force ( – Calibrate press stroke (
5.4.1.1
Top press (calibrating press force) Requirements
The menu Calibrate Top Press must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13)
Accessories
– Calibrated force measuring device incl. pressure sensor (M67 499 1) – Use the
5-14
(yellow) function key) (green) function key)
(yellow) function key to select Calibrate force.
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The screen message Calibrate Top Press will be displayed (shown here on the left). The CompoMat G5 automatically calculates the null force for the top press.
On completion of the null force adjustment, the screen message Calibrate Top Press will be displayed (shown here on the left).
– Place the calibrated force measuring device in or under the top press (see illustration to the left). – Proceed by pressing the
(green) function key.
The screen message Calibrate Top Press will be displayed (shown here on the left). Note the determined force [N] from the force measuring device and enter it as follows: – Select the input position using the function keys.
(yellow) and
(green)
– Use the (Up) and (Down) menu keys to select the required numerical value for the highlighted input position. – Confirm the input using the menu key
.
After successful calibration, the message Calibration finished successfully! will be displayed.
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Chapter 5: Service mode
5.4.1.2
Top press (calibrating press stroke) Requirements
The menu Calibrate Top Press must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13) – Use the
(green) function key to select Calibrate position.
The screen message Calibrate Top Press will be displayed (shown here on the left). The calibration process for the press stroke will be performed and completed automatically.
5.4.2
Calibrating the upper press Requirements
The menu Calibrate must be selected in the Main menu. (see chapter 5.4 on page 5-13) – Use the actuator.
(Up) and
(Down) menu keys to select the desired
– Confirm the selection using the menu key
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Chapter 5: Service mode
The screen message Calibrate Upper Press will be displayed (shown here on the left). Two calibration functions are available: – Calibrate press force ( – Calibrate press stroke (
5.4.2.1
(yellow) function key) (green) function key)
Upper press (calibrating the press force) Requirements
The menu Calibrate Upper Press must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13)
Accessories
– Calibrated force measuring device incl. pressure sensor (M67 499 1) – Use the
(yellow) function key to select Calibrate force.
The screen message Calibrate Upper Press will be displayed (shown here on the left). The CompoMat G5 automatically calculates the null force for the upper press.
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Chapter 5: Service mode
On completion of the null force adjustment, the screen message Calibrate Upper Press will be displayed (shown here on the left).
– Place the calibrated force measuring device into the upper press (see illustration to the left). – Proceed by pressing the
(green) function key.
The screen message Calibrate Upper Press will be displayed (shown here on the left). Note the determined force [N] from the force measuring device and enter it as follows: – Select the input position using the function keys.
(yellow) and
(green)
– Use the (Up) and (Down) menu keys to select the required numerical value for the highlighted input position. – Confirm the input using the menu key
.
After successful calibration, the message Calibration finished successfully! will be displayed.
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Chapter 5: Service mode
5.4.2.2
Upper press (calibrating press stroke) Requirements
The menu Calibrate Upper Press must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13) – Use the
(green) function key to select Calibrate position.
The screen message Calibrate Upper Press will be displayed (shown here on the left). The calibration process for the press stroke will be performed and completed automatically.
5.4.3
Calibrating the lower press Requirements
The menu Calibrate must be selected in the Main menu. (see chapter 5.4 on page 5-13) – Use the actuator.
(Up) and
(Down) menu keys to select the desired
– Confirm the selection using the menu key
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.
5-19
Chapter 5: Service mode
The screen message Calibrate Lower Press will be displayed (shown here on the left). Two calibration functions are available: – Calibrate press force ( – Calibrate press stroke (
5.4.3.1
(yellow) function key) (green) function key)
Lower press (calibrating the press force) Requirements
The menu Calibrate Lower Press must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13)
Accessories
– Calibrated force measuring device incl. pressure sensor (M67 499 1) – Use the
(yellow) function key to select Calibrate force.
The screen message Calibrate Lower Press will be displayed (shown here on the left). The CompoMat G5 automatically calculates the null force for the lower press.
5-20
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Chapter 5: Service mode
On completion of the null force adjustment, the screen message Calibrate Lower Press will be displayed (shown here on the left).
– Place the calibrated force measuring device into the lower press (see illustration to the left). – Proceed by pressing the
(green) function key.
The screen message Calibrate Lower Press will be displayed (shown here on the left). Note the determined force [N] from the force measuring device and enter it as follows: – Select the input position using the function keys.
(yellow) and
(green)
– Use the (Up) and (Down) menu keys to select the required numerical value for the highlighted input position. – Confirm the input using the menu key
.
After successful calibration, the message Calibration finished successfully! will be displayed.
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Chapter 5: Service mode
5.4.3.2
Lower press (calibrating the press stroke) Requirements
The menu Calibrate Lower Press must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13) – Use the
(green) function key to select Calibrate position.
The screen message Calibrate Lower Press will be displayed (shown here on the left). The calibration process for the press stroke will be performed and completed automatically.
5.4.4
Calibrating the scales
Note: When calibrating the scales, the following requirements must be met: – The CompoMat G5 must be set up so that it is free of vibrations. – Do not allow any external force to affect the scales.
5.4.4.1
5-22
Calibrating the press scales Requirements
The menu Calibrate Press Scale must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13)
Accessories
– Calibration weight 500 g (M63 925 1)
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– Relieve the press scales. – Start the calibration process using the
(green) function key.
The device calculates the zero point for the press scales (approx. 3 s).
The screen message Calibrate Press Scale will be displayed (shown here on the left). – Hang the 500 g calibration weight on the suspension pins. – Wait until the weight has stopped moving (approx. 3 s). – Confirm the weight using the
(green) function key.
After successful calibration, the screen message shown on the left will be displayed. – Check the calibration of the press scales. (see Re: 3.20 on page 6-22)
5.4.4.2
Calibrating the RCC scales Requirements
The menu Calibrate RCC Scale must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13)
Accessories
– Calibration weight 500 g (M63 925 1) Note: If the calibration process is aborted using the then the previous calibration is retained.
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(blue) function key,
5-23
Chapter 5: Service mode
– Relieve the RCC scales. – Start the calibration process using the
(green) function key.
The device calculates the zero point for the RCC scales (approx. 3 s).
The screen message Calibrate RCC Scale will be displayed (shown here on the left). – Place 500 g calibration weight in the scales tray. – Wait until the scales tray has stopped moving (approx. 3 s). – Confirm the weight using the
(green) function key.
After successful calibration, the screen message shown on the left will be displayed. – Check calibration of the RCC scales. (see Re: 3.20 on page 6-22)
5.4.4.3
Calibrating the PLS scales Requirements
The menu Calibrate PLS Scale must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13)
Accessories
– Calibration weight 500 g (M63 925 1) Note: If the calibration process is aborted using the then the previous calibration is retained.
5-24
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(blue) function key,
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Chapter 5: Service mode
– Make sure there is nothing on the scale. – Start the calibration process using the
(green) function key.
The device calculates the zero point for the PLS scales. (approx. 3 s).
The screen message Calibrate PLS Scale will be displayed (shown here on the left). – Place 500 g calibration weight on sealing head 3. – Wait until the weight has stopped moving (approx. 3 s). – Confirm the weight using the
(green) function key.
After successful calibration, the screen message shown on the left will be displayed. – Check calibration of the PLS scales. (see Re: 3.20 on page 6-22)
5.4.5
Calibrating detector A Requirements
The menu Calibrate Detector A must be selected in the Calibrate menu. (see chapter 5.4 on page 5-13)
Accessories
– Synthetic block G5 (M67 851 1)
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Chapter 5: Service mode
– Hang the G5 synthetic block on the suspension pins. – Press the
(green) function key.
The calibration process will be performed automatically (multiple screen messages shown)
After successful calibration, the screen message shown to the left will be displayed, presenting the detector calibration data. – The calibration data displayed must be documented. (i.e. values for detectors A1 to A8) – Confirm with the
(green) function key.
The screen display switches back to the Calibrate menu.
Note: The calibration values must be in the range between 50 and 200.
5.4.6
Calibrating ADC & Heads (see chapter 5.2.3.5 on page 5-6)
5.5
Cleaning the press area Warning Risk of injury caused by parts moving autonomously. Crushing hazard Do not reach into the press area while the press or slide are moving! Requirements
5-26
The sub-menu Appl. Service-Mode has been selected in the extended Special functions menu. (see chapter 5.2.5 on page 5-8)
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Chapter 5: Service mode
– Use the (Up) and option Cleanup.
(Down) menu keys to select the menu
– Confirm the selection using the menu key
.
The screen message Cleanup will be displayed (shown here on the left). The following options are shown: – upper press – lower press – slide
5.5.1
Cleaning the upper press Requirements
The menu Cleanup must be selected in the Main menu. (see chapter 5.4 on page 5-13) – Use the (Up) and option Upper Press.
(Down) menu keys to select the menu
– Confirm the selection using the menu key
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Chapter 5: Service mode
The screen message Cleanup Upper Press will be displayed (shown here on the left). – Press and hold the
(green) function key.
The upper press is extended. The upper press can now be cleaned. – Press and hold the
(yellow) function key.
The upper press is retracted. – Press the
(blue) function key.
The screen display switches back to the Cleanup menu. Note: You can only exit the Cleanup Upper Press menu once the upper press has been fully retracted.
5.5.2
Cleaning the lower press Requirements
The menu Cleanup must be selected in the Main menu. (see chapter 5.4 on page 5-13) – Use the (Up) and option Lower Press .
(Down) menu keys to select the menu
– Confirm the selection using the menu key
.
The screen message Cleanup Lower Press will be displayed (shown here on the left). – Press and hold the
(green) function key.
The lower press is extended. The lower press can now be cleaned. – Press and hold the
(yellow) function key.
The lower press is retracted. – Press the
(blue) function key.
The screen display switches back to the Cleanup menu.
5-28
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Chapter 5: Service mode
Note: You can only exit the Cleanup Lower Press menu once the lower press has been fully retracted.
5.5.3
Cleaning the slide Requirements
The menu Cleanup must be selected in the Main menu. (see chapter 5.4 on page 5-13) – Use the (Up) and option Slide.
(Down) menu keys to select the menu
– Confirm the selection using the menu key
.
The screen message Cleanup Slide will be displayed (shown here on the left). – Press and hold the
(green) function key.
The slide is extended. The slide can now be cleaned. – Press and hold the
(yellow) function key.
The slide is retracted. – Press the
(blue) function key.
The screen display switches back to the Cleanup menu. Note: You can only exit the Cleanup Slide menu once the slide has been fully retracted.
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Chapter 5: Service mode
5.6
Setup Requirements
The sub-menu Appl. Service-Mode has been selected in the extended Special functions menu. (see chapter 5.2.5 on page 5-8) – Use the (Up) and option Setup.
(Down) menu keys to select the menu
– Confirm the selection using the menu key
.
The screen message Setup will be displayed (shown here on the left). The following options are shown: – – – –
5.6.1
Language selection Process data Software update Barcode test
Language selection
Note: Language selection only affects the language settings for the operator. Service mode is only available in English. Requirements
5-30
The menu Setup must be selected in the Main menu. (see chapter 5.6 on page 5-30)
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– Use the (Up) and (Down) menu keys to select the menu option Language selection. – Confirm the selection using the menu key
5.6.2
.
Process data Requirements
The menu Setup must be selected in the Main menu. (see chapter 5.6 on page 5-30) Note: Process data settings only affect the user mode. These settings have no effect in service mode. – Use the (Up) and option Process data.
(Down) menu keys to select the menu
– Confirm the selection using the menu key
5.6.3
.
Software update Requirements
The menu Setup must be selected in the Main menu. (see chapter 5.6 on page 5-30)
Accessories
– Update CompoMat G5 VX.X.X USB stick (M67 484 1)
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Chapter 5: Service mode
– Use the (Up) and (Down) menu keys to select the menu option Software update. – Confirm the selection using the menu key
.
The screen message Software update will be displayed (shown here on the left). – Press the
(green) function key.
The update process is started if there is a valid update on the USB stick.
The screen message Software update will be displayed (shown here on the left).
5-32
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Chapter 5: Service mode
The following screen messages will be displayed in sequence:
Once the self-test has been successfully completed, the password will once again be requested for service mode (see chapter 5.2.2 on page 5-2)
5.6.4
Barcode test Requirements
The menu Setup must be selected in the Main menu. (see chapter 5.6 on page 5-30) – Use the (Up) and option Barcode test.
(Down) menu keys to select the menu
– Confirm the selection using the menu key
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5-33
Chapter 5: Service mode
The screen message Barcode scan will be displayed (shown here on the left). – Scan in the test barcode shown below.
The barcode is shown in plain text. (in the screen shot: BC_TEST_VAL or KBC_TEST_VAL)
5.6.5
System information Requirements
The sub-menu Appl. Service-Mode has been selected in the extended Special functions menu. (see chapter 5.2.5 on page 5-8) – Use the (Up) and (Down) menu keys to select the menu option System information. – Confirm the selection using the menu key
.
The screen message System information will be displayed (shown here on the left). The following system information is made available: – – – – – – –
Netname: Network name Process counter: Number of processes run Serial-No.: Serial number Software: Software version Firmware: Firmware version E-Code: Equipment code Version: Complete version number
– Press the
(blue) function key.
The display switches back to the Main menu
5-34
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Chapter 6: TSC / TMC / MA
6
TSC / TMC / MA
6.1
Important information for the procedure TSC
Technical safety check Note: There is no TSC obligation for the CompoMat G5.
TMC
Technical measurement check Note: There is no TMC obligation for the CompoMat G5 .
MA
Annual maintenance In order to avoid personal injury and damage to property, an annual maintenance must be carried out. (see chapter 6 on page 6-1) Once the CompoMat G5 has been opened, the Electrical Safety Check must be carried out before recommissioning the device. (see chapter 6.3 on page 6-12) The following applies to the annual maintenance: After successful completion of the annual maintenance, the CompoMat G5 must be identified with an inspection label. This label must, in a unique and traceable manner, specify the year of the next annual maintenance and the authority or person having performed the annual maintenance.
Tester's qualification
The checks must be performed by the Technical Service of Fresenius Kabi or an institution/person authorized by them. The checks may only be performed by persons qualified to properly perform the specified checks owing to their educational background, training, knowledge and experience. Furthermore, the persons performing the checks must not be bound by any directives when performing this activity.
Test equipment and accessories
The activities described in this technical document require the availability of the necessary technical measuring equipment and accessories.
Specifications
Observe the information on the specifications.
Precautions
Before turning power on, repair any visible damage. Prior to opening the device and when working on the open device, the following precautions have to be observed: – Protect the components against ingress of fluids.
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Chapter 6: TSC / TMC / MA
– Do not touch live parts. – Disconnect and connect all jacks, connectors and components only when the device is turned off.
6.2
Test report - annual maintenance Annual maintenance
Maintenance here relates to checking the sensors and actuators. Checks are carried out without opening the device. Warning Risk of injury caused by electrical voltage. Caused by changes to the cable connection, the way the cables are laid or due to an electrical part. Once the CompoMat G5 has been opened, the Electrical Safety Check must be carried out before recommissioning the device. (see chapter 6.3 on page 6-12) Note: A detailed description of the individual items can be found under chapter Explanations of reports (see chapter 6.4.1 on page 6-14)
6-2
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Chapter 6: TSC / TMC / MA
CompoMat G5
Test report - annual maintenance
Technician's name:
Customer/customer no.:
Version:
Optional:
Device no.:
Service report no.:
RCC scales: Serial number: PLS scales: Serial number:
Equipment code:
No.
Description
2
Visual inspection
2.1
Check the fuses on the power input panel jack. Melting point of the fuses (2x) T 10 A / 230/240 V ~AC.
2.2
Labels and inscriptions are present and legible.
2.3
Mechanical condition permits safe use.
2.4
No contamination or damage.
2.5
The power cable is not damaged.
2.6
The complete housing is cleaned
2.7
Welding head 1-6 (no penetrated liquids)
2.8
Silicone mats from top press, lower press, upper press and door are not worn or damaged
2.9
Top press cleaned and with no damage
2.10
Door cleaned and with no damage
2.11
Touch pad undamaged, key contact points OK
2.12
Check the upper press block with the cleaning program
2.13
Check the lower press block with the cleaning program
2.14
Check the slide with the cleaning program
2.15
Check the allocation of the sealing heads
2.16
Connector plug and circuit from PLS scales and RCC scales undamaged
2.17
Network connection and barcode scanner connection undamaged
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Meas. value
6-3
Chapter 6: TSC / TMC / MA
No.
Description
Correct.
2.18
Device feet undamaged
2.19
Check that the suspension pins of the upper press are secure. Do not bend the suspension pins; replace them if necessary
3
Device-related inspections
3.1
Calibration of ADC and the head sensors Main menu (Service) / Cal. ADC & Heads
Yes No
Calibration value Head 1: Desired value 10-50
________
Calibration value Head 2: Desired value 10-50
________
Calibration value Head 3: Desired value 10-50
________
Calibration value Head 4: Desired value 10-50
________
Calibration value Head 5: Desired value 10-50
________
Calibration value Head 6: Desired value 10-50
________
3.2
Calibrating the top press position Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Top Press
Yes No
3.3
Calibrating the upper press position Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Upper Press
Yes No
3.4
Calibrating the lower press position Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Lower Press
Yes No
3.5
Calibrating the top press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Top Press
Yes No
3.6
Calibrating the upper press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Upper Press
Yes No
3.7
Calibrating the lower press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Lower Press
Yes No
3.8
Calibrating the press scales Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Press Scale
Yes No
3.9
Calibrating the RCC scales Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / RCC Scale
Yes No
3.10
Calibrating the PLS scales Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / PLS Scale
Yes No
6-4
Meas. value
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No.
Description
Correct.
3.11
Calibrating the A1-A8 detectors Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Calibrate / Detector A
Yes No
Calibration value det. A1: Desired value 50-200
________
Calibration value det. A2: Desired value 50-200
________
Calibration value det. A3: Desired value 50-200
________
Calibration value det. A4: Desired value 50-200
________
Calibration value det. A5: Desired value 50-200
________
Calibration value det. A6: Desired value 50-200
________
Calibration value det. A7: Desired value 50-200
________
Calibration value det. A8: Desired value 50-200
________
3.12
Testing the barcode scanner, barcode test (see chapter 5.6.4 on page 5-33)
Yes No
3.13
Testing the network functionality
Yes No
3.14
Testing the WLAN functionality (n.v. = not available)
Yes No n.v.
3.15
Door / Door locks Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. door
Yes No
3.16
Closing characteristics of the door with a bag Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. door Door must close correctly
Yes No
3.17
Top press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. TP force
Yes No
Press stops at a target value of 500 N (±30 N) 3.18
Upper press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. UP force
_______N Yes No
Press stops at a target value of 500 N (±30 N) 3.19
Meas. value
Lower press force Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. LP force Press stops at a target value of 500 N (±30 N)
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_______N Yes No _______N
6-5
Chapter 6: TSC / TMC / MA
No.
Description
3.20
Test of press scales / PLS scales / RCC scales Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. X Scale
3.21
Correct. Yes No
PLS scales unladen target value: 0 g (±3 g)
_______g
PLS scales loaded with 500 g target value: 500 g (±3 g)
_______g
RCC scales unladen target value: 0 g (±3 g)
_______g
RCC scales loaded with 500 g target value: 500 g (±3 g)
_______g
Press scales unladen target value: 0 g (±3 g)
_______g
Press scales loaded with 500 g target value: 500 g (±3 g)
_______g
Slide occlusion Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Slide occl. or Serv. Slide occl. no PLS
Yes No
Target value 0 g (±15 g) 3.22
Meas. value
_______g
Test of CF-Opener top press / door / RCC scales (see Re: 3.22 on page 6-24) Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. CompoFlow
Yes No
Empty CF-Opener top press ⇒ Error message empty CF-Opener Place test tool 3.6 mm in CF-Opener top press ⇒ Error message ERROR CODE 0x0401 Empty CF-Opener door ⇒ Error message empty CF-Opener Place test tool 3.6 mm in CF-Opener door ⇒ Error message ERROR CODE 0x0401 Empty CF-Opener RCC scales ⇒ Error message empty CF-Opener Place test tool 3.6 mm in CF-Opener RCC scales ⇒ Error message ERROR CODE 0x0401
6-6
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No.
Description
Correct.
3.23
A1 - A8 detectors Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Detector A
Meas. value
Yes No
Lower press stops / retracts when det. A1 is covered Lower press stops / retracts when det. A2 is covered Lower press stops / retracts when det. A3 is covered Lower press stops / retracts when det. A4 is covered Lower press stops / retracts when det. A5 is covered Lower press stops / retracts when det. A6 is covered Lower press stops / retracts when det. A7 is covered Lower press stops / retracts when det. A8 is covered 3.24
Opening / closing the heads Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. O./C. heads or Serv. O./C. heads no PLS
Yes No
Close Head 1 Close Head 2 Close Head 3 (optional, only if PLS scales present) Close Head 4 Close Head 5 Close Head 6 Open Head 1 Open Head 2 Open Head 3 (optional, only if PLS scales present) Open Head 4 Open Head 5 Open Head 6 Close all Heads Open all Heads
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Chapter 6: TSC / TMC / MA
No.
Description
Correct.
3.25
Testing the Heads Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Check heads or Serv. Check heads no PLS
Meas. value
Yes No
All Heads empty Tubing requested for all Heads. Head 1, tubing inserted Tubing requested for all remaining Heads Head 2, tubing inserted Tubing requested for all remaining Heads Head 3, tubing inserted (optional, only if PLS scales present) Tubing requested for all remaining Heads Head 4, tubing inserted Tubing requested for all remaining Heads Head 5, tubing inserted Tubing requested for all remaining Heads Head 6, tubing inserted Tubing requested for all remaining Heads All Heads with tubings inserted No error message 3.26
Sealing behavior of the Heads Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Seal heads or Serv. Seal heads no PLS
Yes No
Head 1: Sealing seam and separation at the sealing seam are correct Head 2: Sealing seam and separation at the sealing seam are correct Head 3 (optional, only if PLS scales present): Sealing seam and separation at the sealing seam are correct Head 4: Sealing seam and separation at the sealing seam are correct Head 5: Sealing seam and separation at the sealing seam are correct Head 6: Sealing seam and separation at the sealing seam are correct
6-8
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No.
Description
Correct.
3.27
Head sensors Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Head det. or Serv. Head det. no PLS
Meas. value
Yes No
Head 1: At 30% visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70% visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 2: At 30% visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70 % visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 3: At 30% visual sensitivity (optional) Release at grey scale tone 4 (Tolerance: ±1) At 70% visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 4: At 30 % visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70 % visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 5: At 30 % visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70 % visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) Head 6: At 30 % visual sensitivity Release at grey scale tone 4 (Tolerance: ±1) At 70 % visual sensitivity Release at grey scale tone 2 (Tolerance: ±1) 3.28
Behavior during bag press-out Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / Program selection / Serv. Empty bag
Yes No
Bag is emptied (from the lower press) Bag is emptied (from the upper press) Bag is emptied (from the top press) 3.29
Stud screws for CF-Opener covers tightened hand-tight
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Chapter 6: TSC / TMC / MA
No.
Description
3.30
Expanded test CF-Opener
Correct.
Meas. value
Yes No
CF-Opener Top CF-Opener Door CF-Opener RCC 3.31
System information Main menu (Service) / Special functions / Appl. Service mode / Ready to use / Menu / System information
Yes No
Serial number
________
E-Code
________
Release
________
Test equipment used: Force measuring device (Type, serial number): ________________________________________________________________________________________ Comments:
Date:
6-10
Signature:
Stamp:
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Chapter 6: TSC / TMC / MA
The device has been released for its intended use.
Yes No
Next check: Comments:
Date:
Fresenius Kabi
Signature:
CompoMat G5
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Stamp:
6-11
Chapter 6: TSC / TMC / MA
6.3
Checking the electrical safety Warning Danger of injury from electric voltage due to changes to cable connections, the way the cable is laid or due to an electrical part. Once the CompoMat G5 has been opened, the Electrical Safety Check must be carried out before recommissioning the device. (see chapter 6.3 on page 6-12) Note: A detailed description of the individual items can be found under chapter Explanations of reports (see chapter 6.4.2 on page 6-36)
No.
Description
Correct.
4
Checking the electrical safety (see chapter 6.4.2 on page 6-36) For Germany: in accordance with DIN EN 62353. In other countries, observe the local regulations!
4.1
Visual inspection performed.
4.2
Protective earth resistance max. 0.3 Ω (with power cable)
4.3
Leakage current measurement (device leakage current) max. 500 µA
Meas. value
______ Ω
Differential current measurement acc. to DIN EN 62353, Figure 5
_____ µA
Direct measurement acc. to DIN EN 62353, Figure 4
_____ µA
or
4.4
6-12
Insulation resistance measurement > 2 MΩ
_____ MΩ
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Test equipment used: Force measuring device (Type, serial number): ________________________________________________________________________________________ Protective earth resistance, leakage current, insulation resistance (Type, serial number): ________________________________________________________________________________________ Comments:
Date:
Signature:
The device has been released for its intended use.
Stamp:
Yes No
Next check: Comments:
Date:
Fresenius Kabi
Signature:
CompoMat G5
SM-EN
3/11.10
Stamp:
6-13
Chapter 6: TSC / TMC / MA
6.4
Explanations on the reports Note: The tolerances specified in the report must be observed. Corrections are only required if the measured value lies outside the specified tolerance.
6.4.1
Explanations on the reports "Initial start-up" and "Annual maintenance" Identification
Technician's name: Technician's first name and last name. Device type with option(s) / software: System name with possible options or extras. Service report number: Service operation number. Customer/customer no.: Final customer's number. Device no.: The serial number printed on the type label Inventory no.: Inventory number assigned to the device. Equipment code: The configuration code on the device (E-code xxx). Version: Complete version number.
6-14
Re: 1
Unpacking (only for initial start-up!)
Re: 1.1
Remove the CompoMat G5 from its transport packaging and save the packaging for possible future return shipments.
Re: 1.2
Check that all parts of the CompoMat G5 have been accounted for. Inform your contact at Fresenius immediately of any missing parts.
Re: 1.3
CompoMat G5 cycler without visible shipping damage. Check that the CompoMat G5 has no visible damage or is dirty in a way that could affect safety.
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Re: 2
Visual inspection
Re: 2.1 Check the line fuses accessible from the outside. Melting point of the line fuses (2x) T 10 A / 230/240 V ~AC. To change the fuses, first disconnect the device from the power supply. The line fuses (2) are located behind a cover underneath the power socket (1). 1 2
Re: 2.2
The line fuses (2) can be accessed by pulling and folding out the cover. Fig.: Power connection (1) with line fuses (2)
Labels and inscriptions are present and legible: Labels on front / controls: – – – –
Label about Head numbering; Top press warning label; Press / door warning label; CF-Opener warning label;
Labels on rear: – – – – – –
Type label; Fuse label; Balance A label; Balance B label; Scanner label; Network label.
Re: 2.3
The mechanical condition permits further use.
Re: 2.4
There are no signs of damage or contamination.
Re: 2.5
Power cable not damaged.
Re: 3
Calibration and functional testing of the components, Control of the functional ability and the operational safety The following features of the device are checked for correct function when the device is used for its intended purpose.
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– – – –
Functionality of intended use Functionality of the existing warning devices Measuring function Parameter specifications and their tolerances
Calibration can be carried out in user mode or service mode. For each description, a note will inform you whether calibration/testing must be carried out in user mode or service mode. The user mode is normal operation. The CompoMat G5 starts up as usual with no help from applications in user mode. Service Mode (see chapter 5 on page 5-1) is reserved exclusively for development, production and service and offers a number of advanced functions. Re: 3.1
Calibration of ADC and the head sensors (see chapter 5.2.3.5 on page 5-6)
Re: 3.2 to 3.11
Calibration – – – – – – – – – –
Top press position Upper press position Lower press position Top press force Upper press force Lower press force Press scales RCC scales PLS scales Detectors A1 to A8
(see chapter 5.4 on page 5-13) Re: 3.12
Testing the barcode scanner (see chapter 5.6.4 on page 5-33)
Re: 3.13
Testing the network ethernet RJ45 Accessories: – 2x network cable (M67 810 1) – 1x LAN hub 5-port (M67 481 1) Preparation: – Connect CompoMat G5 to LAN hub assy. using a network cable – Connect CompoMaster Net G5 PC to LAN hub assy. using a network cable – Start CompoMat G5 in user mode – Start CompoMaster Net G5. Test: – Deactivate WLAN interface on the PC on which the CompoMaster Net G5 is installed. – Configure Ethernet interface on the PC on which the CompoMaster Net G5 is installed as follows:
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IP address:
192.168.0.250
Netmask:
255.255.255.0
Gateway:
(No entry)
DNS:
(No entry)
– Select configured ethernet interface in CompoMaster Net G5 (See User Manual, CompoMaster Net G5, Configuration / CompoMat G5 Parameters) – Set up CompoMat G5 on CompoMaster Net G5 (Allocate serial number, IP address and network name). – Reboot CompoMaster Net G5. The CompoMaster Net G5 recognizes the connected CompoMat G5. The status bar on the top right of the screen should show the following: = CompoMaster Net G5 connected, process data activated. or = CompoMaster Net G5 connected, process data deactivated. Re: 3.14
Testing the network WLAN functionality Accessories: – WLAN stick (M67 478 1) – WLAN access point (M67 479 1) Preparation: Note: Ensure nothing is connected to the network port on the CompoMat G5. – Plug in the WLAN stick into a free USB port on the CompoMat G5. – Deactivate Ethernet interface on the PC on which the CompoMaster Net G5 is installed. Test: – Configure WLAN interface on the PC on which the CompoMaster Net G5 is installed as follows:
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IP address:
192.168.0.250
Netmask:
255.255.255.0
Gateway:
(No entry)
DNS:
(No entry)
ESSID:
g5Net
Password:
CompoMasterNet
Encryption:
WPA/PSK
EncyptType:
TKIP
Mode:
Managed
– Start CompoMat G5 in user mode – Start CompoMaster Net G5. – Select configured WLAN interface in the CompoMaster Net G5. (See User Manual, CompoMaster Net G5, Configuration / CompoMat G5 Parameters) – Set up CompoMat G5 on CompoMaster Net G5 (Allocate serial number, IP address and network name). – Reboot CompoMaster Net G5. The CompoMaster Net G5 recognizes the connected CompoMat G5. The status bar on the top right of the screen should show the following: = CompoMaster Net G5 connected, process data activated. or = CompoMaster Net G5 connected, process data deactivated. Re: 3.15
Door / Door locks If the door is blocked, then the error message Error: Close Door should be generated. Following this, the correct closure of the door is tested. Accessories: – USB stick service G5 (M67 482 1) – Suitable implement for blocking the door (e.g. screwdriver handle) Caution Risk of damage to device surface by introducing sharp objects. Risk of scratching device surface. – Do not use any metallic or edged implements to block the door.
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Warning Risk of injury since door closes automatically. Crushing hazard – Do not reach into the movement area of the door with your hands. Preparation: – Service program: Select Serv. Door. (see chapter 5.2.6 on page 5-9) Test: – Prevent door closure by introducing a suitable object between the door lock and the door. – Press the
(green) function key ⇒ Door closes.
– An audible warning is sounded. – Door re-opens automatically. The screen message shown to the left will be displayed: Error / Error: Close Door – Press the
(green) function key.
The audible warning sound is switched off. The screen message Ready to use is displayed. – Remove blockage between lock case and door.
Check that the door closes properly:
– Press the
(green) function key again ⇒ Door closes.
Program step Wait for Start is displayed. – Manual opening of the door must not be possible. – No air gap must be visible between the door lock and door. – Press the
(green) function key.
The screen message Ready to use is displayed.
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Re 3.16
Closing characteristics of the door with a bag The ability of the door to close properly under pressure is tested by placing a filled dual-bag system inside. Accessories: – USB stick service G5 (M67 482 1) – Dual-bag system (M63 925 1) – Tube clamp Preparation: – Service program: Select Serv. Door. (see chapter 5.2.6 on page 5-9) Test: – Allow the entire liquid content of the dual-bag system to run into one bag. – Close the tubing with a tube clamp. – Hang up the filled bag in the press area so that the tube hangs below. – Place the bag suspension in the front notch of the suspension pins. – Insert the tube over the pulley into Head 6. Caution Damage to press scales with tubing under tension. Overloading the press scales – Do not pull the tube when placing it over the pulley and when inserting Head 6. – Press the
(green) function key.
The door closes and locks without an error message. – Press the
(green) function key.
The screen message Ready to use is displayed. Re: 3.17
Top press force The press force of the top press is measured by placing a force measuring device into the top press. Accessories: – USB stick service G5 (M67 482 1) – Tool for force measurement G5 (M67 228 1) – Calibrated force measuring device incl. pressure sensor (M67 449 1) Preparation: – Service program: Select Serv. TP force. (see chapter 5.2.6 on page 5-9)
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Test: – Insert the pressure sensor underneath into the G5 force measuring device (see arrow). Position the G5 force measuring device with the pressure sensor in the middle of the top press. – Press the
(green) function key.
The door closes, the top press is retracted. 1. Screen display: Top Press close until 500 N 2. Screen display: Toppress force 500 N – After 10 s, note the value on the force measuring device and enter this into the report. – Press the
(green) function key.
The screen message Ready to use is displayed. Re: 3.18
Upper press force The press force of the upper press is measured by placing a force measuring device into the upper press. Accessories: – USB stick service G5 (M67 482 1) – Tool for force measurement G5 (M67 228 1) – Calibrated force measuring device incl. pressure sensor (M67 499 1) Preparation: – Service program: Select Serv. UP force. (see chapter 5.2.6 on page 5-9) Test: – Insert the pressure sensor at the top into the G5 force measuring device (see arrow). – Position the G5 force measuring device with pressure sensor centrally on the door (see illustration). – Press the
(green) function key.
The door closes, the upper press is extended. 1. Screen display: Upper Press close until 500 N 2. Screen display: Upper Press force 500 N – After 10 s, note the value on the force measuring device and enter this into the report. – Press the
(green) function key.
The screen message Ready to use is displayed.
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Re: 3.19
Lower press force The press force of the lower press is measured by placing a force measuring device into the lower press. Accessories: – USB stick service G5 (M67 482 1) – Tool for force measurement G5 (M67 228 1) – Calibrated force measuring device incl. pressure sensor (M67 499 1) Preparation: – Service program: Select Serv. LP force. (see chapter 5.2.6 on page 5-9) Test: – Insert the pressure sensor underneath into the G5 force measuring device (see arrow). – Position the G5 force measuring device with pressure sensor centrally on the door (see illustration). – Press the
(green) function key.
The door closes, the lower press is extended. 1. Screen display: Lower Press close until 500 N 2. Screen display: Lower Press force 500 N – After 10 s, note the value on the force measuring device and enter this into the report. – Press the
(green) function key.
The screen message Ready to use is displayed. Re: 3.20
Test of press scales / PLS scales / RCC scales Accessories: – Calibration weight 500 g (M63 925 1) Preparation: – Service program: Select Serv. Press scale, Serv. PLS scale or Serv. RCC scale. (see chapter 5.2.6 on page 5-9)
Testing the PLS scales
– Press the
(green) function key.
The following screen message is displayed: Processing... Press START for weighing Scale: PLS-Scale Weight: XXX g – Enter the weight shown (XXX g) into the report – Load the PLS scales with 500 g calibration weight. – Press the
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(green) function key.
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The weight determined is transferred to the CompoMaster Net G5 and appears in the PLS scales field. – Enter the weight displayed into the report Testing the RCC scales
The following screen message is displayed: Processing... Press START for weighing Scale: RCC-Scale Weight: XXX g – Load the RCC scales with 500 g calibration weight. – Enter the weight shown (XXX g) into the report – Press the
(green) function key.
The weight determined is transferred to the CompoMaster Net G5 and appears in the RCC scales field. – Enter the weight displayed into the report The door opens. Testing the press scales
The following screen message is displayed: Processing... Press START for weighing Scale: Press Scale Weight: XXX g – Enter the weight shown (XXX g) into the report – Load the press scales with 500 g calibration weight. – Press the
(green) function key.
The weight determined is transferred to the CompoMaster Net G5 and appears in the Press scales field. – Enter the weight displayed into the report The screen message Ready to use is displayed. Re: 3.21
Slide occlusion Accessories: – Dual-bag system (M63 924 1) Preparation: – Service program: Select Serv. Slide occl. or Serv. Slide occl. no PLS. (see chapter 5.2.6 on page 5-9) Test: – Allow the entire liquid content of the dual-bag system to run into one bag. – Hang the dual-bag system on the suspension pins in the press area of the upper press. – Place the empty bag in the PLS scales plasma deaeration unit and place the connection tubing into clamp 1. – Press the
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(green) function key.
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The door closes. The display then shows the following sequence of messages: – – – – – –
Both Presses out until 150 N Both Presses to 45.0 mm Both Presses out until 650 N Slide out Wait 60 s Press START for weighing
– Press the
(green) function key.
– In the Process Data window (Scales weights/PLS scale), note the first value = reference value. – Lower Press out for 100 s – Press START for weighing – Press the
(green) function key.
– In the Process Data window (Scales weights/PLS scale), note the second value = reference value. – Enter the difference between the reference value and measurement value in the report. Re: 3.22
Test CF-Opener Top, CF-Opener Door and CF-Opener RCC Accessories: – USB stick service G5 (M67 482 1) – Test tool 3.6 mm (661 578 1) Preparation: – Service program: Select Serv. CompoFlow or Serv. CompoFlow no RCC. (see chapter 5.2.6 on page 5-9)
Test CF-Opener Top
– Press the
(green) function key ⇒ Door closes.
Screen message Processing... CF-Opener Top is displayed. – Press the
(green) function key.
Screen message Error / Error: CF-Opener is empty! is displayed, audible signal is sounded. – Press the
(green) function key.
The audible warning sound is switched off. Screen message Pause... Open CF-Opener Top is displayed, – Place 3.6 mm test tool in the CF-Opener Top. – Press the
(green) function key.
The following screen message is displayed: Technical error! Actor: 0x03, Action: 0x17 ERROR-CODE: 0x0401 – Press the
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(green) function key.
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Screen message Pause... Open CF-Opener Top is displayed, – Press the
(yellow) function key.
Screen message Processing... CF-Opener Door is displayed. Test CF-Opener door
– Press the
(green) function key.
Screen message Processing... CF-Opener Door is displayed. – Press the
(green) function key.
Screen message Error / Error: CF-Opener is empty! is displayed, audible signal is sounded. – Press the
(green) function key.
The audible warning sound is switched off. Screen message Pause... Open CF-Opener Door is displayed, – Place test tool 3.6 mm in the CF-Opener door – Press the
(green) function key.
The following screen message is displayed: Technical error! Actor: 0x04, Action: 0x17 ERROR-CODE: 0x0401 – Press the
(green) function key.
Screen message Pause... Open CF-Opener Door is displayed. – Press the
(yellow) function key.
Screen message Processing... CF-Opener RCC is displayed. Test of CF-Opener RCC (optional)
– Press the
(green) function key.
Screen message Processing... CF-Opener RCC is displayed. – Press the
(green) function key.
Screen message Error / Error: CF-Opener is empty! is displayed, audible signal is sounded. – Press the
(green) function key.
The audible warning sound is switched off. Screen message Pause... Open CF-Opener RCC is displayed. – Place test tool 3.6 mm in the CF-Opener RCC. – Press the
(green) function key.
The following screen message is displayed: Technical error! Actor: 0x05, Action: 0x17 ERROR-CODE: 0x0401 – Press the
(green) function key.
Screen message Pause... Open CF-Opener RCC is displayed. – Press the
(yellow) function key.
The program is terminated, the door opens.
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Re: 3.23
Multi-detector field (detectors A1 to A8) Accessories: – USB stick service G5 (M67 482 1) – Black foam mat (661 545 1)
Preparation:
– Service program: Select Serv. Detector A. (see chapter 5.2.6 on page 5-9) Test: – Press the
(green) function key.
The door closes, the program starts. The screen message Lower Press out until Det A1 is displayed. The lower press is extended slowly. – Hold a black foam mat in front of the A1 detector field. The lower press is retracted. The screen message Lower Press out until Det A2 is displayed. – Hold a black foam mat in front of the A2 detector field. The lower press is retracted. The screen message Lower Press out until Det A3 is displayed. – Hold a black foam mat in front of the A3 detector field. The lower press is retracted. The screen message Lower Press out until Det A4 is displayed. – Hold a black foam mat in front of the A4 detector field. The lower press is retracted. The screen message Lower Press out until Det A5 is displayed. – Hold a black foam mat in front of the A5 detector field. The lower press is retracted. The screen message Lower Press out until Det A6 is displayed. – Hold a black foam mat in front of the A6 detector field. The lower press is retracted. The screen message Lower Press out until Det A7 is displayed. – Hold a black foam mat in front of the A7 detector field. The lower press is retracted. The screen message Lower Press out until Det A8 is displayed. – Hold a black foam mat in front of the A8 detector field. The lower press is retracted, the door opens. Re: 3.24
Opening / closing the Heads (without tubes) Accessories: – USB stick service G5 (M67 482 1)
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Preparation: – Service program: Select Serv. O./C. heads or Serv. O./C. heads no PLS . (see chapter 5.2.6 on page 5-9) Test: – Press the
(green) function key.
The door closes, the program starts. Screen message Processing... Close head 1 is displayed. – Press the
(green) function key.
Head 1 is closed. Screen message Processing... Close head 2 is displayed. – Press the
(green) function key.
Head 2 is closed. Optional: Screen message Processing... Close head 3 is displayed. – Press the
(green) function key.
Head 3 is closed. Screen message Processing... Close head 4 is displayed. – Press the
(green) function key.
Head 4 is closed. Screen message Processing... Close head 5 is displayed. – Press the
(green) function key.
Head 5 is closed. Screen message Processing... Close head 6 is displayed. – Press the
(green) function key.
Head 6 is closed. Screen message Processing... Open head 1 is displayed. – Press the
(green) function key.
Head 1 is opened. Screen message Processing... Open head 2 is displayed. – Press the
(green) function key.
Head 2 is opened. Optional: Screen message Processing... Open head 3 is displayed. – Press the
(green) function key.
Head 3 is opened. Screen message Processing... Open head 4 is displayed. – Press the
(green) function key.
Head 4 is opened. Screen message Processing... Open head 5 is displayed.
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– Press the
(green) function key.
Head 5 is opened. Screen message Processing... Open head 6 is displayed. – Press the
(green) function key.
Head 6 is opened. Screen message Processing... Close all heads is displayed. – Press the
(green) function key.
All Heads are closed. The screen message Processing... open all heads is displayed. All Heads are opened. Screen message Processing... Wait for START is displayed. – Press the
(green) function key.
The program is terminated, the door opens. Re: 3.25
Testing the Heads (with tubings) Accessories: – USB stick service G5 (M67 281 1) – Empty 3.1 x 4.2 mm PVC tubing or six short tubing sections (each approx. 10 cm) (M60 024 1) Preparation: – Service program: Select Serv. Check heads or Serv. Check heads no PLS . (see chapter 5.2.6 on page 5-9) Test: – Press the
(green) function key.
The door closes, the program starts. Screen message Processing... No tubes in heads is displayed. – Press the
(green) function key.
The screen message shown to the left will be displayed: Error / Error: Check Head Inspect 1 2 3 4 5 6 – Press the
(green) function key.
– Insert the tubing into Head 1. – Press the
(green) function key.
Screen message Error / Error: Check Head Inspect 2 3 4 5 6 is displayed. – Remove the tubing from Head 1 and insert it into Head 2. – Press the
(green) function key.
Screen message Error / Error: Check Head Inspect 1 3 4 5 6 is displayed.
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– Remove the tubing from Head 2 and insert it into Head 3, if the PLC scales are installed. If not, insert the tubing into Head 4. – Press the
(green) function key.
Screen message Error / Error: Check Head Inspect 1 2 4 5 6 is displayed. – Remove the tubing from Head 3 and insert it into Head 4. – Press the
(green) function key.
Screen message Error / Error: Check Head Inspect 1 2 3 5 6 is displayed. – Remove the tubing from Head 4 and insert it into Head 5. – Press the
(green) function key.
Screen message Error / Error: Check Head Inspect 1 2 3 4 6 is displayed. – Remove the tubing from Head 5 and insert it into Head 6. – Press the
(green) function key.
Screen message Error / Error: Check Head Inspect 1 2 3 4 5 is displayed. – Insert a tubing into all Heads. – Press the
(green) function key.
The program is terminated without an error message, the door opens. Re: 3.26
Sealing behavior of the Heads Accessories: – USB stick service G5 (M67 482 1) – A 4.2 mm tube (approx. 50 cm long) filled with saline solution (0.9% NaCl) for making corresponding pieces of tubing each with a length of 80 mm – Vise with a jaw length of 50 mm – Caliper (M67 963 1) – Spring balance Preparation: – Service program: Select Serv. Seal heads or Serv. Seal heads no PLS . (see chapter 5.2.6 on page 5-9) Test: – Insert a tubing into all Heads. – Press the
(green) function key.
The door closes, the program starts. The tubings in all Heads are sealed. The program is terminated without any errors. – Remove the tubing from Head 1 and check it: Sealing seam successfully passes a visual inspection.
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Separation at the sealing seam is correct. – Remove the tubing from Head 2 and check it: Sealing seam successfully passes a visual inspection. Separation at the sealing seam is correct. – Remove the tubing from Head 3 and check it: Sealing seam successfully passes a visual inspection. Separation at the sealing seam is correct. – Remove the tubing from Head 4 and check it: Sealing seam successfully passes a visual inspection. Separation at the sealing seam is correct. – Remove the tubing from Head 5 and check it: Sealing seam successfully passes a visual inspection. Separation at the sealing seam is correct. – Remove the tubing from Head 6 and check it: Sealing seam successfully passes a visual inspection. Separation at the sealing seam is correct. Test criteria for sealing seam:
1. Visual inspection:
The sealing seam must have a symmetrical shape on both, its bottom and top sides, as well as to the left and right of the cut. There must be no sharp edges or leaks in the transitional area between tubing and sealing seam. 2. Tensile load:
1
2
3
1 Sealed length of tubing 2 Sealing seam 3 Spring balance – Allow the sealing seam to cool down for 2 min. – Pull the two segments of the line apart smoothly and uniformly, using the spring balance. The tensile loading capacity of the sealing seam should be between 10–50 N (1–5 kg).
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3. Pressure test: Note: The pressure test only functions with a completely filled tubing (no air bubbles), as only then can a correspondingly high pressure build up in the tubing. Two balloons form during the pressure test. Clamp the section symmetrical between the clamping jaws of the vise. The tubing must project for 15 mm at both ends of the jaws (see following illustration).
With the bench vise tightened, no sealing seams should be opened and no saline solution should escape. Re: 3.27
Head sensors Accessories: – USB stick service G5 (M67 482 1) – Gray wedge 13 levels (679 514 1) Preparation: – Service program: Select Serv. Head det. or Serv. Head det. no PLS. (see chapter 5.2.6 on page 5-9) Test:
Head 1
– Press the
(green) function key.
The door closes. Screen message Processing... Grey wedge in Head 1 | 30 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
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(green) function key.
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Screen message Processing... Close Head 2 at signal / Head detector 1 | red | 30% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 2 closes. Screen message Processing... Grey wedge in head 1 | 70 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
(green) function key.
Screen message Processing... Close Head 2 at signal / Head detector 1 | red | 70% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 2 closes. Head 2
Screen message Processing... Grey wedge in head 2 | 30 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
(green) function key.
Screen message Processing... Close Head 3 at signal / Head detector 2 | red | 30% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 3 closes. Screen message Processing... Grey wedge in head 2 | 70 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
(green) function key.
Screen message Processing... Close Head 3 at signal / Head detector 2 | red | 70% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 3 closes. Head 3
Screen message Processing... Grey wedge in head 3 | 30 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
(green) function key.
Screen message Processing... Close Head 4 at signal / Head detector 3 | red | 30% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 4 closes. Screen message Processing... Grey wedge in head 3 | 70 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
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(green) function key.
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Screen message Processing... Close Head 4 at signal / Head detector 3 | red | 70% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 4 closes. Head 4
Screen message Processing... Grey wedge in head 4 | 30 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
(green) function key.
Screen message Processing... Close Head 5 at signal / Head detector 4 | red | 30% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 5 closes. Screen message Processing... Grey wedge in head 4 | 70 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
(green) function key.
Screen message Processing... Close Head 5 at signal / Head detector 4 | red | 70% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 5 closes. Head 5
Screen message Processing... Grey wedge in head 5 | 30 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
(green) function key.
Screen message Processing... Close Head 6 at signal / Head detector 5 | red | 30% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 6 closes. Screen message Processing... Grey wedge in head 5 | 70 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
(green) function key.
Screen message Processing... Close Head 6 at signal / Head detector 5 | red | 70% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 6 closes. Head 6
Screen message Processing... Grey wedge in head 6 | 30 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
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(green) function key.
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Screen message Processing... Close Head 1 at signal / Head detector 6 | red | 30% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 1 closes. Screen message Processing... Grey wedge in head 6 | 70 is displayed. – Place a 13-level step wedge, beginning at 0, into the Head. – Press the
(green) function key.
Screen message Processing... Close Head 1 at signal / Head detector 6 | red | 70% is displayed. – Increase the grey level by moving the step wedge. – Note the grey value at which Head 1 closes. Re: 3.28
Behavior during bag press-out Accessories: – USB stick service G5 (M67 482 1) – Dual-bag system (M63 924 1) Preparation: – Service program: Select Serv. Empty bag. (see chapter 5.2.6 on page 5-9) Test: – Attach dual-bag system. – Place the empty bag under the top press. – Place the connection tubing into Head 1. – Press the
(green) function key.
The door closes. Both presses are extended until the bag is touched. Both presses are retracted to 55 mm. The lower press is fully extended. The slide is extended. The upper press is fully extended. Head 1 closes. ⇒ The bag in the press must have been pressed out completely. Screen message Processing... Wait for START is displayed. – Press the
(green) function key.
Both presses and the slide are fully retracted. Head 1 opens. Top press closes. Head 1 closes. ⇒ The dual-bag system in the top press must have been pressed out completely.
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Chapter 6: TSC / TMC / MA
Screen message Processing... Wait for START is displayed. – Press the
(green) function key.
Head 1 opens. Top press opens. The program is terminated without an error message, the door opens. Re: 3.30
Extended test CF-Opener Top, CF-Opener Door and CFOpener RCC Note: A service program is not required for this test. Accessories: – 9 CompoFlows Preparation: – Disconnect CompoMat G5 from the customer’s network and reboot without the service stick. – Connect the service technician’s CompoMaster Net G5 using a crossover network cable. Test: – Program the following processes for CF-Opener Top, door and RCC.
– 9 CompoFlows are to be marked (TOP_01 ... TOP_03, DOOR_01 ... DOOR_03, RCC_01 ... RCC_03). – Open 3 CompoFlows using the related CF-Opener.
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Chapter 6: TSC / TMC / MA
The CompoFlow in the tubing is completely opened (illustration on the left).
Re: 3.31
System information (see chapter 5.6.5 on page 5-34)
6.4.2
Explanations on electrical safety checks Re: 4
Check of the electrical safety: – In Germany according to DIN EN 62353 (DIN VDE 0751-1; edition 08/2008) – In other countries, observe the local regulations!
Re: 4.1
Perform visual inspection. – Check the fuses accessible from the outside Melting point of the fuses (2x) T 10 A / 230/240 V AC. – Labels and inscriptions are present and legible. – The mechanical condition permits further safe use. – There are no signs of damage or contamination. – The power cable is not damaged.
Re: 4.2
Protective earth resistance max. 0.3 Ω (with power cable) Measurement point: – Screws for attaching the housing sheet (see arrow)
6-36
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Chapter 6: TSC / TMC / MA
Re: 4.3
Measurement of the leakage current (device leakage current) Differential current measurement acc. to DIN EN 62353, Figure 5
or Direct measurement acc. to DIN EN 62353, Figure 4
Basic conditions: – Measurement of the protective earth resistance performed. – When performing a direct measurement, the following precautions also must be observed: The device must be insulated when installed. All external connections must have been removed from the device. Additional conditions: If the value scaled to the nominal voltage is higher than 90% of the admissible alarm limit (= 450 µA), the last measured value or the first measured value must additionally be considered for the rating. If necessary, reduce the interval for the regular test.
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Chapter 6: TSC / TMC / MA
Re: 4.4
Insulation resistance measurement > 2 MΩ Measurement between the active parts and any conductive part that can be touched, including the protective earth conductor.
Confirmation of the test
Test equipment used: Type and serial number of the test equipment used. Comments: Any irregularities which occurred during the test are documented in this section. Date, signature, stamp Performance of the check must be confirmed with the date, the signature of the person performing the check and a stamp.
Assessment of the test
The device has been released for its intended use. During the intended use of the device it must be ensured that the device does not present a hazard to patients, employees or other third parties. As part of overall evaluation, testers are obliged to give their official approval for the use of the device. If defects are identified, then the device owner must be informed of these without delay. Date of next inspection: The next inspection date has to be entered in the report. The intervals specified by the manufacturer have to be observed. Comments: Any irregularities which occurred during the assessment are documented in this section. Date, signature, stamp: Assessment of the initial start-up has to be confirmed with date, tester's signature and stamp.
6-38
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Chapter 7: Error Messages
7
Error Messages
7.1
CompoMat G5 Error Codes
Error message
Possible cause
Action required
0x0001
Internal error XXX
Turn off/on device
0x0002
Internal error XXX
Turn off/on device
0x0003
– Indicates presence of a syntax error in a programmed procedure. – CompoMaster Net G5 version incompatible with device version.
Turn off/on device
0x0004
– Indicates presence of a syntax error in a programmed procedure. – CompoMaster Net G5 version incompatible with device version.
Turn off/on device
0x0005
– Indicates presence of blockage or defect involving the presses.
Turn off/on device
In relation to other actuators (e.g. CF-Opener, door, clamp, etc.): – Indicates presence of defect in actuator 0x0006
Internal error XXX
Turn off/on device
0x0007
Internal error XXX
Turn off/on device
0x0008
Internal error XXX
Turn off/on device
0x0009
Internal error XXX
Turn off/on device
0x000A
– Indicates presence of a syntax error in a programmed procedure. – CompoMaster Net G5 version incompatible with device version.
Turn off/on device
0x000B
Internal error XXX
Turn off/on device
0x000C
Internal error XXX
Turn off/on device
0x0100
Internal error XXX
Turn off/on device
0x0101
Internal error XXX
Turn off/on device
0x0200
Internal error; ADC not calibrated
ADC must be re-calibrated. If the error continues to occur, then this may indicate that the Application Board bought-in assembly is defective.
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7-1
Chapter 7: Error Messages
Error message
Possible cause
Action required
0x0201
Internal error; ADC not calibrated
ADC must be re-calibrated. If the error continues to occur, then this may indicate that the Application Board bought-in assembly is defective.
0x0202
Internal error; digit < 2300 or digit > 2700
Check scales, re-calibrate device as required
0x0203
Internal error; digit < 1350 or ADCValueSum > 1750
Check scales, re-calibrate device as required
0x0204
Internal error XXX
ADC must be re-calibrated. If the error continues to occur, then this may indicate that the Application Board bought-in assembly is defective.
0x0400
Internal error XXX
Turn off/on device
0x0401
CF-Opener is blocked.
Turn off/on device
0x0402
CompoFlow has not been opened
Turn off/on device
0x0404
CompoFlow has been opened
Turn off/on device
0x0500
Scales are not calibrated
Check scales, re-calibrate device as required
0x0501
Internal error; communication with scales disrupted
Check scales, re-calibrate device as required
0x0502
Internal error; calibration value not plausible
Check scales, re-calibrate device as required
0x0503
Internal error; calibration value not plausible
Check scales, re-calibrate device as required
0x0600
Internal error XXX
Check Heads
0x0601
Sealing defective
Check Heads, insert tubing
0x0602
Error during Head check
Check Heads, insert tubing
0x0604
Erroneous ADC value from head sensors
Check head sensor
0x0607
Erroneous ADC value from head sensors during calibration
Check head sensor
0x0900
Internal error XXX
Check Trinamic Board bought-in assembly
0x0901
Fault on the Trinamic Board bought-in assembly, Application Board bought-in assembly, or software error.
Turn off/on device
0x0902
Step motor out of step.
If this error persists, then the corresponding unit must be verified/replaced.
0x0903
Calibration error
Check presses
7-2
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Chapter 7: Error Messages
Error message
Possible cause
Action required
0x0905
Door not closing during press movement
Check door sensor and door motor
0x0B00
Not possible to calibrate photodetection board
Check PDB
0x8001
Internal error ADC timeout
Re-calibrate ADC.
0x8002
5V in the range < 4500 or > 5500 mV Possible defect in power adapter or the Application Board bought-in assembly.
Change Application Board bought-in assembly (M68 137 1)
0x8004
12 V within range 11000 13000 mV Possible defect in power adapter or the Application Board bought-in assembly.
Change Application Board bought-in assembly (M68 137 1)
0x8008
24 V within range 23000 25000 mV Possible defect in power adapter or the Application Board bought-in assembly.
Change Application Board bought-in assembly (M68 137 1)
0x8010
Internal error; I2C bus 0 defective
Turn off/on device
0x8020
Internal error; I2C bus 0 defective
Turn off/on device
0x8040
Internal error; I2C bus 1 defective
Turn off/on device
0x8080
Internal error; I2C bus 1 defective
Turn off/on device
0xFFFF 0x7001
Turn off/on device Red cells have been detected by a head detector The error appears in plain text on the display: Error Head sensor x alarm This is a monitoring function that has been programmed into the procedure.
0x7010
Fresenius Kabi
The error appears in plain text on the display: Error: No weight rising on PLS Scale! e.g. – Kinks in the tubing; – clamp closed; – breaker not opened. – etc.
CompoMat G5
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3/11.10
Confirm with the key.
(green) function
Then assess whether the procedure should be aborted or should continue. – Correct the problem; – Confirm with the (green) function key.
7-3
Chapter 7: Error Messages
7.2
Actuator, action and error codes
7.2.1
Example In the example on the left the following error is indicated: Actuator: 0x1d = AS_Slide Action: 0x03 = AC_Close Error-Code: 0x0200 = ERR_ADC_NOT_CALIBRATED
7.2.2
Error codes
Significance
Error codes
ERR_UNKNOWN
0x0001
ERR_OUTOFMEMORY
0x0002
ERR_INVALID_ACTOR
0x0003
ERR_INVALID_ACTION
0x0004
ERR_TIMEOUT 0X0005
0x0005
ERR_RESOURCE_INUSE
0x0006
ERR_RESOURCE_STOPPED
0x0007
ERR_PERIPH_INUSE
0x0008
ERR_ARGUMENT_OUTOFRANGE
0x0009
ERR_INVALID_PARAMETER
0x000A
ERR_PROCESSES_STILLACTIVE
0x000B
ERR_HIGHPOWERDEVICE_INUSE
0x000C
ERR_EEPROM_WRITE
0x0100
ERR_EEPROM_READ
0x0101
ERR_ADC_NOT_CALIBRATED
0x0200
ERR_ADCOFFSET_NOT_CALIBRATED
0x0201
ERR_ADC_LOW_CALIBRATION
0x0202
7-4
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Chapter 7: Error Messages
Significance
Error codes
ERR_ADC_HIGH_CALIBRATION
0x0203
ERR_ADC_OFFSET_CALIBRATION
0x0204
ERR_DOOR_LOCK
0x0300
ERR_DOOR_UNLOCK
0x0301
ERR_DOOR_CURRENT
0x0302
ERR_DOOR_STOPPED
0x0303
ERR_DOOR_SENSOR
0x0304
ERR_BREAKER_NOTAVAILABLE
0x0400
ERR_BREAKER_CURRENT
0x0401
ERR_BREAKER_NOT_OPEN
0x0402
ERR_BREAKER_CLOSURE_NOT_OPEN
0x0403
ERR_BREAKER_TUBE_OPEN
0x0404
ERR_SCALE_NOT_CALIBRATED
0x0500
ERR_SCALE_OFFLINE
0x0501
ERR_SCALE_INVALID_CALIBRATION
0x0502
ERR_SCALE_CALIBRATE_DELTA
0x0503
ERR_SCALE_NOTSTABLE
0x0504
ERR_HEAD_NOT_AVAILABLE
0x0600
ERR_HEAD_SEAL_FAILED
0x0601
ERR_HEAD_CHECK_FAILED
0x0602
ERR_HEADDETECTOR_BLINKING
0x0603
ERR_HEADDETECTOR_CALCULATION
0x0604
ERR_HEADDETECTOR_INUSE
0x0605
ERR_HEAD_INUSE
0x0606
ERR_HEADDETECTOR_CALIBRATION
0x0607
ERR_COMPRESSOR_TIMEOUT
0x0700
ERR_COMPRESSOR_LOW
0x0701
ERR_COMPRESSOR_PERMANENT_TIMEOUT
0x0702
ERR_SLIDE_NOTAVAILABLE
0x0800
ERR_SLIDE_CURRENT
0x0801
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7-5
Chapter 7: Error Messages
Significance
Error codes
ERR_PRESS_TRINAMICCOMMAND
0x0900
ERR_PRESS_NOTINPROCESSMODE
0x0901
ERR_PRESS_CALIBRATE_DELTA
0x0902
ERR_PRESS_CALIBRATE_FORCE
0x0903
ERR_PRESS_VERIFY_DELTA
0x0904
ERR_PRESS_DOORNOTCLOSED
0x0905
ERR_PDB_CALIBRATION
0x0B00
ERR_STATE_ADC_ERROR
0x8001
ERR_STATE_5V
0x8002
ERR_STATE_12V
0x8004
ERR_STATE_24V
0x8008
ERR_STATE_I2C0_SCL
0x8010
ERR_STATE_I2C0_SDA
0x8020
ERR_STATE_I2C1_SCL
0x8040
ERR_STATE_I2C1_SDA
0x8080
ERR_PROCESSING
0xFFFF
ARM9_ERR_RED_CELL
0x7001
ARM9_ERR_TIMEOUT_MUTE
0x7005
ARM9_ERR_PLS_MONITORING
0x7010
ARM9_ERR_RCC_MONITORING
0x7015
ARM9_ERR_DET_A_COVERED
0x7020
7.2.3
Actuator codes
Actuator codes
Significance
0x00
AS_Null=0
0x01
AS_All
0x02
AS_Both_Presses
0x03
AS_Breaker_Top
Breaker_0
0x04
AS_Breaker_Front
Breaker_1
7-6
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Chapter 7: Error Messages
Actuator codes
Significance
0x05
AS_Breaker_RCC
Breaker_2
0x06
AS_Det_0
Head 1
0x07
AS_Det_1
Head 2
0x08
AS_Det_2
Head 3
0x09
AS_Det_3
Head 4
0x0a
AS_Det_4
Head 5
0x0b
AS_Det_5
Head 6
0x0c
AS_Det_6
Head 7
0x0d
AS_Det_7
Head 8
0x0e
AS_Det_A0
Multidetection board 1
0x0f
AS_Det_A1
Multidetection board 2
0x10
AS_Det_A2
Multidetection board 3
0x11
AS_Det_A3
Multidetection board 4
0x12
AS_Det_A4
Multidetection board 5
0x13
AS_Det_A5
Multidetection board 6
0x14
AS_Det_A6
Multidetection board 7
0x15
AS_Det_A7
Multidetection board 8
0x16
AS_Door
0x17
AS_Head
0x18
AS_Lower_Press
0x19
AS_Process_Mode
0x1a
AS_Scale_Press
Scale_0
0x1b
AS_Scale_RCC
Scale_1
0x1c
AS_Scale_Plasma
Scale_2
0x1d
AS_Slide
0x1e
AS_Sync_Presses
0x1f
AS_Top_Press
0x20
AS_Upper_Press
0x21
AS_BARCODE
0x22
AS_RFID
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7-7
Chapter 7: Error Messages
Actuator codes
Significance
0x23
AS_EEProm
0x24
AS_Production
0x25
AS_Deaerate
0x26
AS_Debug
0x27
AS_Trincamic
0x28
AS_Counter
0x29
AS_Breaker_3
Breaker_3 NOT AVAILABLE
0x2a
AS_Breaker_4
Breaker_4 NOT AVAILABLE
0x2b
AS_Breaker_5
Breaker_5 NOT AVAILABLE
7.2.4
Action codes
Action codes
Significance
0x00
AC_Null=0
0x01
AC_Calibrate
0x02
AC_Check
0x03
AC_Close
0x04
AC_Close_Det
0x05
AC_Close_Weight
0x06
AC_Close_Delta
0x07
AC_Close_Det_A
0x08
AC_Close_Force
0x09
AC_Close_Scale_0
0x0a
AC_Close_Scale_1
0x0b
AC_Close_Scale_2
0x0c
AC_Get_Cal
0x0d
AC_Get_State
0x0e
AC_Get_Timeout
0x0f
AC_Get_Val
0x10
AC_Home
7-8
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Chapter 7: Error Messages
Action codes
Significance
0x11
AC_Seal
0x12
AC_Set_Cal
0x13
AC_Set_Timeout
0x14
AC_Set_Val
0x15
AC_Stop
0x16
AC_To_Pos
0x17
AC_Open
0x18
AC_Open_Close
0x19
AC_Open_Delta
0x1a
AC_Open_Force
0x1b
AC_Enable
0x1c
AC_Disable
0x1d
AC_Set_Limit
0x1e
AC_Get_Limit
0x1f
AC_Reset
0x20
AC_Init
0x21
AC_Flash
0x22
AC_Verify
0x23
AC_Debug_0
0x24
AC_Debug_1
0x25
AC_Start
0x26
AC_Wait
0x27
AC_Wait_for_Start
0x28
AC_Display_Text
0x29
AC_Close_Time
0x2a
AC_Close_with_Check
0x2b
AC_Take_Tare
0x2c
AC_Close_Det_A_PLS
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7-9
Chapter 8: Calibration / adjustment
8
Calibration / adjustment
8.1
Calibration (see chapter 5.4 on page 5-13)
8-1
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Chapter 9: Servicing / repair
9
Servicing / repair
9.1
Description / warnings Caution CompoMat G5 and CompoMaster Net G5 may only be operated by qualified and specialized personnel. Caution The CompoMat G5 may only be opened by qualified and skilled staff. Caution Operators are wholly responsible for any processes that they create in CompoMaster Net G5 and which are executed by the CompoMat G5. This applies in particular to possible loss of blood and blood products by incorrect programming. See the User Manual for CompoMaster Net G5 for information about using the CompoMaster Net G5 to program the CompoMat G5. Caution Operators are wholly responsible for preparatory tasks, such as storage, centrifuging, transport to the CompoMat G5, suspending on the pins and snapping any possible rated break points, all of which can have a significant influence on the quality of separation of the blood components. For these reasons, Fresenius Kabi does not provide information in advance concerning the quality of results as regards blood components obtained using CompoMat G5 processes. Fresenius Kabi only claims that there is a relatively high reproducibility of results for processed blood components within a relatively short preparation time. Please refer to the relevant literature for specific quality results for blood components processed with the CompoMat G5 in daily practice at a blood bank.
Fresenius Kabi
CompoMat G5
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3/11.10
9-1
Chapter 9: Servicing / repair
9.2
Electrical hazards Warning Risk of injury caused by electrical voltage. Electric shock – When connecting the CompoMat G5 to a mains supply, the local regulations that apply have to be observed. Warning Risk of injury caused by electrical voltage. Electric shock – Improper commissioning and use of the electrical equipment can result in injuries, such as burns and electrical shocks. Warning Risk of injury caused by electrical voltage. Electric shock – When using safety class I systems, the quality of the protective ground of the installation is of particular importance. It must be taken into consideration that in many countries regulations have been enacted by national authorities. The rear panel of the CompoMat G5 is provided with a connection for a grounded power cable. Warning Risk of injury caused by electrical voltage. Electric shock – Disconnect the power plug before opening the CompoMat G5. Warning Risk of injury caused by electrical voltage. Electric shock If the power cable needs to be replaced, use only the original power cable listed in the spare parts catalog. If additional equipment, which is not included in the accessories, is connected to the device, there will be a danger that the permissible leakage currents will be exceeded.
9-2
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Chapter 9: Servicing / repair
Caution Loss of the preparation when disconnecting the power plug or in the event of a power failure. – If there is a loss of power while processing a program in the CompoMat G5, all sealing heads/clamps will open and the presses will stop. This may cause a loss of the preparation.
9.3
Mechanical hazards Warning Risk of injury caused by parts moving autonomously. Crushing hazard – To avoid injury, operators must ensure to keep a sufficiently large distance to all moving parts of the CompoMat G5 . Moving parts are: – – – – – –
Door upper press lower press slide Top press BG-CompoFlow Opener
Warning Risk of injury caused by parts moving autonomously. Crushing hazard – Keep hands clear of the inside of the CompoMat G5 during operation of the device.
9.4
Risk of burning Warning Risk of burning by touching the sealing electrodes. – Do not touch the sealing electrodes of Heads 1-6 during the sealing process. – Do not place any live parts into the Heads. – Maintain a sufficient distance from the sealing electrodes in the Heads.
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9-3
Chapter 9: Servicing / repair
Warning Risk of injury by burning Skin injury – The devices are not suitable for use with flammable mixtures or nitrous oxide.
9.5
Biological hazards Warning Risk of infection by leaking blood bags. It is always possible that donated blood could be infected by germs of contagious diseases. It must always be treated as being potentially infectious. – Wear surgical or similar gloves when processing blood products. – Immediately clean and disinfect work surfaces that are contaminated with blood or blood products. The cleaning instructions must be observed! Observe your local laws and regulations concerning handling of potentially infectious material. Warning Risk of contamination by leaking tubes. Risk of infection – The operator should not exert any force on tubing, which is currently being sealed.
9-4
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3/11.10
Chapter 9: Servicing / repair
9.6
Replacements / Repairs
9.6.1
Replacing the Application Board bought-in assembly (M68 137 1) CompoMat G5 preparation
– Turn on the CompoMat G5 via the main switch. The device performs a self-test. – Wait until the top press and the door are open. – Switch off main switch on the CompoMat G5 so that the top press and the door remain open.
Measures required
– Remove PLS scales. – Loosen screws for the SUB-D connectors for the following connections: Balance A/B as well as Scanner twice.
– Loosen the four screws for the Application Board bought-in assembly as per the following illustration.
– To simplify subsequent assembly, mark all cables and connections. – Loosen all cables. – Loosen all four fastening screws for the Application Board bought-in assembly as per the following illustration.
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9-5
Chapter 9: Servicing / repair
– To simplify subsequent assembly, mark all cables and connections, in particular those for the Heads. – Loosen all cables. – Pull Application Board bought-in assembly to the side of the PLS scales out of the CompoMat G5 (see arrow).
The new Application Board bought-in assembly is fitted in the reverse order of removal. The following must be noted during this process: – On connection X90 head 1 starts on the right side. – Position 3 is not used.
9-6
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Chapter 9: Servicing / repair
– Apply Loctite 243 to the screws for the SUB-D connectors undone previously. – Then tighten screws to a torque of 0.8Nm. – Ensure the connections X2 and X31 are in the correct position. Settings, calibration and tests
– All calibrations and tests must be performed again as specified in the test report - annual maintenance (see chapter 6.2 on page 6-2). – Explanation of Test report - annual maintenance (see chapter 6.4.1 on page 6-14).
9.6.2
Replacing the Display G5 printed circuit board bought-in assembly (M68 115 1) Settings, calibration and tests
Once the Display printed circuit board bought-in assembly in the CompoMat G5 has been replaced, the following steps have to be taken: – Use the menu key
to switch off the CompoMat G5.
– Insert USB stick service G5 in a USB port in the CompoMat G5. Note: The software version of the service G5 USB stick must match the customer's software version! Entering the E-Code
– (see chapter 5.2.3.2 on page 5-4)
Entering the serial number
– (see chapter 5.2.3.1 on page 5-3) – The Service-Menu is displayed.Select Set E-Code. – Set E-Code is displayed.
– The display shows: Advice Calibration successful. Confirm with the (green) function key. – The Service Menu is displayed.Select Set Serial-Num.
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9-7
Chapter 9: Servicing / repair
– The display shows: Set Serial-Num Enter serial number – The display shows: Advice Calibration successful. Please restart. Confirm with the (green) function key. – The following message is displayed: Standby the CompoMat G5 enters standby mode. – Use the menu key
to switch on the CompoMat G5.
– All calibrations and tests must be performed again as specified in the test report - annual maintenance. (see chapter 6.2 on page 6-2) – Explanation of Test report - annual maintenance (see chapter 6.4.1 on page 6-14).
9.6.3
Replacing the Trinamic Board bought-in assembly Settings, calibration and tests
– All calibrations and tests must be performed again as specified in the test report - annual maintenance (see chapter 6.2 on page 6-2). – Explanations regarding test report - annual maintenance (see chapter 6.4.1 on page 6-14).
9-8
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Chapter 9: Servicing / repair
9.6.4
Changing the top press silicon mat G5 (M68 129 1) Removing the old silicon mat
– Lift the silicon mat by one corner and fold it back as far as the old adhesive will permit. – At this point, pull slowly and evenly in order to detach the adhesive.
Cleaning the top press contact area
– remove as much as possible of the residual adhesive without damaging the surface of the top press. – Clean the surface with an alcohol-based cleaning agent (e.g. Freka®-NOL). The cleaning instructions must be observed!
Preparing the replacement mat
– Use emery paper (grain min. 180) to lightly roughen the side of the replacement mat which is to be affixed with adhesive and then clean it again.
Applying the adhesive
– The silicon mat is to be glued to the top press contact area by applying silicon adhesive M67 879 1 (Elastosil E43, 90 ml tube) in 3 places. To do so, apply adhesive to the circular areas (diameter approx. 10 mm) as highlighted in the illustration and spread slightly. – Lay the silicon mat down flat and press down evenly, removing all noticeable ridges.
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Chapter 9: Servicing / repair
9.6.5
Replacing the BG-CompoFlow Opener Top and door CompoMat G5 preparation
– Use the main switch to turn off the CompoMat G5 and – disconnect the power cable
Opening the housing
To open the CompoMat G5, proceed as follows: – Loosen the two screws on the lower left and unscrew completely (see arrows in the following illustration).
– Loosen the two screws on the lower right and unscrew completely (see arrows in the following illustration).
– Open the cover to the rear, disconnect the protective earth cable and remove the cover.
Note: To facilitate removal of the BG-CompoFlow Opener, it is helpful to dismount the PLS scales.
9-10
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Chapter 9: Servicing / repair
Disassembling BGCompoFlow Opener Top – Use an Allen wrench size 2 (M67 978 1) to unscrew the stud screws (see arrows) on both sides of the assembly. – Remove assembly. .
Tip The stud screws must not be removed.
– Remove four socket screws. (See 4 arrows in both illustrations)
– Unscrew the grounding cable. – Remove the cable completely from the cable ducts. – Disconnect related connector X51 on the Application Board boughtin assembly. – Remove BG-CompoFlow Opener Top from the housing of the CompoMat G5.
Fitting BG-CompoFlow Opener Top – Place mounting tool CFO G5 (661 586 1) on the pins on the CFO Top (red part in the illustration). – Guide BG-CompoFlow Opener Top into the housing of the CompoMat G5. – Fit the grounding cable.
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Chapter 9: Servicing / repair
Observe the installation direction of the BG-CompoFlow Opener Top as follows: Description
Position of the long leg (CompoMat G5 viewed from the front)
BG-CompoFlow Opener Top
Left
– Secure the BG-CompoFlow Opener in position using the four pan head screws M4x8. The BG-CompoFlow Opener Top is automatically correctly positioned by the mounting tool. – Remove CFO G5 mounting tool. – Re-route cables through the cable ducts. – Connect related connector X51 on the Application Board bought-in assembly. – Fit assembly and use an Allen wrench size 2 to fasten the stud screws on both sides of the assembly. Note: The BG-CompoFlow Opener Top assembly must be flush with the housing. Disassembling BGCompoFlow Opener door – Use an Allen wrench size 2 (M67 978 1) to unscrew the stud screws (see arrows) on both sides of the assembly. – Remove assembly.
.
Tip The stud screws must not be removed.
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Chapter 9: Servicing / repair
– Remove four socket screws. (See 4 arrows in both illustrations)
– Unscrew the grounding cable. – Remove the cable completely from the cable ducts. – Disconnect related connector X52 on the Application Board boughtin assembly. – Remove BG-CompoFlow Opener door from the housing of the CompoMat G5.
Fitting BG-CompoFlow Opener door – Place mounting tool CFO G5 (661 586 1) on the pins for the CFO door (red part in the illustration). – Guide BG-CompoFlow Opener door into the housing of the CompoMat G5. – Fit the grounding cable. Observe the installation direction of the BG-CompoFlow Opener door as follows: Description
Position of the long leg (CompoMat G5 viewed from the front)
BG-CompoFlow Opener Door
Right
– Secure the BG-CompoFlow Opener door in position using the four pan head screws M4x10. The BG-CompoFlow Opener door is automatically correctly positioned by the mounting tool.
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Chapter 9: Servicing / repair
– Remove CFO G5 mounting tool. – Re-route cables through the cable ducts. – Connect related connector X52 on the Application Board bought-in assembly. – Fit assembly and use an Allen wrench size 2 to fasten the stud screws on both sides of the assembly. Note: The BG-CompoFlow Opener assembly must be flush with the housing. Close the housing
– Slide the cover back onto the CompoMat G5 from the rear. – Connect the grounding cable. – Close the cover completely and secure it with screws.
9.6.6
Replacing the BG-CompoFlow Opener RCC Disassembling BGCompoFlow Opener RCC – Use an Allen wrench size 2 (M67 978 1) to unscrew the stud screws (see arrows) on both sides of the assembly. – Remove assembly.
.
Tip The stud screws must not be removed.
– Unscrew both mounting pins (see arrows) using a size 7 socket. – Remove yellow RCC (M68 119 1). – Unscrew four oval head screws M3x4 from the protective cover and remove protective cover.
– Use a hot air gun to heat up two screws M6x16 coated with Precote 80 on the top of the RCC platform and unscrew.
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Chapter 9: Servicing / repair
– Unsolder cable from the weighing cell (M63 526 1) and remove the BG-CompoFlow Opener RCC with platform.
Fitting BG-CompoFlow Opener RCC
– Fasten RCC platform and the spacer plate 5.0 mm to the weighing cell using two screws M6x16 (M68 324 1) coated with Precote 80. – During this process align the RCC platform and the base plate so they are parallel with each other. – Lay cable behind the motor to the microswitch and fasten using the two fastening elements H2P 029. – Lay cable away from the weighing cell as shown in the illustration below.
– During this process ensure that the cable does not protrude and then fix the cable in this position.
RCC Scale
Solder points
– Solder strain gauge cable to the RCC cable as shown in the illustration below. +VE input (green )
-VE output (white)
1 2 3 4
1 4 2
RCC Endposition
9 10
470
14 13
+
RCC Motor
1
-VE input (black ) +VE output (red)
200
30
M -
– Connect cable to the motor. – Pull a piece of heat shrink tubing over the cable and ensure the cable is not touching the motor housing.
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Chapter 9: Servicing / repair
– Apply Loctite 243 to four oval head screws M3x4. – Attach protective cover to the platform and the bearing block using the screws.
– Screw both mounting pins into the RCC platform using a torque wrench (M683151+M683171+M683181) and a torque of 0.8 Nm. – Fit assembly and use an Allen wrench size 2 to fasten the stud screws on both sides of the assembly.
Note: The BG-CompoFlow Opener RCC assembly must be flush with the housing.
9.6.7
Testing the BG-CompoFlow Opener The following tests must be carried out: – Check both legs for easy movement by pressing them together. – Both legs must move easily. – The legs must open again automatically.
2)
– None of the two legs may have any axial clearance. – When the sealer is open, the pin of leg 2 must reliably trigger the microswitch. 1) Pin, leg 2 and microswitch 2) Axial clearance 1)
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The position of the eccentric must be correct: – Fit the assembly tool CFO Top/door (661 591 1). The assembly tool must sit firmly on the drive holder CFO (Motor board RCC) and the eccentric firmly on the assembly tool. – Apply Loctite 243 to the threaded pin M4x6. – Press down the eccentric and the drive shaft for the DC motor – Tighten the threaded pin to 1.8 Nm and in this way fasten the eccentric. – Remove assembly tool CFO Top/door. 1) 3)
1) Eccentric 2) Assembly tool CFO Top/door 3) Threaded pin
2)
Adjusting the BGCompoFlow Opener If the sealer is stuck or jammed, an adjustment is required: – Loosen the stud screw. 1)
– Adjust the clearance by moving the shaft of the BG-CompoFlow Opener using parallel pliers or a similar tool. – Apply Loctite 243 to the stud screw and then re-tighten the screw. Both legs must move easily, but neither leg may have any axial clearance.
2)
1) Stud screw 2) CFO shaft
Adjusting microswitch If the microswitch is not triggered reliably, it can be adjusted as follows:
1)
– Loosen the pan head screws (1). – Position the FCO switch bracket (2) so that the microswitch is triggered reliably.
2)
1) Pan head screws
1)
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Chapter 9: Servicing / repair
Calibration and tests
After the replacement of a BG-CompoFlow Opener the following tests must be performed: – Calibrate RCC scales (see chapter 5.4.4.2 on page 5-23) – Calibrate PLS scales (see chapter 5.4.4.3 on page 5-24) – Press force for the upper press (see Re: 3.20 on page 6-22) – Test press scales / PLS scales / RCC scales (see Re: 3.20 on page 6-22) – BG-CompoFlow Opener height measurement (see chapter 9.7.1 on page 9-34) – BG-CompoFlow Opener Installation (see chapter 9.7.2 on page 9-35) – BG-CompoFlow Opener opening (see chapter 9.7.3 on page 9-35) – BG-CompoFlow Opener height assembly (see chapter 9.7.4 on page 9-35) – Expanded test BG-CompoFlow Opener for the replaced BGCompoFlow Opener (see Re: 3.30 on page 6-35) – Perform the electrical safety check (see chapter 6.4.2 on page 6-36).
9.6.8
Replacing the Heads CompoMat G5 preparation
The following description applies to Heads 1-6, but does not include Head 3 which is located on the PLS scales (see chapter 9.6.9 on page 9-22). Disconnect the CompoMat G5 from the power supply. – Use the main switch to turn the device off and – disconnect the power cable
Opening the housing
To open the CompoMat G5, proceed as follows: Tip To open the housing, the PLS scales and the RCC scales must not be removed! – Loosen the two screws on the lower left and unscrew completely (see arrows in the following illustration).
9-18
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– Loosen the two screws on the lower right and unscrew completely (see arrows in the following illustration).
– Pull the cover to the rear to remove. – Disconnect the protective earth cable. – Remove the cover.
Dismantling the Head
All Heads have the same design. The following description refers to Head 5 and can be applied to all other Heads.
2
1
– Loosen grooved nut. Tip If the grooved nut (1) is very tight, use the service tool for manual screwing (2) to loosen it (see illustration).
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Chapter 9: Servicing / repair
1
– Remove the head cover (1) (see illustration).
3
2
1
Remove the following plug connectors from Head 5: – BNC connector, RF (1) (already removed in the illustration) – Four-pole connector, (sensor 2) (2). – Two-pole connector, (magnet 2) (3).
– Lift and remove Head 5 (see illustration). Installing the Head
9-20
The installation is described on the example of Head 5 and is identical for all heads.
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– Assemble the individual parts of the head as shown in the illustrations.
– Insert Head 5 into the housing from above. Note: Observe the following items when installing: – The Head position is determined by the design. – Make sure that the head opening is correctly aligned. Caution Damage can occur to cables. Crushing hazard – Make sure not to damage the cables on the side of the Head when inserting and positioning the head.
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Chapter 9: Servicing / repair
Insert the following plug connectors into Head 5: – BNC connector (RF) – Four-pole connector (sensor 2) – Two-pole connector (magnet 2)
– Position Head 5 cover and manually tighten the grooved nut (see illustration). Testing Heads
9.6.9
After the replacement of a Head the following tests must be performed: – Calibrate Head sensors (see chapter 5.2.3.5 on page 5-6)
Replacing Head 3 (PLS scales) CompoMat G5 preparation
– Use the main switch to turn the CompoMat G5 off. – Disconnect the power cable.
Disassembling the PLS scales
Head 3 is part of the PLS scales. The PLS scales must be dismounted before dismounting Head 3: – Tilt the CompoMat G5 to the rear and place it onto its rear panel (see chapter 3.3 on page 3-3). – Loosen and remove PLS scalesplug (Back board: Balance B). – Remove the connection cable from the cable clips. – Disconnect the BNC connector for Head 3. – Loosen and unscrew the three screws on the PLS scales fixing bracket. –
9-22
Completely remove the PLS scales.
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Chapter 9: Servicing / repair
Dismantling Head 3
To replace Head 3, proceed as follows:
1
– Loosen both screws on the upper device housing (1) of the PLS scales Note: Both screws are located on the rear of the PLS scales and are only accessible once the PLS scales have been unmounted. – Disconnect the BNC connector (RF). – Disconnect the four-pole connector (sensor 2). – Disconnect the two-pole connector (magnet 2). – Loosen the grooved nut on Head 3. Tip If the grooved nut is very tight, use the tool for manual screwing to loosen it (see illustration). – Unscrew and remove the head cover. – Remove Head 3. Installing Head 3
(see Installing the Head on page 9-20) – Mount the upper scales housing and secure it with two screws.
Fitting PLS scales
Procedure for mounting the PLS scales(see chapter 3.3 on page 3-3).
Connect the PLS scales
Procedure for connecting the PLS scales (see chapter 3.4 on page 3-8). Note: The PLS scales must be re-calibrated after mounting. (see chapter 5.4.4.3 on page 5-24) After calibrating the scales, the scales must be tested (see Re: 3.20 on page 6-22).
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Chapter 9: Servicing / repair
Checking Head 3 on the PLS scales. Note: The integrated Head 3 on the PLS scales must be inspected for functionality after assembly of the PLS scales. (see Re: 3.24 on page 6-26) (see Re: 3.25 on page 6-28) (see Re: 3.26 on page 6-29) (see Re: 3.27 on page 6-31)
9.6.10 Replacing the weighing cell RCC (M63 526 1) Disassembling weighing cell RCC – Loosen RCC scales at connection B. – Use an Allen wrench size 2 (M67 978 1) to unscrew the stud screws (see arrows) on both sides of the assembly. – Remove assembly. .
Tip The stud screws must not be removed.
– Unscrew both mounting pins (see arrows) using a size 7 socket. – Remove yellow RCC (M68 119 1). – Unscrew four oval head screws M3x4 from the protective cover and remove protective cover.
– Use a hot air gun to heat up two screws M6x16 secured using Precote 80 on the top of the RCC platform and unscrew.
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– Unsolder cable from the weighing cell (M63 526 1) and remove the BG-CompoFlow Opener RCC with platform. – Use a hot air gun to heat up two screws M6x16 coated with Precote 80 screwed into the weighing cell from below and unscrew. – Similarly, unscrew the two countersink head screws M6x16 with which the weighing cell (M63 526 1) is fastened to the RCC base plate. – Remove spacer plate 0.6 mm. – Unsolder cable for the weighing cell and remove the weighing cell. Fitting weighing cell RCC
– Apply Loctite 243 to four countersink head screws M6x16. – Fasten weighing cell (M63 526) and the spacer plate 0.6 mm on the cable side of the weighing side and fasten to the RCC base plate using the four countersink head screws. – Prior to finally tightening the screws from below, screw the weighing cell assembly tool (661 534 1) into the threaded bores on the weighing cell and align it. – After tightening the countersink head screws, remove the assembly tool again. – Fasten RCC platform and the spacer plate 5.0 mm to the weighing cell using two screws M6x16 (M68 324 1) coated with Precote 80.
– During this process align the RCC platform and the base plate so they are parallel with each other. – Screw two screws M6x16 (M68 324 1) coated with Precote 80 screwed into the weighing cell from below.
– Adjust distance between base plate and countersink head screw to 0.6 mm.
Warning There must not be any dust or other foreign bodies between the weighing cell and the base plate.
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Chapter 9: Servicing / repair
– Align four spacer bolts until there is a distance of 0.7 mm to the RCC platform. For this purpose place the RCC scales upright and secure to a table using a screw clamp.
– Tighten four nuts M6 and ensure that the distance is now 0.6 mm.
RCC Scale
Solder points
– Solder RCC cable to the weighing cell for the RCC scales as shown in the illustration below. +VE input (green )
-VE output (white)
1 2 3 4
1 4
RCC Endposition
2
9 10
470
14 13
30
200
+
RCC Motor
1
-VE input (black ) +VE output (red)
M -
– Protect cable with heat shrink tubing. – Lay cable away from the weighing cell as shown in the illustration below.
– During this process ensure that the cable does not protrude and fix the cable in this position. – Apply Loctite 243 to four oval head screws M3x4. – Attach protective cover to the platform and the bearing block using the screws.
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– Screw both mounting pins into the RCC platform using a torque wrench (M683151+M683171+M683181) and a torque of 0.8 Nm. – Fit assembly and use an Allen wrench size 2 to fasten the stud screws on both sides of the assembly.
Note: The BG-CompoFlow Opener RCC assembly must be flush with the housing.
9.6.11 Testing the weighing cell RCC After the replacement of the weighing cell RCC the following tests must be performed: – Calibrate RCC scales (see chapter 5.4.4.2 on page 5-23) – Calibrate PLS scales (see chapter 5.4.4.3 on page 5-24) – Test press scales / PLS scales / RCC scales (see Re: 3.20 on page 6-22) – BG-CompoFlow Opener height measurement (see chapter 9.7.1 on page 9-34) – BG-CompoFlow Opener Installation (see chapter 9.7.2 on page 9-35) – BG-CompoFlow Opener height assembly (see chapter 9.7.4 on page 9-35) – Perform the electrical safety check (see chapter 6.4.2 on page 6-36).
9.6.12 Replacing the weighing cell PLS (M63 526 1) CompoMat G5 preparation
– Use the main switch to turn off the CompoMat G5. – disconnect the power cable
Disassembling weighing cell PLS
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– Loosen BNC connection and PLS connector. – Unscrew three screws M5x16 from the PLS scales (1).
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Chapter 9: Servicing / repair
1
– Unscrew two screws M4x10 and replace lower cover. – Use a hot air gun to heat up two screws M6x16 coated with Precote 80 screwed into the weighing cell from below and unscrew. – Similarly, use a hot air gun to heat the two screws M6x16 secured with Precote 80 that fasten the platform to the spacer plates 5.0 mm and unscrew. – Similarly, using a hot air gun heat the two countersink head screws M6x16 with which the weighing cell (M63 526 1) is fastened to the PLS base plate and unscrew. – Remove spacer plate 0.6 mm. – Unsolder cable for the weighing cell and remove the weighing cell.
Fitting weighing cell PLS
– Apply Loctite 243 to two countersink head screws M6x16. – Fasten weighing cell (M63 526) and the spacer plate 0.6 mm on the cable side of the weighing side and fasten to the base plate using the two countersink head screws. – Prior to finally tightening the screws from below, screw the weighing cell assembly tool (661 534 1) into the threaded bores on the weighing cell and align it.
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– After tightening the countersink head screws, remove the assembly tool again. – Fasten platform and the spacer plate 5.0 mm to the weighing cell using two screws M6x16 (M68 324 1) coated with Precote 80. – During this process align the platform and the base plate so they are parallel with each other. – Screw two screws M6x16 (M68 324 1) coated with Precote 80 screwed into the weighing cell from below.
– Adjust distance between base plate and countersink head screw to 0.6 mm.
Warning There must not be any dust or other foreign bodies between the weighing cell and the base plate. – Loosen screw for the cable holder on the weighing cell (M63 526 1) and lay the cable as shown in the illustration on the left. – Lay cable for the weighing cell through the hole in the base plate. – Solder PLS cable to the weighing cell for the PLS scales as shown in the illustration below.
Plasma load cell +VE input (green )
-VE output (white)
Plasma Sensor
1
11
2
12
1
5 6 7
1
Plasma Magnet
8
1 2 3 4
-VE input (black ) +VE output (red)
Warning The cable must not touch the lower cover under any circumstances! – Check whether the distance between spacer bolt and platform is 0.6 mm.
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Chapter 9: Servicing / repair
Warning There must not be any dust or other foreign bodies between the weighing cell and the base plate. – If not: Align four spacer bolts until there is a distance of 0.7 mm to the platform. For this purpose place the PLS scales upright and secure to a table using a screw clamp. – Tighten four nuts M6 and ensure that the distance is now 0.6 mm. – Fasten lower cover with two screws M4x10 using a torque wrench and a torque of 0.4 Nm. – Finally re-fit the PLS scales (see chapter 3.3.1 on page 3-4).
9.6.13 Testing the weighing cell PLS After the replacement of the weighing cell PLS the following tests must be performed: – Calibrate Head sensors (see chapter 5.2.3.5 on page 5-6) – Calibrate RCC scales (see chapter 5.4.4.2 on page 5-23) – Calibrate PLS scales (see chapter 5.4.4.3 on page 5-24) – Test press scales / PLS scales / RCC scales (see Re: 3.20 on page 6-22) – Open/close the Heads (see Re: 3.24 on page 6-26) – Test the Heads (see Re: 3.25 on page 6-28) – Head sensors (see Re: 3.27 on page 6-31) – Sealing behavior of the Heads (see Re: 3.26 on page 6-29) – Perform the electrical safety check (see chapter 6.4.2 on page 6-36).
9.6.14 Replacing the scales 3 (M68 109 1) CompoMat G5 preparation
– Use the main switch to turn off the CompoMat G5 and – disconnect the power cable
Opening the housing
9-30
To open the CompoMat G5, proceed as follows:
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Chapter 9: Servicing / repair
– Loosen the two screws on the lower left and unscrew completely (see arrows in the following illustration).
– Loosen the two screws on the lower right and unscrew completely (see arrows in the following illustration).
– Open the cover to the rear, disconnect the protective earth cable and remove the cover.
Disassembling scales 3
– Loosen connector X56 on the Application Board bought-in assembly. – Remove the cable completely from the cable ducts. – Loosen screw M4x10 with which the grounding cable is fastened to the front press guide. – Ensure that all washers and locking washers are removed. – Unscrew four screw M4x20 and remove the silicon insert top press G5 (M68 117 1). – Unscrew two screw M4x20 and carefully remove the sensor unit top press G5 (M68 113 1). – Unscrew two screws M4x30.
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Chapter 9: Servicing / repair
– Carefully move holder back and forward using pliers (see arrows).
Caution During the next work step do not grasp the scales at the weighing cell under any circumstances. – Carefully pull out scales 3 and remove cable. Fitting scales 3
– Fit scales 3 (M68 109 1) in the block for the upper press and fasten using two screws M4x30. – Tighten the two screws alternately until they are tight.
– Fasten sensor unit upper press G5 (M68 113 1) with two screws M4x20 using a torque wrench and a torque of 0.8 Nm.
– Fit silicon insert upper press G5 (M68 117 1) and fasten with two screws M4x20 using a torque wrench and a torque of 0.2 Nm. The plastic may break at a higher torque. – Fasten grounding cable for the front press guide (M67 469 1) to the scales 3 for the upper press using a screw M4x10.
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– During this process place a locking washer and spacer under the cable lug as well as a further spacer under the Allen screw.
Allen screw Spacer Cable lug Spacer Locking washer
– Fasten cable using a few cable ties as shown in the illustration below.
– Lay new cable through the cable ducts like the old one and connect to connector X56 on Application Board bought-in assembly. Close the housing
– Slide the cover back onto the CompoMat G5 from the rear. – Connect the grounding cable. – Close the cover completely and secure it with screws.
9.6.15 Testing scales 3 After the replacement of the scales 3 the following tests must be performed: – Calibrate press stroke for upper press (see chapter 5.4.2.2 on page 5-19) – Calibrate press force for upper press (see chapter 5.4.2.1 on page 5-17) – Calibrate press scales (see chapter 5.4.4.1 on page 5-22) – Calibrate RCC scales (see chapter 5.4.4.2 on page 5-23) – Calibrate PLS scales (see chapter 5.4.4.3 on page 5-24) – Calibrate detector A (see chapter 5.4.5 on page 5-25) – Upper press force (see Re: 3.18 on page 6-21) – Test press scales / PLS scales / RCC scales (see Re: 3.20 on page 6-22)
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Chapter 9: Servicing / repair
– Multi-detector field (detectors A1 to A8) (see Re: 3.23 on page 6-26) – Perform the electrical safety check (see chapter 6.4.2 on page 6-36).
9.7
Tests after the replacement of components
9.7.1
BG-CompoFlow Opener height measurement Accessories: – Test tool height CF-Opener G5 (661 570 1) – Allen key size 2 (661 526 1) Preparation: – Fully switch off CompoMat G5. – Remove assembly from the CF-Opener (M67 987 1). – Switch on the dial gauge (part of the test tool height BG-CompoFlow Opener G5). – Place the dial gauge on the adjusting piece and press the ORIGIN button. – Place the dial gauge on each CF-Opener in turn and make a note of the measured value. Measured values: CF-Opener
Meas. value
Desired value Top: 0 mm ± 0.7 mm
______ mm
Desired value door: 0 mm ± 0.7 mm
______ mm
Desired value RCC: 0 mm ± 0.7 mm
______ mm
Ensure that the assembly for the dial gauge is firmly seated on the housing during all measurements. Test result: CF-Opener
Test result
All CF-Opener within tolerance
9-34
Fresenius Kabi
Yes No
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9.7.2
BG-CompoFlow Opener installation Accessories: – Mounting tool CFO G5 (661 586 1) – Allen key size 2 (M67 978 1) Preparation: – Fully switch off CompoMat G5. – Fit mounting tool CFO G5 to each CF-Opener. Test result: Mounting tool can be simply inserted.
9.7.3
Test result
CF-Opener Top
Yes No
CF-Opener Door
Yes No
CF-Opener RCC
Yes No
BG-CompoFlow Opener opening This test is also performed during the annual maintenance (see Re: 3.22 on page 6-24). – After the replacement of a BG-CompoFlow Opener the test must, however, be undertaken using the test tool production 3.3 mm (661 580 1) and not using the test tool service 3.6 mm (661 578 1). – Also only the BG-CompoFlow Opener that has been replaced needs to be tested. Note: During this service work all actual limits for the CF-Opener are exceeded. For this reason, on the completion of the service work the CompoMat G5 must be rebooted. Without a reboot the correct function of the CF-Opener cannot be ensured.
9.7.4
BG-CompoFlow Opener height assembly Accessories: – Test tool height assembly CF-Opener G5 (661 576 1) – Digital vernier caliper, round depth gauge (M67 963 1) – Allen key size 2 (M67 978 1) Preparation: – Fully switch off CompoMat G5. – Fit assembly (M67 987 1) to the CF-Opener and fasten. – Place test tool to each assembly.
Fresenius Kabi
CompoMat G5
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3/11.10
9-35
Chapter 9: Servicing / repair
– Using the vernier caliper measure the distance between the surface of the test tool and the bottom of the CF lever through the 3 mm opening.
– Make a note of the absolute values found during the height measurement (see BG-CompoFlow Opener height measurement on page 9-34). – Determine the desired value as well as the related tolerance and compare with the measured value. CF-Opener Top desired value 35.1 mm ± (magnitude of the measured value CFOpener Top + 0.3 mm)
Meas. value
35.1 mm ± ______ mm
______ mm
CF-Opener door desired value 35.1 mm ± (magnitude of the measured value CFOpener door + 0.3 mm)
Meas. value
35.1 mm ± ______ mm
______ mm
CF-Opener RCC desired value 29.7 mm ± (magnitude of the measured value CFOpener RCC + 0.3 mm)
Meas. value
29.7 mm ± ______ mm
______ mm
Example CF-Opener Top: The measured value for the height measurement was -0.52 mm. It follows that: Desired value: 35.1 mm ± (0.52 mm + 0.3 mm) = 35.1 mm ± 0.82 mm Measured values between 34.28 mm and 35.92 mm are in order. Test result: CF-Opener
Test result
All CF-Opener within tolerance
9-36
Fresenius Kabi
Yes No
CompoMat G5
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Chapter 10: Passwords
10 Passwords 10.0.0.1 Service password The service password works only in Service Mode with an inserted Service G5 USB stick. It cannot be changed by the operator.
Passwor d
Function
Description
1462
Service
Enables the Service mode
10.0.0.2 Default settings for passwords in CompoMaster Net G5 The passwords only apply for the User mode. By default the following passwords are assigned. Passwor d
Function
1000
Program selection
2000
Calibration
3000
Cleaning
4000
Setup
Tip For further information see: User Manual, CompoMaster Net G5
10.0.0.3 Defining individual passwords in CompoMaster Net G5
Tip For further information see: User Manual, CompoMaster Net G5
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10-1
Chapter 11: Functional Description
11 Functional Description 11.1 Description of the therapy Note: For information regarding this chapter see: Operating Instructions, CompoMat G5
11.2 Physical Description Note: For information regarding this chapter see: Operating Instructions, CompoMat G5
11.3 Functional description 11.3.1 Application Board bought-in assembly (M68 137 1) The functional component group Application Board bought-in assembly is responsible for the entire control of the actuators as well as for monitoring sensors. The Application Board bought-in assembly controls communication with the functional component group Trinamic Board bought-in assembly. Communication with the functional component group Display G5 printed circuit board bought-in assembly is carried out via a USB connection.
11.3.2 Display G5 printed circuit board bought-in assembly (M68 115 1) The functional component group Display G5 printed circuit board bought-in assembly controls the external interfaces to superior systems (such as BIS - Blood Bank Information System) as well as the user guidance and communication with the internal sub-systems.
11-1
Fresenius Kabi
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Chapter 11: Functional Description
11.3.3 HF generator 24V bought-in assembly (M66 178 1) The functional components group HF generator 24V G5 is responsible for the generation of HF (high frequencies). It is controlled via the functional component group Application Board bought-in assembly.
11.3.4 Relay box G5 (M68 107 1) The functional components group relay box G5 is responsible for the channeling of HF (high frequencies). It is controlled via the functional component group Application Board bought-in assembly.
11.3.5 Sealing Head El.Mag. Drive assembly (M68 144 1) The functional group Sealing Head El.Mag. Drive assembly is responsible for clamping and sealing the tubes and for the detection of red cells. Control and evaluation of the data is done by the functional component group Application Board bought-in assembly.
11.3.6 Trinamic Board bought-in assembly (M68 138 1) The functional component group Trinamic Board bought-in assembly controls the stepper motors and measures the power required by them. It is controlled via the functional component group Application Board bought-in assembly.
Fresenius Kabi
CompoMat G5
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11-2
Fresenius Kabi
6
M
CompoMat G5
M
door lock
5
OUT IN
4
B/ASM HFgenerator 24V (M66178) B/ASM relay box (M66407) OUT6
OUT5
OUT4
OUT3
OUT2
OUT1
3
author: M.Hock
date: 21.04.2009 scale
M
X48
X48
X48
X48
X48
slider
K6
K5
K4
K2
K1
2.* ASMCompoFlow Opener (M66810)
1* B/ASM-Board detector (M60841)
1
2
1:1
V1.4
version
sheet
drawing no.
block diagram G5
1
1 of 1
Fresenius Kabi Deutschland GmbH
2*
RF
door sensor
Boot USB
S M
X9 3
A
CON304
Mixer
D
RF
Ethernetconnection
CON302
M
lower press
1*
upper press
breaker1
2*
breaker0
X9 3
CON306
USB
X55 X46 X47 X30 X31
Mlp
S M D lp
S M D up
Mup
top press
RF
door motor
CON303
CON301
X10
X60 X57
DMS 1
X81
X50
B/ASMTrinamic board (M66960) Communication
S M D tp
Mtp
X9 3
door
GND
X2
X30 0
B/ASM-Application board (M66639)
GND/24V
DMS 2 Motor 0 DMS 0 Motor 2
X80
X56
X51
X52
RF
K/ASM display G5 board (M66826) CON LED
CON300
(M66969)
+24V
power supply
X30 1
X1
X53
X200
X1000
X11
X9 3
display G5 front foil (M66829)
display G5 (M66824)
N
G
L
Reserve out
Jtag
USB Hub
X43
1 x USB intern
2
RF
Ethernet 4000V Isolation
ac
RF X93
K3
X48
X21
X42
3
X9 3
B
C
ASM-Plasma scale (M66846)
X20
X54
X41
X12
2 x USB
X13
X44
scanner
X90.6 X90.5 X90.4 X90.3 X90.2
RFID
breaker2
X40
D
CF opener
4
X45
5
X90.1
ASM-RCC-Scale (M66860)
0
REV.
ASM-sealing head cpl (M67174)
11-3 Motor 1
6
A
B
C
D
Chapter 11: Functional Description
11.4 Block diagram
SM-EN
3/11.10
Chapter 11: Functional Description
11.5 Component layouts 11.5.1 Application Board bought-in assembly
Fresenius Kabi
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11-4
Chapter 11: Functional Description
11.5.2 Display G5 printed circuit board bought-in assembly
11.5.3 LP1361
11-5
Fresenius Kabi
CompoMat G5
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3/11.10
Chapter 11: Functional Description
11.5.4 Trinamic Board bought-in assembly
Fresenius Kabi
CompoMat G5
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11-6
Chapter 11: Functional Description
11.6 Flow diagram (Service Menu) Entering the password
Main menu (Service) Set Serial number Program selection
Set E-Code Set MAC-Adress
01
Update/Init ARM7
02
Update/Init Trinamic Cal. ADC & Heads Special functions
50
Special functions Appl. Service mode Download files
Main menu
Unittest screenshot Unittest Network stress Create Production-Stick Production state
Program selection Seal & weighing Calibrate Cleanup Setup Cleanup
Calibrate
System information Upper Press
Top Press
Lower Press
Upper Press
Slide
Lower Press
Setup Press Scale Language selection
RCC scales
Process data Software update
PLS Scale Process data
Language selection
Process data off
English
Process data on
German
Detector A
Barcode test
Italian ...
11-7
Fresenius Kabi
CompoMat G5
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3/11.10
Chapter 12: Spare parts catalog
12 Spare parts catalog
Pos.
Part no.
Description
1
M68 109 1
Scale 3 f. Service
2
M68 110 1
Suspending pin f. Service (2x)
Pos.
Part no.
Description
1
M68 113 1
Sensor unit upper press G5 f. Service
Fresenius Kabi
CompoMat G5
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12-1
Chapter 12: Spare parts catalog
12-2
Pos.
Part no.
Description
2
M68 105 1
UP.DETECTOR COVER DETECTION f. Service
3
M68 149 1
DETECT.BOARD A8-A2 COMPOMAT f. Service
Pos.
Part no.
Description
1
M67 991 1
textile EMI gask f. Service (Set)
2
M68 114 1
Display G5 f. Service
3
M68 150 1
ferrite core filter display f. Service 10x
4
M68 115 1
Display G5 board ARM9 f. Service
Fresenius Kabi
CompoMat G5
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Chapter 12: Spare parts catalog
Pos.
Part no.
Description
1
M63 526 1
SCALES CELL COMPOGUARD
2
M67 986 1
Rear cover PLS + clamp collar f. Service
3
M68 123 1
Upper cover G5 f. Service
4
M68 122 1
Lower cover f. Service
5
M68 121 1
Terminal strip f. Service
6
M68 144 1
Sealing head cpl. G5 f. Service
7
M68 120 1
Strip sheet coated f. Service
Fresenius Kabi
CompoMat G5
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12-3
Chapter 12: Spare parts catalog
12-4
Pos.
Part no.
Description
1
M68 138 1
Trinamic board f. Service
2
M68 137 1
Application board ARM7 LP1349 f. Service
Pos.
Part no.
Description
1
M66 178 1
EE/ HF-generator 24V G5 adjusted + tested
2
M68 107 1
Relay box G5 f. Service
3
M68 139 1
Powerbox Medline 450 f. Service
4
M67 997 1
ethernet isolator f. Service
Fresenius Kabi
CompoMat G5
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3/11.10
Chapter 12: Spare parts catalog
Pos.
Part no.
Description
5
M67 988 1
BNC panel jack 10HC 049 f. Service (5x)
6
M67 989 1
D-SUB-mounting set UNC 4-40 f. Serv. 4x
7
M67 996 1
components clip V-1001 f. Serv. (Set 10)
8
M68 103 1
COVERING CAP F. CIRCUIT f. Service (10x)
9
M68 142 1
Glider PGB 40x20x8 f. Service (8x)
Fresenius Kabi
CompoMat G5
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12-5
Chapter 12: Spare parts catalog
12-6
Pos.
Part no.
Description
1
M68 125 1
Step motor f. press with spindle f. Serv.
2
M68 124 1
double guide bearing + flange f. Serv. 4x
3
M68 146 1
Proximity sensor G5 f. Service
4
M68 106 1
SHOCK ABSORBER f. Service
5
M68 127 1
Guide bearing slide f. Service 2x
6
M68 126 1
Slide drive cpl. f. Service
Fresenius Kabi
CompoMat G5
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3/11.10
Chapter 12: Spare parts catalog
Pos.
Part no.
Description
1
M67 994 1
wiper 16_22_04 f. Service (2x)
2
M68 125 1
Step motor f. press with spindle f. Serv.
3
M68 128 1
Pressing plate G5 incl. label f. Service
4
M68 131 1
Double guide sleeve top press (Serv. 2x)
5
M68 130 1
Force sensor top press f. Service
6
M68 129 1
Silicone mat toppress G5 f. Service
7
M67 992 1
Disk wiper f. Service (2x)
8
M68 104 1
CountersinkScr.M6X16+precote80 f. S. 20x
Fresenius Kabi
CompoMat G5
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12-7
Chapter 12: Spare parts catalog
12-8
Pos.
Part no.
Description
1
M67 987 1
Fixture active breaker G5 f. Service
2
M68 119 1
covering RCC f. Service
3
M63 526 1
SCALES CELL COMPOGUARD
4
M68 132 1
CompoFlow Opener G5 RCC f. Service
Pos.
Part no.
Description
M68 145 1
Interface Detector f. Service
Fresenius Kabi
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Chapter 12: Spare parts catalog
Pos.
Pos.
Fresenius Kabi
Part no.
Description
M67 987 1
Fixture active breaker G5 f. Service
Part no.
Description
M68 101 1
passive insert activebreaker G5 f. Serv.
CompoMat G5
SM-EN
3/11.10
12-9
Chapter 12: Spare parts catalog
Pos.
Pos.
12-10
Part no.
Description
M68 108 1
Force sensor upper+down press f. Service
Part no.
Description
M68 111 1
CompoFlow Opener TOP-Pr. f. Service
M68 112 1
COMPOFLOW Opener Upper-Pr. f. Service
Fresenius Kabi
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Chapter 12: Spare parts catalog
Pos.
Pos.
Fresenius Kabi
Part no.
Description
M68 117 1
Silicone inlay upper press G5 f. Service
Part no.
Description
M68 118 1
Silicone inlay lower press G5 f. Service
CompoMat G5
SM-EN
3/11.10
12-11
Chapter 12: Spare parts catalog
12-12
Pos.
Part no.
Description
1
M68 144 1
Sealing head cpl. G5 f. Service
2
M68 298 1
top electrode f. sealing head G5 f. Serv
Pos.
Part no.
Description
1
M68 134 1
assyembly door G5 f. Service
2
M68 135 1
Door G5 plate f. Service
3
M67 993 1
plug_B-Plastic_SFL 18x0_8-2 f. Service 5x
4
M68 136 1
Silicone inlay for door G5 f. Service
Fresenius Kabi
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Chapter 12: Spare parts catalog
Pos.
Pos.
Fresenius Kabi
Part no.
Description
661 524 1
B/ASM-packaging RCC scales
Part no.
Description
661 525 1
B/ASM-packaging plasma-Scale
CompoMat G5
SM-EN
3/11.10
12-13
Chapter 12: Spare parts catalog
Pos.
Pos.
12-14
Part no.
Description
M67 216 1
B/ASM-packaging CompoMat G5
Part no.
Description
M68 126 1
Slider drive cpl. f. Service
Fresenius Kabi
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Chapter 12: Spare parts catalog
Pos.
Pos.
Fresenius Kabi
Part no.
Description
M68 133 1
Door drive cpl. f. Service
Part no.
Description
M68 141 1
Lock G5 f. Service
CompoMat G5
SM-EN
3/11.10
12-15
Chapter 12: Spare parts catalog
12-16
Pos.
Part no.
Description
1
M67 990 1
support bypass pin
2
M67 999 1
profile seal f. Service
3
M68 116 1
display front foil G5 f. Service
Pos.
Part no.
Description
M68 143 1
Rear panel sheet G5 f. Service
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CompoMat G5
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Chapter 12: Spare parts catalog
1
2
3
Pos.
Part no.
Description
1
M68 299 1
IEC power connector G5 f. Service
2
M68 301 1
ON/OFF SWITCH 10A 250V f. Service
3
M68 302 1
COVERING CAP F. CIRCUIT BRAKER f. Service
1
2
3
Pos.
Part no.
Description
1
M66 514 1
cable RF sealhead K1/5/6
2
M67 446 1
cable RF sealhead K2/4
3
M67 447 1
cable RF switchbox - RF-generator
1
2
3
Pos.
Part no.
Description
1
M67 449 1
cable RF sealhead K3
2
M67 301 1
cable power supply ARM7-board X1
3
M67 306 1
cable power supply ARM9-board X2
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CompoMat G5
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3/11.10
12-17
Chapter 12: Spare parts catalog
1
Pos.
Part no.
Description
1
M67 310 1
cable RFID ARM7-board - Connector X21
2
M67 314 1
cable power supply RF-generator X30
3
M67 322 1
cable relaybox - ARM7-board X31
1
2
3
Pos.
Part no.
Description
1
M67 330 1
cable PLS ARM7-board - Connector X53
2
M67 342 1
cable door motor X55
3
M67 346 1
cable slider motor X57
1
12-18
3
2
2
3
Pos.
Part no.
Description
1
M67 354 1
cable door lock X47
2
M67 357 1
Cable CF-Opener Toppress X51
3
M67 363 1
Cable CF-Opener Upperpress X52
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Chapter 12: Spare parts catalog
1
2
3
Pos.
Part no.
Description
1
M67 368 1
cable power supply Trinamic Board X80
2
M67 372 1
cable sealhead K1/2/4 X90.1/90.2/90.4
2
M67 383 1
cable sealhead K5 X90.5
2
M67 386 1
cable sealhead K6 X90.6
3
M67 392 1
cable sealhead sensor K1 X40
1
2
3
Pos.
Part no.
Description
1
M67 395 1
cable sealhead sensor K2 X41
2
M67 397 1
cable sealhead sensor K4 X43
3
M67 399 1
cable sealhead sensor K5 X44
1
2
3
Pos.
Part no.
Description
1
M67 402 1
cable sealhead sensor K6 X45
2
M67 404 1
cable communication X81Trinamic
3
M67 412 1
cable powerline powerinlet
Fresenius Kabi
CompoMat G5
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12-19
Chapter 12: Spare parts catalog
1
2
3
Pos.
Part no.
Description
1
M67 434 1
cable powerline powerinlet blue
2
M67 463 1
cable sealhead K3 crossing cable
3
M67 464 1
cable photodetection board X60
Other spare parts not illustrated Pos.
12-20
Part no.
Description
644 066 1
GV FUSE 10 A/T (D5 X 20 MM) SHORT
M68 324 1
Hex. socket scr.M6x16+Precote80 f. S. 10x
M67 995 1
Oval head screw ISO7380 M5x8 f. Serv. 20x
M67 998 1
warning label CompoFlow f. S. (54x)
M68 102 1
Hex. socket scr.M5x16+Precote80 f. S. 30x
M68 176 1
sticker set sealing head G4/G5 1-8 A B
M68 140 1
IEC power conn. PF0033/20/63 f. Service
M67 432 1
cable USB communication
M67 433 1
cable Ethernet communication
M67 438 1
Power cord EU except UK
M67 448 1
cable RF PLS-scales
M67 520 1
FUSE 8 A/T (D5 X 20 MM)
M67 416 1
cable grounding power line
M67 420 1
cable grounding power supply
M67 424 1
cable powerline powersupply black
M67 428 1
cable grounding back panel
M67 439 1
cable powerline powersupply blue
M67 469 1
cable grounding Front press guidance
M67 471 1
cable grounding Toppress
M67 494 1
cable grounding Scale CF-Toppress
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CompoMat G5
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3/11.10
Chapter 12: Spare parts catalog
Other spare parts not illustrated Pos.
Part no.
Description
M67 495 1
cable grounding CF Upperpress
M68 147 1
RCC-cable f. Service
M68 148 1
PLS-cable f. Service
12.1 Tools and accessories
1
2
3
4
5
6
7
8
9
Fresenius Kabi
CompoMat G5
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12-21
Chapter 12: Spare parts catalog
10
13
11
14
12
15
16
17
18
19
20
21
12-22
Fresenius Kabi
CompoMat G5
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3/11.10
Chapter 12: Spare parts catalog
22
23
24
25
26
27
28
29
30
31
32
33
Fresenius Kabi
CompoMat G5
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3/11.10
12-23
Chapter 12: Spare parts catalog
34
35
36
37
38
39
40
41
42
43
44
45
46
12-24
Fresenius Kabi
CompoMat G5
SM-EN
3/11.10
Chapter 12: Spare parts catalog
Tools and accessories Pos.
Part no.
Description
1
M68 287 1
ASM-electrical test equipment for G5
2
M68 288 1
EE motor switch box G5
3
661 545 1
black foam mat G5
4
M67 228 1
Service tool power measurement G5
5
M63 925 1
CALIBRATION WEIGHT 500G F1 + CERTIFICATE
6
M67 851 1
EE/SYNTHETIC BLOCK G4+G5 calibrated
7
M63 924 1
TWIN-BAG SYSTEM COMPOMAT G4
8
M67 501 1
CLOSURE DEVICE IN HOUSING 4.2 STERILIZED
9
661 537 1
flare double-ended ring spanner 17x19
10
679 514 1
OPTICAL FILTER 13 LEVELS
11
M67 980 1
hexagon socket screwkey SW4 (Service)
12
M60 024 1
PVC-TUBE 3.1X4.2 MM COMPOSEAL
13
M67 499 1
Mobile force gauge EasyForce 2kN
14
M67 502 1
service tool manual screwing G5
15
M67 981 1
Tool for manual screwing f. Service
16
M67 979 1
double-end. ring span. deep offset 12x13
17
M67 978 1
hexagon socket screw key SW2 f. Service
18
M67 507 1
ferrit opener
19
661 534 1
Assembly tool load cell
20
M67 482 1
USB Stick Service CompoMat G5
21
661 570 1
testing tool height CompoFlowOPener G5
22
661 576 1
testing tool height fixture G5
23
661 586 1
Assembly-Tool CFO G5
24
M67 963 1
dig. calliper gauge, round depth gauge
25
661 535 1
talcum Pressol 10 588 50gr.
26
M64 006 1
glue - SICOMET 77 20G bottle
27
661 575 1
Torque Wrench 4-20 Nm
28
M67 977 1
Silicone ELASTOSIL E43 90ml Tube
29
M68 198 1
case I for G5 service tools CFO empty
30
M68 199 1
case II for G5 service tools empty
31
M67 985 1
testing tool single empty blood bag
Fresenius Kabi
CompoMat G5
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3/11.10
12-25
Chapter 12: Spare parts catalog
Tools and accessories
12-26
Pos.
Part no.
Description
32
661 578 1
Testing-Pin Holder for Service G5
33
661 580 1
Testing-Pin Holder for Production
34
M68 170 1
Syringe Grease POLYLUB GLY151 6 ml
35
661 592 1
Assembly tool CFO RCC
36
661 591 1
assembly tool CFO Top/Door
37
641 950 1
GLUE LOCTITE NO.243; 50ML
38
M60 698 1
LOCTITE GLU NO.270/50 ML SCREWSAFE
39
M62 029 1
REINIGER LOCTITE 7063 400 ML-SPRUEHDOSE
40
M67 961 1
Service tool power measurement slide G5
41
M67 484 1
Update CompoMat G5 V01.01.06 USB-Stick
42
M68 314 1
dynamometric screwdriver 10-80cNm
43
M68 315 1
dynamometric screwdriver 40-250cNm
44
M68 316 1
reversing blade 6mm with 1/4”-bit-drive
45
M68 317 1
reversing blade 6mm with external square
46
M68 318 1
hexagon socket wrench - SW7
Fresenius Kabi
CompoMat G5
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3/11.10
