Vacuum Housing Upgrade from Configuration 1 to Configuration 2

Parts and Materials Required

• Proper PPE

• Panther Systems with Serial #s lower than 00281 also require:
  • DUCT 7 FAN KIT
  • VAC HSG
  • CHILLER RAMP
• Combination hex wrench set
• 4 mm long handle hex driver
• 5 mm long handle hex driver
• Flat blade screwdriver
• Hex driver set
• Loctite 222 or 242
• Phillips head screwdriver
• Tubing cutter
• Zip ties
• VACUUM HOUSING
• PCB, VACUUM PLL CU

Time Required

• 2 hours

Procedure

1. Put on proper PPE.
2. Power down the Panther System.
3. Remove the Bleach, Wash Buffer, and Deactivation Buffer bottles from the Universal Fluids Drawer.
4. Remove the Universal Fluids Drawer.

   1. Pop the drawer out of the drawer slides by lifting the front detent.

      

   2. Ensure the drawer is supported prior to disconnecting it from the drawer slides.
   3. Push the slides back to pop free the rear horizontal detent.

      

   4. Being careful not to stretch kink the tubing, move the drawer out of the way.

      

   5. Set the drawer on an appropriately-sized supporting object (such as a sturdy box).

      

5. Remove the Vacuum Module.

   1. Unlatch and unhook the buckle mechanism from the chassis base.

      

   2. Pull the Vacuum Module forward and remove the cable holder.

      

   3. Disconnect the control cable connector by grasping the sides of the connector.

      

   4. Disconnect the power and ground lugs.

      

   5. Slide the Vacuum Module forward.

      

   6. Disconnect the inlet and outlet tubing from the Vacuum Module.

      

   7. Remove the Vacuum Module from the system.

   Note—Do not lift the Vacuum Module by the vacuum fittings.

6. Remove the vacuum pumps from the Vacuum Module base by removing the 8 mounting screws from the mounting feet of each of the pumps.

   

7. Disconnect the power and control cables from the PCB.
8. Remove the buckle mechanism and its mounting screws. Do not discard the buckle and mounting screws—they will be used on the new housing.

   Note—Do not discard the original base.

9. Disconnect the black Norprene tubing sets from the pump head right-angle fittings.

   Note—Be very careful not to break the fittings on the head.

   

10. Remove the 4 pump head mounting screws on each of the vacuum pump heads.

    

11. Rotate the pump head 90° so that the input/output barbed fittings are opposite the pump controller. Perform this operation on both pumps. It is not necessary to disassemble the pump head by removing the center screw.

    

12. Disassemble the new vacuum housing in preparation for installing the pumps.

    1. Remove the front cover of the housing by removing the 10 M5X10 button head cap screws (BHCS) using a 3 mm Allen key.

       

    2. Unfasten the inner housing from the outer housing by removing the 10 M5X8 BHCSs using a 3 mm Allen key.

       

    3. Slide the inner housing out of the outer housing.

       

    4. Unfasten the pump mounting assembly from the inner housing by removing the 4 M6X8 BHCSs from the bottom of the inner housing using a 4 mm Allen key.

       

    5. Remove the mounting assembly from the inner housing.

       

    6. Remove the pump mounting bracket by removing the 4 socket head cap screws (SHCS) using a 5 mm Allen key.

       

    7. Remove the 8 M6X14 SHCSs from the bracket and base.

13. Using 4 M6X14 SHCSs, install one pump on the new housing pump base. Orient the pump so that the fittings are on the side of the notch T-shaped feature in the base. The pump controller should be on the opposite side.

    

14. Prepare the cables.

    1. Disconnect the pump ribbon cable connector from the pump controller.

       

    2. Connect the new ribbon cable so that wire #1 (designated with a stripe) is oriented down and the ribbon cable exits the connector toward the pump.

       

       Note—Only one of the two sides of the flex cable allows you to connect it like this. If the striped wire is not facing down, flip the flex cable around and use the opposite side connector. The connectors are polarized with narrow and wide slots that match up to narrow and wide posts on the mating connector.

    3. Bundle and zip tie the longer pump control cable with the smaller connector (previously plugged into the small PCB on the original pump base—it will no longer be connected).

       

15. Mount the new PCB.

    1. Remove the 3 nuts from the standoffs on the pump bracket.
    2. Install the PCB in the orientation shown in the photo.

       

    3. Apply Loctite 222 or 242 to the standoff threads and tighten the 3 nuts to secure the PCB to the standoffs.

       

16. Optional: Snap off the 8 connector locks to ease future servicing. The lock is a small flexure on the inside of the connector post that is easy to break off. Do not snap off the entire post—only the small flexure.

    

17. Using 4 M6X14 SHCSs, install the upper pump onto the bracket. The fittings of the pump should face the skinny legs of the bracket.

    

18. Install the mounting bracket and upper pump onto the pump base by vertically sliding the bracket over the lower pump. The upper pump should be oriented so that the inlet/outlet fittings are on the same side as the lower pump fittings. The bracket will have to be spread apart slightly to fit over the lower pump controller. Fasten the bracket to the base with 4 M6X14SHCSs.

    

19. Connect the ribbon cable from the pump and the new ribbon cable from the controller to the new PCB.

    Note—Note how the new cable is flipped over to make the connection. The striped side of the ribbon cable is on the bottom at the pump control box, and then flips to the top at the PCB connector. The connectors are polarized with narrow and wide slots that match up to narrow and wide posts on the mating connector. Zip tie the cables so that they are tucked away neatly.

    

20. Load the vacuum pumps assembly into the inner housing.

    1. Connect the fan wire to either of the 2 fan connectors on the PCB.

       

    2. Connect the power and control wires.

       

    3. Place the vacuum pumps assembly into the inner housing.

       

21. Route the power cables.

    1. Route the power cable into the 2 clips.

       

    2. Route the power cable out of the inner housing and install the grommet into the feature at the top of the housing.

       

    3. Gently pull the fan cable from the top of the grommet in the fan channel of the housing (where the fan is mounted) so that the excess cable resides in the upper channel and will not rub against the tops of the pumps.

       

22. Using a 4 mm Allen key, secure the stacked pump assembly into the inner housing with 4 M6X8 BHCSs from the bottom of the inner housing.

    

23. Slide the inner housing into the outer housing. Be careful not to pinch your fingers.

    

    Helpful Hint—From this point forward, it is up to the discretion of the field engineer to move the installed vacuum housing to the floor by the system. This is to help prevent heavy lifting of the vacuum housing.

24. Using a 3 mm Allen key, secure the inner housing with 10 M5X10 BHCSs.

    

25. Install 8 new pieces of black Norprene tubing from the pumps to the manifold.

    WARNING—Correct connection is critical.

    

26. Install the front cover.

    1. Slip the power and control cables through the front cover hole.

       

    2. Using a 3 mm Allen key, secure the front cover with 10 M5X10 BHCSs.

       

27. Install the inlet tubing.

    

28. Install the fitting assembly and buckle.

    

29. Prepare the vent:

    For Panther System Serial #s lower than 00281:

    1. Remove the plate from the upper location and install it on the rear location. Use the upper set of mounting holes so that the plate is pushed down.

       

    For Panther System Serial #s 00281 and greater:

    1. Leave the upper plate installed.
    2. Add the rear vent duct.

       

30. Upgrade the fan guard on the Cooling Module.

    1. Pull off the black plastic fan guard.

       

    2. Install the new wire fan guard using mounting screws/washers from the package. (Screws/washers may come separate, without the gasket. Only sue the screws and washers. Discard the gasket if included in the kit.)

       

31. Prepare power for the new vacuum box. (It may be helpful to remove the power supply from the system.)

    1. Pull the cable panel off and remove the original power cable.
    2. Install the new power cable and attach lugs to the power supply.
    3. Route the new power cable to the vacuum box.

       

    4. It is optional to use zip ties to hold the cables in place.
    5. Discard the old power cable

32. Cut off the barbed fitting at the end of the tubing from the waste drawer and discard.

    

33. Remove the existing (dual) muffler and exhaust tubing from the system. (The new vacuum box has an internal muffler and a new exhaust system.)

    1. Although not required, removing the Cooling Module may be helpful.
    2. Remove the dual muffler assembly (refer to Installation of the Secondary Vacuum Muffler).

34. Remove and discard the existing control cable between the pump and the Cooling Module PCB.
35. For newer Panther Systems (Serial # 00281 and greater), no further system modifications are necessary. Install the new vacuum housing module with the rear vent already attached to the vacuum box.

    1. Slide the vacuum housing module into the system.

       

    2. Attach the vacuum tubing from the waste drawer to the barbed fitting.

       

    3. Connect the power cable.

       

    4. Attach the communication cable to the Cooling Module PCB.

       

    5. Lock the vacuum box in place with the buckle mechanism.

       

Note—For older systems (Serial #s 00280 and lower), follow the instructions below for Chiller Ramp Upgrade for Older Panther Systems before installing the vacuum box.

Chiller Ramp Upgrade for Older Panther Systems (Serial #s 00280 and lower)

Older Panther Systems share the Chiller Ramp exhaust vent to exhaust hot air from the vacuum housing. This procedure describes modifications to the Chiller Ramp and installation procedures for the top vent on the vacuum housing.

1. Reconfigure the Chiller Ramp for systems Serial #s 00280 and lower.

   1. Open the Service Drawer.
   2. Remove the Chiller Ramp Module.
   3. Unclamp the cable holder attached to the underside of the Chiller Ramp duct.
   4. Remove the Chiller Ramp duct from the Service Drawer by removing the four screws.
   5. Remove the Chiller Ramp fan from the duct by twisting the fan and mounting sleeve.
   6. Remove the rubber fan mounting sleeve from the fan.
   7. Install the mounting sleeve on the new fan so that the air flow direction indicated by the arrow on the side of the fan is toward the mounting sleeve. The fan label should be on the side with the sleeve.

      

   8. Install the fan and cable camp on the new Chiller Ramp duct.

      

   9. Install the fan power cable grommet into the clip.

      

   10. Transfer the cable clamp onto the new duct.

       

   11. Reinstall the Chiller Ramp duct.

       

   12. The tab goes under the chute tab.

       

   13. Reinstall the Chiller Ramp.

2. Install the vacuum housing upper duct to share the Chiller Ramp vent with the new Chiller Ramp duct.

   1. Slide the vacuum housing into the system, then slide the Service Drawer out to allow access to the top of the housing.

      

   2. Loosen the rear screw half-way to ease duct installation.

      

   3. Install the duct onto the vacuum box.

      

   4. Install and tighten the 3 screws.

      

Verification

1. Power on the Panther System.
2. In Service Software, check to see if the vacuum is running.
1. Launch Service Software.
2. In the LiVaCo System and Drawer tab, select Vacuum Waste Drawer.

   

3. In the Pump section, select Init and then Activate.

   

4. Allow the system to run for at least 5 minutes.
5. To read the manifold vacuum level for each configuration, select Read in the Vacuum and Waste Drawer window.

   

6. Make sure to re-optimize the Panther System ported manifold since the new vacuum box is a little more restrictive.

   Since the new Vacuum Box has a slightly more restrictive internal manifold connecting the pumps together, the Panther System ported manifold may need to be re-configured to achieve the optimum vacuum level. The optimum level is between 203 and 237 mbar vacuum. Vacuum levels greater than 237 mbar will cause the PID control system to start acting to control the pumps, which may result in the beating sound. Vacuum levels less than 203 mbar are not desirable for system performance. The optimum range is shown in green in the figure below, which is displayed as negative millibars (mbar) pressure to correspond to the values that will be displayed in Service Software. The Panther System main software provides the vacuum level in units of inches of mercury (in-Hg).

   

   Start with the manifold cover port configuration with the lowest vacuum level so that the PID control system is not acting to control the vacuum level, and the pumps are forced to run at full speed. Increased airflow into the manifold through the ported manifold cover reduces the vacuum level. Therefore, the configuration that will result in the lowest vacuum level is the “both ports open” configuration (neither port plug screws installed), which should be the initial “as installed” configuration. The left port has a larger diameter air pathway than the right port. Therefore, the second configuration should be the “left port open, right port plugged” configuration followed by the “right port open, left port plugged” configuration. Finally, the “both ports plugged” configuration provides the highest vacuum level.

7. Once the vacuum level is set correctly, the installation is complete.
8. Using the Panther System Main software, perform a System PrimeOperation of pumping fluid through tubing to ensure proper and consistent fluid delivery (remove air from the tubing, etc.). to verify that the vacuum system functions properly during Magnetic Wash Station aspiration.
3. Verification is complete.