Product Documentation: Project: Cryomini Topic: Service Manual

Zimmer Medizinsysteme GmbH Tel. 0731 / 9761-0 info@zimmer.
de
Junkersstraße 9 Fax 0731 / 9761-118 www.zimmer.de
Product Documentation
Project: CryoMini
Topic: Service Manual
Revision: Rev. A
Date: 10.01.2008
Originator: Petraschka
Date:
Proofed by:
Rev. A
CryoMini Service Date:
10.01.2008
Document history
Rev. Date Change Originator
A 10.01.2008 Initial Release A. Petraschka
Table of contents
1. Safety Instructions .................................................................................................................................................................. 3
2. Returning a device.................................................................................................................................................................. 4
2.1. Packaging ........................................................................................................................................................................ 4
3. Repairing printed circuit boards ............................................................................................................................................. 5
4. Incidents .................................................................................................................................................................................. 5
5. Device Description .................................................................................................................................................................. 6
5.1. Overview.......................................................................................................................................................................... 6
5.2. Electronics ....................................................................................................................................................................... 6
5.3. Refrigeration System ...................................................................................................................................................... 7
5.3.1. Compressor ..................................................................................................................................................... 7
5.3.2. Condenser........................................................................................................................................................ 7
5.3.3. Filter Dryer ....................................................................................................................................................... 7
5.3.4. Capillary tube ................................................................................................................................................... 8
5.3.5. Evaporator........................................................................................................................................................ 8
5.3.6. Refrigerant ....................................................................................................................................................... 8
5.4. Safety Measures ............................................................................................................................................................. 8
5.5. Technical Data ................................................................................................................................................................ 9
5.6. Accessories ..................................................................................................................................................................... 9
6. Block Diagram.......................................................................................................................................................................10
7. Problem Solving....................................................................................................................................................................11
7.1. Starting Problems..........................................................................................................................................................11
7.1.1. The device does not run; the display is dark and does not respond to key presses.................................11
7.1.2. Low Cooling Power........................................................................................................................................11
7.1.3. “Condensate container full” message appears on the display....................................................................11
7.1.4. “Clean filter” message lights .........................................................................................................................11
7.1.5. Error Messages .............................................................................................................................................12
7.2. Service Report...............................................................................................................................................................13
8. Accessory List.......................................................................................................................................................................14
9. Service Mode ........................................................................................................................................................................15
9.1. Opening Service Mode .................................................................................................................................................15
9.2. Freeze-over Simulation.................................................................................................................................................16
9.3. Hour Meter.....................................................................................................................................................................16
9.4. Manual Component Control..........................................................................................................................................17
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10. Troubleshooting ..................................................................................................................................................................19

10.1. Starting Problems........................................................................................................................................................20
10.2. Problems without error message ...............................................................................................................................20
10.3. EEPROM write error ...................................................................................................................................................20
10.4. WATCHDOG error ......................................................................................................................................................21
10.5. Temperature Sensor (Evaporator).............................................................................................................................21
10.6. Refrigeration System Temperature Sensor...............................................................................................................21
10.7. Incorrect Mains Frequency <45Hz or >65Hz.............................................................................................................21
11. Assembly and Service ........................................................................................................................................................22
11.1. Device Structure and Part List....................................................................................................................................22
11.2. Overview......................................................................................................................................................................24
11.2.1. Spare Parts Handling ....................................................................................................................................24
11.2.2. Required Equipment......................................................................................................................................24
11.2.3. Safety Notice..................................................................................................................................................24
11.3. Removing and Attaching the Therapy Tube..............................................................................................................25
11.4. Opening the Housing ..................................................................................................................................................25
11.5. Closing the Housing....................................................................................................................................................26
11.6. Test Run ......................................................................................................................................................................26
12. Repairs and Component Replacement .............................................................................................................................27
12.1. Electronics ...................................................................................................................................................................27
12.1.1. Mains Supply Side.........................................................................................................................................27
12.1.2. Low-voltage Side ...........................................................................................................................................27
12.1.3. Board..............................................................................................................................................................28
12.1.4. Board Replacement.......................................................................................................................................28
12.2. Replacement of Mains Filter Input Socket, Main Switch ..........................................................................................29
12.3. Replacement of LCD and Keyboard ..........................................................................................................................29
13. Refrigeration System Components....................................................................................................................................30
13.1. Refrigeration System ..................................................................................................................................................30
13.2. Evaporator Sensor Replacement...............................................................................................................................30
13.3. Replacement of Temperature Sensor cooling circuit................................................................................................30
13.4. Replacement of Therapy Fan.....................................................................................................................................30
14. Pin Assignments and Component Names ........................................................................................................................31
14.1. Board mains input connection ....................................................................................................................................31
14.2. Power Side Connections ............................................................................................................................................32
14.3. Evaporator temperature sensor connection ..............................................................................................................32
14.4. Refrigeration system temperature sensor connection ..............................................................................................32
14.5. Keyboard connection ..................................................................................................................................................32
14.6. Display control signals connection.............................................................................................................................32
14.7. Display power supply connection...............................................................................................................................33
14.8. Level sensor connection.............................................................................................................................................33
14.9. Board external control in/out connection ...................................................................................................................33
14.10. Firmware update connection ....................................................................................................................................33
15. Test Protocol .......................................................................................................................................................................34
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1. Safety Instructions
Zimmer Medizinsysteme GmbH as the manufacturer of electromedical devices can only accept liability for the safety and
reliability of the device under the following conditions:
• the electrical installation conforms to the requirements specified for operation of the device
• the device is operated as specified by the operating manual
• extensions, new settings or changes are only carried out by persons authorized by Zimmer Medizinsysteme.
Zimmer Medizinsysteme reserves the right to makes changes to delivery options and technical features. Contract service
partners are responsible for all repairs that they conduct.
Screws that must be removed to open the housing are protected by a special warranty seal. Only authorized persons are
permitted to remove them. If the seal is missing or has been manipulated, the device will no longer be under warranty.
The information in the service documentation is the property of the manufacturer and intended for internal use by our
technicians only. Publication of this information or distribution to unauthorized persons is prohibited. If the service
contract is canceled, the technician(s) is/are required to return the service documentation to Zimmer Medizinsysteme
GmbH.
Warning!
Unauthorized modifications or repairs to the device may cause it to malfunction and cause serious injuries.
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2. Returning a device
2.1. Packaging
Every unit that is sent to the manufacturer for service must be packed in the original packaging to prevent any
damage during shipping. Always include a detailed description of any faults. Please use the service report included
with the documentation (Chap. 7.2 )
Defrost the device and drain the condensate container before packaging it
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3. Repairing printed circuit boards

Faulty boards must be repaired by the manufacturer only. After replacing a module, the faulty part must be labeled with
the serial number of the device and returned to the manufacturer with the service report (1.4.6.).
4. Incidents
Zimmer Medizinsysteme is required to record malfunctions and incidents of any type. Please report all unusual incidents
(e.g. electric shock, freezing etc. ). Please use the service report included with the documentation (Chap. 7.2 ) Your
reports will contribute to improving the quality and reliability of our products.
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5. Device Description
5.1. Overview
The CryoMini is a refrigerated air therapy device that pulls in room air and cools it to therapeutically effective
temperature ranges down to -20 °C. The device is mounted on rollers for ease of use in various locations.
The device has a metal housing and a plastic top attached to an aluminum frame. The power supply connection,
main switch with fuse and air filter are on the back of the device. The condensate container is on the left side of the
device.
A therapy fan, which can be set to any of nine speeds, directs room air through a coarse dust filter into the
evaporator, where it is refrigerated and directed to the patient through an insulated application tube. The air pulled
into the therapy fan is not used to cool the device.
The device is operated by a capacitive keyboard behind a glass plate and a LCD display. All device functions and the
regulation and monitoring of the cold circuit are controlled by a microprocessor.
The device should be left for half an hour after transport and repairs to allow the oil to accumulate in the bottom of
the compressor.
5.2. Electronics
The electronic hardware of the CryoMini is on one printed-circuit board mounted under the device top.
The controller and power unit with the device power supply are combined on one board.
The device and the treatment regime are monitored and controlled by the microprocessor with appropriate
peripherals. Functions include a self-test on start-up, monitoring of limit values of critical components, including
temperatures, control of function status and monitoring of supply voltages.
The analog hardware consists of a mains power and output unit, motor controller, display and input components and
temperature sensors.
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5.3. Refrigeration System

The CryoMini refrigerated air device draws in air at room temperature, refrigerates it, blows out the refrigerated
therapeutic air. The room-temperature air is cooled by a single-stage, refrigerated cooling circuit .The heat from the
refrigeration process is released to the room air. The device is capable of producing a temperature of –20°C very
quickly and maintaining this continuously, resulting in a released air temperature of no more than approximately –
5°C. The refrigeration system contains the following components (for the layout in the device see Figure 8 ):
Figure 1
5.3.1. Compressor
The compressor (hermetically sealed in a steel housing) extracts overheated refrigerant vapor from the
evaporator. An additional compression step increases the pressure of the refrigerant vapor (to approx. 15 bar)
and the temperature (to approx. 60 °C). The compressor is fitted with a special start-up device to ensure that it
starts even at a high pressure difference.
5.3.2. Condenser
The heated refrigerant is cooled in the condenser at a steady pressure (to approx. 20 °C) to liquefy it. This
process is assisted by a radial fan located below the condenser. It draws in the room air behind the dust filter
through the condenser (compression heat is absorbed) and expels it to the outside.
5.3.3. Filter Dryer
The filter dryer collects residual humidity, solder residue and dirt to prevent blockage of the cooling circuit.
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5.3.4. Capillary tube

A pressure and temperature decrease occurs (from approx. 15 bar / 20°C to approx. 2,0 bar / -31°C) at the
Capillary tube. The liquid refrigerant, which can completely evaporate during the heating process, is injected
into the evaporator.
5.3.5. Evaporator
Heat is extracted from the evaporator and thus the therapy air by evaporation of the refrigerant. The room air
drawn into the therapy fan is available as refrigerated therapy air at the outlet of the application tube. A defrost
drain is installed at the bottom of the evaporator housing to drain defrosted water. The defrosted water flows
through a tube to a container on the left side of the device.
5.3.6. Refrigerant
The refrigerant R507 consists of an azeotropic mixture with an ozone destruction potential of “0”. R507 is non-
flammable and non-toxic. There is danger of suffocation if the volume in the air exceeds approximately 12%.
There is 300g of R507 in CryoMini.
5.4. Safety Measures

The CryoMini refrigerated air device has numerous hardware and software safety features for the safety of patients
and users.
The main switch also includes an automatic circuit-breaker that switches off the device in case of malfunction.
Dangers that may arise from undefined control conditions or functional errors in the device are prevented by various
safety circuits.
The compressor is protected by an integrated overload protection in the compressor.
If the device malfunctions, the software initiates a controlled shutdown of the device by setting all modules to a safe
status and indicating the fault with a warning sound. The reason for this action is shown on the display by an error
message.
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The device runs a self-test when switched on to check all important components. The 5V operating voltage is also
checked. If a fault occurs, a fault display will be shown. The device can only be switched off in this case.
If the processor operating voltage is not 5 V, it will remain on reset continuously. The device cannot be reactivated.
The processor functions are monitored by a watchdog device. It monitors the program operation and initiates a
processor reset in the event of malfunction (such as an endless loop).
5.5. Technical Data

Operating voltage: 220-240V, 50Hz/60Hz
100-120V, 50/60Hz
Power consumption ~1 kW max.
in stand-by mode: approx. 100 W
Mains fuses: 16A, slow-blow power system switch
Noise emission (max.): 70 dB(A)
Protection class: IEC 601-1, Class 1, Type B
MedGV (medical devices act): Group 3
MDD/MPG: Class IIa
Treatment tube length: 180 cm
Ambient temperature in operation: +10 °C to +35 °C
Housing dimensions: H650mm x W335mm x L600mm
Weight: 35,5kg
Packaging: the device should only be shipped in the original packaging
5.6. Accessories
Only original accessories from Zimmer Medizinsysteme should be used. If accessories are combined, note the
approved combinations and the relevant legal regulations. If third-party accessories are used, this will result in a new
medical system and the user will be solely responsible for the correct combination or modification.
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6. Block Diagram
Main switch
(S1) PCB
Main fuse RS 232
Buzzer (H1)
(F1)
J8 Trafo1+2
J4 Keyboard
Line filter
(Z1)
Relay J5/
Display
J6
J1 µC
User Interface
Relay
Condensor fan
(M2) J1
J1
J1
Therapy fan
(M3) Optocoupler
Compressor J9 J2 J3 J12 J6 J10

(M1)
Temperature
cooling circuit (P3) Water tank
Cooling circuit control switch
(P4)
Temperature
Vaporizer Vaporizer
(P2)
Figure 2 (Blockdiagramm 115V/230V device)
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7. Problem Solving
7.1. Starting Problems
7.1.1. The device does not run; the display is dark and does not respond to key presses.
Ø Plug in power cable.
Ø The main switch is also an automatic circuit-breaker that may switch off the device immediately at low
mains voltages. If the device does not start up after several attempts, contact a qualified service technician
(a separate power supply for the CryoMini may be necessary).
Ø The device display is operating and precooling menu is displayed but the compressor does not start.
Please contact our customer service.
7.1.2. Low Cooling Power

Ø Start a defrosting process.
Ø Check the location of the device. It must not be too close to heat sources (radiator, sauna, etc.).
Ø Minimum distance from walls: 0.5 m
Ø Increased humidity and room temperatures over 30 °C may affect the refrigeration output.
Ø Devices with strong electromagnetic fields (x-ray and diathermal devices) may influence the function of the
CryoMini.
Ø The air output is too weak. Detach the therapy tube from the device and check it for blockage by blowing
through it.
Ø Empty the condensate container and run a defrosting process. If no water is found in the condensate
container the drainage tube is blocked. Attach the therapy hose and repeat therapy mode several times in
succession. The pressure build-up in the evaporator may clear the drainage tube, otherwise remove the
drainage tube.
Ø If the above measures are not successful, please contact customer service.
7.1.3. “Condensate container full” message appears on the display

A new therapy cannot be started. Follow the directions on the display and drain the condensate container,
which is on the left side of the device. When reinstalling the condensate container in the device make sure that
the container is pushed in completely and locked in position.
7.1.4. “Clean filter” message lights

Clean the air filter (metal filter) from the outside. Larger dirt particles can be easily removed by surface
vacuuming. The filter display will indicate that cleaning is required every 150 hours. After cleaning the filter the
signal can be reset by pressing the OK button.
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7.1.5. Error Messages

Important hardware components are tested while the device is starting up and at times while the device is
operating. If an error is detected, the treatment session will be stopped, all inputs and outputs prevented and an
error message will be displayed in the top line of the display. An acoustic warning will also be sounded and
repeated every three seconds.
Ø Many errors can be resolved by shutting off the device, waiting 5 seconds and re-starting the device. These
errors are referred to as fleeting errors, which do not influence continued operation of the device. If the
same error occurs repeatedly, please prepare a detailed description of the error. Inform the customer
service or use the attached service report. Give it to a field representative or send it directly to the factory.
Ø If error messages indicating excessive temperature or pressure occur, the device should not be switched
on again for 30 minutes because this is an excess temperature or pressure situation. The CryoMini requires
time to cool down. This may be caused by high outside and room temperatures that affect the refrigeration
capacity. If the error occurs again in a short time, please contact customer service.
Possible error messages:

Ø UNKNOWN ERROR: Error is not explicitly defined in the system
Ø EEPROM data lost: The data stored in the EEPROM has been lost
because of external influences (e.g. EMC interference).
This means that the software must be reinstalled
Ø EEPROM fault: The processor system cannot access the EEPROM
Ø Overpressure in refrigeration system: An error in the refrigeration system has caused an
overpressure that has caused a safety shutdown. The
cause for this may be a non-functional condenser fan,
a blockage in the refrigeration system or high ambient
temperature
Ø Temp. sensor board fault The temperature sensor on the board does not supply
data to the processor system
Ø Temp. sensor evaporator fault: The temperature sensor mounted on the evaporator is
not sending data to the processor system
Ø Temp. sensor in refrigeration system fault: The temperature sensor mounted on the refrigeration
system is not sending data to the processor system
Ø Low board temperature: The temperature on the board has fallen below –10 °C
Ø High board temperature The temperature on the board has risen above 60 °C
Ø High evaporator temperature The temperature in the evaporator has fallen below
–52 °C
Ø High evaporator temperature The temperature in the evaporator housing has risen
above 60 °C
Ø Low refrigeration system temperature The temperature at the refrigeration system has fallen
below –10 °C
Ø High refrigeration system temperature The temperature at the refrigeration system has risen
above 80 °C
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7.2. Service Report

Serial no.: ...........................................
Software Version ...........................................
Date/signature ...........................................
Name ...........................................
Customer Information
Customer: .............................................................. Date: ............................
Description of fault:
................................................................................................................................................................................................
................................................................................................................................................................................................
................................................................................................................................................................................................
................................................................................................................................................................................................
Occurrence of fault: once several times frequent always with

............................................................................................................
Under the following conditions: after switching on with a warm device

during treatment (after ………….. minutes)
Other:
....................................................................................................................................………….............................................
Special environmental conditions:
Humidity:............... Temperature:............... Power connection:........…………………………..................................................

State of air filter:....................................................................................…………………….....................................................
Other:.............................................................................................................................................................….....................
Prior repairs and installed spare parts (name, serial number):
................................................................................................................................................................................................
................................................................................................................................................................................................
Other notes:..........................................................................................................……………..............................…..............
.............................................................................................................................................…...............................................
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8. Accessory List
If accessories are combined, note the approved combinations and the relevant legal regulations. If third-party
accessories are used, this will result in a new medical system and the user will be solely responsible for the correct
combination or modification.
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9. Service Mode
9.1. Opening Service Mode
Various service programs have been implemented for the test field and subsequent testing of the device. This
program level can only be opened by entering a 4-digit password. The password (secured by Zimmer) can be input
after selecting the “Service” button (Figure 3), and the input is confirmed by pressing OK. Then the program switches
to the service level (Figure 4), in which the functions of individual components can be tested. Navigation in the
service menu is similar to operation in standard operation and is not described in detail here.
Please enter password:
[............]
OK Start/ Stop
1 2 3 4
Figure 3
Freeze-over simulaton
Freeze-over simulation
Cryo devie type
Cryo device type
Componet Rutime
Component RuntimeCoute
Counter
Manual component control
Manual component control
Automatic
Automatic Service
Service Program S01
Program S01
Automatic Service Program S02
OK Automatic Sevie Program S02 Start/ Stop
Back Select
Figure 4
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9.2. Freeze-over Simulation

Freeze-over simulation at condenser ?
Freeze-over simulation at condenser?
OK Start/ Stop
Yes No
Figure 5
In standard operation an hour meter monitors how long the device operates continuously without being switched off.
After more than 24 hours an information message is shown on the display to prompt the user to run a defrost cycle.
This function can be enabled and tested by selecting “Freeze-over Simulation” in the menu. When “Freeze-over
Simulation” is enabled and the user returns to the standard therapy level the warning message to defrost must
appear on the display.
The “Freeze-over Simulation” is disabled when the device is switched off.
9.3. Hour Meter

As in the service level the hour meters for the various components are shown. The meters for the individual
components can also be reset to 0 in the service level, for example, if a component is replaced.
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9.4. Manual Component Control

In this program menu every component can be actuated and controlled individually. The status of the control inputs
(temperature values, etc.) is also displayed and can be monitored.
Kom 60°C VER -15°C KRE 30°C PCB 22°C
KOM = 0 CLR = 16 TLR = 2 HZG = 0
P=0 ExO = 0 ExI = 0 ExS = 0
OK Start/ Stop
Compressor Cond.-Fan Th.-fan Heating
Figure 6
- The component (compressor, condenser fan, therapy fan) is started or stopped by pressing the relevant
button.
- The speed of the condenser fan can be increased by pressing and holding the OK button and pressing the
condenser fan button once at the same time. Every time the condenser fan button is pressed the speed is
increased one step.
- The speed of the fan can be reduced by pressing and holding the Start/Stop button and pressing the
condenser fan button once at the same time. Every time the condenser fan button is pressed the speed is
reduced one step.
- The speed of the fan can be increased by pressing and holding the OK button and pressing the therapy fan
button once at the same time. Every time the therapy fan button is pressed the speed is increased one step.
- The speed of the fan can be reduced by pressing and holding the Start/Stop button and pressing the
therapy fan button once at the same time. Every time the therapy fan button is pressed the speed is
reduced one step.
- This menu can only be closed by pressing the OK and the Start/Stop buttons simultaneously.
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Legend for Figure 6:

Display Meaning Values Solutions
If the temperature does not reach the
specified set temperature even after
Display of temperature in Tmin = -52 °C
VER –5 °C defrosting and extended cooling time
evaporator Tmax= 60 °C
(> 30 min.), there is a fault in the refrigeration
system or its actuation relay on the board.
Display of temperature of
refrigeration system; in standard
mode the speed of the condenser
Tmin = -10 °C
KRE 30 °C fan is regulated depending on this -
Tmax= 100 °C
temperature. The higher the
temperature the faster the
condenser fan
Display of board temperature; it is
measured near the power parts of
If the temperature exceeds the upper limit
the board (load relay, Tmin = -10 °C
PCB 22 °C value the air filter is dirty or the ventilation
transformers, etc.) and represents Tmax= 60 °C
duct under the device cover is blocked.
the maximum temperature on the
board.
0 = compressor off If the compressor does not start, check
Status of compressor
KOM = 0 1 = compressor electrical connections and start-up current
running limitation.
If the fan does not start, check the electrical
The fan speed can be connections.
CLR = 0 Status of condenser fan manually controlled in If the fan runs continuously at max. speed,
0 – 23 steps. the frequency detection on the board may be
faulty.
The speed is shown in If the fan does not start, check the electrical
TLR = 2 Status of therapy fan
steps of 1 from 1 – 9; connections to the fan and the fuse F4
0 = water tank empty If the value set is permanently set to “1”,
Status of water level control
P=0 1 = water tank full check the water tank level, the wiring and the
switch
/switch dripped) connection on the PCB. It is a N.C signal
ExO = 0 Not in use
ExI = 0 Not in use
ExS = 0 Not in use
If an incorrect frequency is shown, check that
f = 50Hz the power supply frequency is stable. If it is,
f = 50Hz Detection of main frequency
f = 60Hz the frequency detection on the board may be
faulty.
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10. Troubleshooting
If you are here, you have not been able to resolve your problem with the information in chapter 1.4. Problem Solving. It is
not a user error but probably an equipment error (defective hardware or a defective part in the refrigeration system).
Important hardware components are tested while the device is starting up and at times while the device is operating. If
an error is detected during this process, active therapy is stopped, all inputs and outputs are disabled and an error
message is output. An acoustic warning will also be sounded and repeated every three seconds. These error measures
protect the patient by bringing the device into a safe status with all components switched off.
The error messages are shown in plain text on the top line of the display (status line). Therapy is no longer possible; the
device can only be switched off.
Overpressure Cooling
Overpressure circuit
Colig circuit
P2 7 10:00
OK Start/ Stop
Figure 7
Many errors can be resolved by shutting off the device, waiting 5 seconds and re-starting the device. These errors are
referred to as fleeting errors, which do not influence continued operation of the device.
If an overtemperature error of a component or an overpressure error in the refrigeration system is indicated, the device
should not be switched on again for at least 30 minutes because the temperature or pressure has been exceeded. The
CryoMini requires time to cool down. This may be caused by high outside and room temperatures that affect the
refrigeration capacity.
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10.1. Starting Problems

The device does not switch out of the “Precooling” menu and the status bar that displays the cooling process remains
static without changing its value.
I. Compressor test: switch to manual component control in the service level and switch on the compressor as
described in 9.3.
Ø The compressor does not start: compressor is faulty or load relay or actuator on the board is faulty.
Replace load relay or board.
II. Refrigeration test

1. Run device for half an hour
2. Switch to manual component control (9.3) and start therapy fan and run at maximum speed.
Ø If cold air comes out, a faulty evaporator sensor is the cause of the long flashing; it must be replaced
Ø If uncooled room air comes out, the refrigeration system is faulty.
III. Refrigeration test

1. The function of the evaporator sensor can be tested in the manual component control (9.3). Switch the
condenser fan to setting 10 and then switch on the compressor. The temperature gauge must now count
down to approx. –20 °C. If the temperature gauge remains still, jumps back and forth or does not count
down, replace the evaporator sensor.
2. If the temperature gauge only moves between values of approx. +5 °C and 0 °C, the refrigeration system is
faulty. It may be blocked or refrigerant may have been lost. In this case the fault must be located by a
refrigeration technician and repaired.
10.2. Problems without error message

I. No air is blown out or the air stream is too weak:
Ø Disconnect the therapy tube from the device and blow through it to check for blockage, holes or
compression points.
Ø Check therapy fan function in manual component control (see 9.3 )
Ø Empty the condensate container and run a defrosting process. If no water is found in the condensate
container the drainage tube may be blocked.
Ø Attach the therapy hose and repeat therapy mode several times in succession. The increased pressure in
the evaporator may clear the drainage tube.
II. If there is oil leaking under the Cryo the fault is in the refrigeration system (compressor fault, leakage in
refrigeration system, etc. ). Call a refrigeration mechanic or contact Zimmer Medizinsysteme.
10.3. EEPROM write error

It is not possible to write at least one cell of the EEPROM correctly. Device-specific parameters such as pitch,
volume, language, etc. are stored in the EEPROM.
Remedy:
Ø Reflash program
Ø Replace CPU board
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10.4. WATCHDOG error
This error indicates that the monitoring system for program crashes integrated in the microprocessor has been
activated. If this error occurs sporadically, this indicates external sources of interference. If it always occurs at the
same place, this generally indicates a program error.
Remedy:
Ø Replace program (EPROM) (2.3.2)
Ø Replace CPU board (2.3.4.)
10.5. Temperature Sensor (Evaporator)

The sensor shows temperature values outside the range of -50 °C and +55 °C. The cause of this may be a faulty
sensor, cable or CPU board.
Remedy:
Ø Check the sensor cable and the terminals for defects (cracks, oxidation, contact problems)
Ø Replace sensor
10.6. Refrigeration System Temperature Sensor

The sensor shows temperature values outside the range of -20 °C and +110 °C. The cause of this may be a faulty
sensor cable or CPU board.
Remedy:
Ø Check the sensor cable and the terminals for defects (cracks, oxidation, contact problems)
Ø Replace sensor
10.7. Incorrect Mains Frequency <45Hz or >65Hz

This fault occurs if the mains frequency is out of range (45 Hz … 65 Hz) or if the mains supply is not sinusoidal for
more than three half-waves.
Remedy:
Ø Check mains supply
Ø Check power supply
21
Rev. A
10.01.2008
11. Assembly and Service

11.1. Device Structure and Part List
38
24
21
3 8
32
6
13
4
35
36
16
10
1
37
14
15
23
9
18
19
5 22
12
2
31
Figure 8 20
17
11
30
22
Rev. A
10.01.2008
Spare Part List:
Note:
The last digit at the part number can vary as it indicates the latest revision of the desired part. Zimmer
will always send the latest compatible revision to your attention. Therefore always add the device serial
number to your order!
Link Part number Part name

1 34011420 Main Switch
2 34045300 Water level control switch
3 35230373 Main filter
4 37115601 Therapy Fan
5 37115609 Assembly kit Condensor fan
6 37115610 Compressor 115V
7 38853262 Air filter
8 46000480 LCD Display
9 63490110 Frame CryoMini
10 63490210 Mounting plate condensor fan
11 63490410 Housing water tank
12 63490510 Housing vaporizer CryoMini
13 63490710 Vaporizer holder CryoMini
14 63490910 Bottom plate CryoMini
15 63491010 Rear plate housing
16 63491130 Housing
17 63491410 Door water tank
18 63491510 Vaporizer CryoMini
19 63491610 Condensor CryoMini
20 65372417 Air Inlet Vaporizer
21 65490110 Top cover
22 65850410 Wheel protection cover
23 65851810 Air Outlet Vaporizer
24 66490110 Glas plate including display
25 68490110 Cable harness 115V
26 68490210 Cable harness Power Inlet – Main Filter
27 68490310 Ground wire CryoMini
28 68851010 Keyboard cable
29 68851510 Ground wire air filter earth
30 80026510 Water tank
31 80400751 Wheel
32 92490111 PCB 115V CryoMini
33 98850210 Temperature sensor cooling circuit
34 98850613 Temperature sensor vaporizer
Cooling circuit including Pipe1 (63491710), Pipe2
(63491810), Pipe 3 (63491910), Pipe4 (63492010) and
35 - capillarity pipe (63492110)
36 95371710 Noise isolation therapy fan
37 35647890 Power inlet
38 63853510 threaded pins
23
Rev. A
10.01.2008
11.2. Overview
11.2.1. Spare Parts Handling

Electronic spare parts, such as boards, must be handled in accordance with the general ESD guidelines
(electrostatic discharge)
The electrical parameters of new modules (e.g. CPU, etc.) supplied by Zimmer Medizinsysteme have been
preset at the factory.
All boards must be inspected before installation (shipping damage, etc.).
11.2.2. Required Equipment

Ø A workplace with antistatic protection
Ø A digital multimeter
Ø A oscilloscope – 20 MHz (digital or analog)
Ø NSP3000 safety tester
11.2.3. Safety Notice
Do not touch modules or parts in the device when working on an open device with the power cable plugged in.
Electrical cables and wires may have a voltage up to 240 V. Unplug power cable before opening and closing the
device.
Some parts of the refrigeration system may become very hot during operation (e.g. compressor, condenser)
and other parts may become very cold (e.g. evaporator, thermal expansion valve) Temperatures may vary
from –45 °C to +90 °C.
Caution! - Do not touch parts!
24
Rev. A
10.01.2008
11.3. Removing and Attaching the Therapy Tube

Removal:
Ø The tube connection is held by a bayonet catch.
è To release the tube push the connection back and turn it slightly counterclockwise.
è Then pull the tube forward.
Attachment:
Ø The tube connection it is held by a bayonet catch.
è To attach the tube place the connection on the air outlet and rotate until the connection can be
pushed on to the air outlet.
è Push the connection up as far as possible and then rotate slightly clockwise and pull down slightly.
11.4. Opening the Housing
! Caution with prior operation: parts of the refrigeration system may still be very hot !
1. Unplug power cable from power source.

2. Remove the tube (see 11.3 )
3. Unscrew the glass unit and unplug the cables from the PCB (Glas plate including display number 24 in Figure
8). Be careful the glass unit is linked to the PCB by 3 cables
4. Unscrew the threaded pins from the frame.
5. Unscrew the rear plate housing (15), be careful the plate is linked with a cable to the line filter (you must not
remove this cable)
6. Remove the air filter (7)
7. Unscrew the 4 wrench screws located at rear bottom of the top cover (21)
8. Unscrew the 4 screws located in the glass unit area
9. Now the cover can be placed aside.
10. Remove the 4 wheel protection covers (22)
11. Removing the metal housing (16)
Ø Unscrew the 6 screws [M4] on the back of the enclosure.
Ø Unscrew the 2 screws [M4] on the left and right side of the enclosure.
Ø Lift the enclosure above the 4 wheel covers and spread it at the back and push it forward.
25
Rev. A
10.01.2008
11.5. Closing the Housing

Before closing the housing always check the following:
Ø Correct fuses are installed
Ø The board and all other components are fastened in place
Ø All connectors are fixed
Ø No loose parts (such as screws) in the housing
Ø All foam parts installed
1. Installing metal housing:

Ø Slide the metal housing from the front over the base frame until it encloses the device
Ø On the left and right side screw the 2 screws [M4] into the device
Ø Screw the 6 screws [M4] into the device at the back
Ø Screw the back panel to the device with the 4 screws
Ø Install the dust filter and plug in the protective conductor to the terminal block
2. Cover installation:
a. Slide the cover over the top of the frame
b. Fix the cover with the 4screws (where later on the glass unit is mounted)
c. Screw the 4 wrench screws located at rear bottom of the top cover (21)
3. Plug the cables of the glass unit into the PCB (Glas plate including display number 24 in Figure 8) and screw
the glass unit onto the cover. Check that no cables are clamped.
4. Screw the threaded pins into the frame.
11.6. Test Run

The following is required after every CryoMini repair (module replacement):
Ø The device must be visually inspected (loose parts, protective conductor, defrosted water container, solder
points clean and solid, etc.)
Ø Device must remain standing for 30 minutes to allow the oil to collect in the compressor
Ø A technical safety check must be conducted (see 15, Electrical safety)
Ø Device must pass the S01 test program (see instructions for use) If no error messages are triggered the device
can be placed back in operation
1st cooling phase < 30 min O OK
2nd cooling phase < 30 min O OK
3rd cooling phase < 30 min O OK
0 min < defrost < 60 min O OK
26
Rev. A
10.01.2008
12. Repairs and Component Replacement

12.1. Electronics
The controller board and motherboard components are combined on one single board.
All plug connectors are sequentially numbered with J(y); there is only one sequential numbering system for the entire
device for unique identification of every connector.
12.1.1. Mains Supply Side

The mains supply side on the device starts at the mains socket. It is designed as a high-current type of a non-
heating device socket to allow different mains cable to be supplied for different countries.
The main switch is designed for mains voltages of 115 V and 230 VAC. A 15 A mains fuse is integrated in the
main switch to monitor both mains cables and it provides a 2-way shutdown.
The mains voltage is distributed to the individual components on the board and is monitored by fuses where
necessary.
The compressor is switched on and off by the µC via an ELR load relay. Further switch-on control uses a
switch-on electrical system that is supplied by the compressor manufacturer (230V model) or integrated into the
compressor (115 V model).
The condenser fan is also controlled by the µC. This is a phase section controller, which also controls the fan
by an ELR. It controls the speed of the fan depending on the temperature of the refrigeration system.
The therapy fan is also controlled by the µC. This is a phase section controller, which also controls the fan by
an ELR. It controls the speed of the fan depending on speed level insert in the menu by the user.
The low voltage for the board is supplied by two transformers. The second transformer is supplied the technical
safety reasons. The voltage generated by this transformer is used for the control voltage of the therapy fan and
the switching voltage of the pressure sensor. It is electrically isolated from the low voltage of transformer 1,
which supplies the voltage for the rest of the board and low-voltage components.
All ELR, transformers and optocouplers that connect to low voltage and mains voltage are tested with an
electrical isolation of 4 kV and are defined as UL-listed components. When these components are replaced it is
very important to replace them with the same types; no other types are approved.
12.1.2. Low-voltage Side

The low-voltage side of the device includes the processor section of the board with various signal inputs and
outputs. The signal inputs are two temperature sensors, the dripper tray level monitor and the keyboard input
along with an input for a sensor in the handpiece of the tube (not in use).
The signal outputs are the display control and 2 phase controlled modulation signals running the therapy fan
and condenser fan.
27
Rev. A
10.01.2008
12.1.3. Board
The controller and power circuit of the device are combined on one board. The controller, RAM, EPROMs,
ADUs, DAUs, multiplexer, graphics controller and corresponding logic blocks are the digital components of the
CryoMini. The device and the treatment regime are monitored and controlled by the microprocessor with
appropriate peripherals. Functions include a self-test on start-up, monitoring of limit values of critical
components, including temperatures, control of function status and monitoring of supply voltages.
The analog hardware consists of a mains power and output unit, motor controller, display and input components
and temperature sensors.
12.1.4. Board Replacement

Removal:
Ø To replace the board first release and remove the cover (see 11.4).
Ø Then disconnect all remaining plug connectors from the board and unscrew the board.
Installation:
Ø Before installing the board check to make sure you have the board with the correct mains voltage
range. The adjustment must be made manually by the soldering jumper beside fuse F5
(see Figure 9).
- Jumpers BR2 and BR3 and jumpers BR5 and BR6 must be set for a board with the voltage
range 90 – 120V.
- Jumpers BR1 and BR4 must be set for a board with the voltage range 210 – 250 V.
- Input J10 must always be jumpered
F5
Figure 9 Soldering jumper

Ø Screw the board onto the frame
Ø Connect all cables to the board
Ø Mount the cover and glass unit (see 11.5).
Ø Run function test.
28
Rev. A
10.01.2008
12.2. Replacement of Mains Filter Input Socket, Main Switch

Removal:
Ø To replace these components first release and remove the cover (see 11.4).
Ø Then the specific component can be released and the replacement part installed.
Installation:
Ø After replacement of the component all cables in the device must be connected.
Ø Connect all cables from the device.
Ø Mount the cover and glass unit (see 11.5).
12.3. Replacement of LCD and Keyboard

Removal:
Ø Unscrew the glass unit and unplug the cables from the PCB (Glass plate including display number 24
in Figure 8). Be careful the glass unit is linked to the PCB by 3 cables
Installation:
Ø Check if the 4 Screws the cover is fixed to the frame are locked
Ø Connect the cables to the PCB board
Ø Fix the glass unit to the cover
29
Rev. A
10.01.2008
13. Refrigeration System Components

13.1. Refrigeration System
The refrigeration system is a reliable complex system. Only refrigeration technicians may perform repairs on the
refrigeration system. If faults are detected in the refrigeration system please contact customer service or use the
enclosed service report (see 7.2). Send it directly to the factory.
13.2. Evaporator Sensor Replacement
Ø If the device was recently in operation, run a defrost first (see user instructions).
Ø Remove the cover (see 11.4) and place it to one side. It is not necessary to remove the panels.
Ø Pull the evaporator sensor carefully by the cable out of the evaporator.
Ø Push a new evaporator sensor into the opening.
Ø Seal the evaporator with some silicone.
Ø In the service menu switch to manual component control and check the sensor temperature display.
Ø Now run complete function test.
Ø Mount cover (see 11.5).
Ø Run function test again.
13.3. Replacement of Temperature Sensor cooling circuit

Ø Remove the cover and panel (see chapter 11.4) and place it to one side.
Ø Pull the cable out of the tubing
Ø Fasten the sensor into the tubing by attaching a new Armaflex adhesive band.
Ø Run the cable into the device and attach it to the places provided with the cable clips and connect it to
the PCB.
Ø In the service menu switch to manual component control and check the sensor temperature display.
Ø Mount cover (see chapter 11.5).
Ø Function test again.
13.4. Replacement of Therapy Fan

Ø Remove the cover and panel (see chapter 11.4) and place it to one side.
Ø Remove the PCB baord
Ø Pull the plug connector off the therapy fan. Reach under the therapy fan and pull the connector off.
Ø Unscrew the fan from the vaporizer holder (13)
Ø Insert new fan and screw it onto the vaporizer holder
Ø Connect plug connectors
Ø Place the PCB onto the vaporizer holder and connect all cables
Ø Mount panel and cover (see 11.5).
30
Rev. A
10.01.2008
14. Pin Assignments and Component Names

Name Note Name Note
F1 CryoMini main fuse K1 Compressor start-up current limitation
Board mains voltage outputs for all AC M1 Compressor
J1
devices M2 Condenser fan
J3 Board evaporator temperature sensor M3 Therapy fan
J4 Board keyboard terminal P1 Compressor temperature sensor
J5 Board display signal terminal P2 Evaporator temperature sensor
J6 Level sensor terminal P3 Condenser fan temperature sensor
J7 Board external control in/out
P4 Water level sensor
J8 Board mains voltage input
J9 Board therapy fan control signal S1 Main switch
J10 Board pressure sensor
Z1 Mains filter
Board condenser fan temperature
J12
sensor
J13 Board RS232 port for firmware update
J14 Board display power supply terminal

J18 Board K1 board side
J19 K1 compressor side terminal
J20 Compressor terminal
J23 Condenser fan terminal
J24 Therapy fan terminal
Plug connector terminal on glass
J25
keyboard
External In/Out interlock terminal on
J26
device
J27 Level sensor terminal
J28 Pressure monitor terminal
14.1. Board mains input connection

J8 Mains filter Signal
1 Load N Zero
2 Load P Phase
31
Rev. A
10.01.2008
14.2. Power Side Connections

J1 Plug/pin Component Signal Note
1 J18/2 Compressor K1 start-up electrics Zero for 230V device
2 J18/1 Compressor K1 start-up electrics Phase for 230V device
3 J23/2 Condenser fan M2 Zero
4 J23/1 Condenser fan M2 Phase
5 J24/4 Therapy fan M3 Zero
6 J24/5 Therapy fan M3 Phase

7 Spare
8 Spare
14.3. Evaporator temperature sensor connection

J3 Signal
1 GND
2 Signal
3 5V
4 Spare (for I²C)
14.4. Refrigeration system temperature sensor connection

J12 Signal
1 GND
2 Signal
3 5V
4 Spare (for I²C)
14.5. Keyboard connection
J4 J25 Signal
1 1 GND
2 2 5VDC
3 3 Key 0
4 4 Key 1
5 5 Key 2
6 6 Key 3
7 7 Key 4
8 8 Key 5
9 9 spare
10 10 spare
14.6. Display control signals connection

J5 Signal
1 Reset (/RES)
2 Master (/CSA)
3 Slave (/CSB)
4 Data or command selection (A0)
5 Serial data (SCL)
6 Serial clock (SI)
7 Power supply (3V)
32
Rev. A
10.01.2008
8 GND
9 DC/DC converter
10 DC/DC converter
11 DC/DC converter
12 DC/DC converter
13 DC/DC converter
14 DC/DC converter
15 Crystal power supply (3V)
20 N.C.
21 Selection for voltage setting
22 N.C.
14.7. Display power supply connection

J14 Signal
1 VCC
2 GND
14.8. Level sensor connection

J6 Signal
1 GND
2 GND
14.9. Board external control in/out connection
J7 J26 Signal
Interlock In (+),
1 1
5-20V >10mA
2 2 Interlock In (-)
3 3 Interlock Out
4 4 Interlock Out
14.10. Firmware update connection

J13 Signal
1 5V
2 MD2
3 RX
4 TX
5 N.C.
6 Reset
7 MD0
8 GND
9 N.C.
10 N.C.
33
Rev. A
10.01.2008
15. Test Protocol

CryoMini serial number:
Visual inspection:
Visual check
Software version:_____________________________
Condenser fan fuse (5A-T) O OK
Therapy fan fuse (5A-T) O OK
115V device, jumpers BR2 and BR3 and jumpers BR5 and BR6 are set.
230V device, jumpers BR1 and BR4 are set O OK
Power switch and cable O OK
Internal wiring O OK
All screws present and tight O OK
Protective conductor present and tight O OK
Housing (no damage, labels legible, no dirt, no rust) O OK
Therapy tube O OK
Electrical safety:
Protective conductor resistance (<0.2 Ohm) O OK
Ground leakage current (max.500µA) O OK
Ground leakage current 1st error (max.1000µA) O OK
Housing leakage current (max.100µA) O OK
Housing leakage current 1st error (max.500µA) O OK
Function test:
Keys O OK
LCD display O OK
Therapy clock O OK
Power switch O OK
Level switch O OK
Therapy fan (9 speeds) O OK
Service program S01:
1. cooling phase < 30 min O OK
0 min < defrost < 60 min O OK
Test run: O OK
All items checked O OK
Date: ______________________________
Name: _______________________________
Signature: ____________________________
Please observe the legal regulations for repairs and maintenance of medical devices in your country.
34

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Zimmer Medizinsysteme GmbH Tel. 0731 / 9761-0 info@zimmer.

Topic: Service Manual

Rev. Date Change Originator

A 10.01.2008 Initial Release A. Petraschka

10. Troubleshooting ..................................................................................................................................................................19

• the device is operated as specified by the operating manual

3. Repairing printed circuit boards

5.3. Refrigeration System

5.3.3. Filter Dryer

5.3.4. Capillary tube

5.4. Safety Measures

The compressor is protected by an integrated overload protection in the compressor.

5.5. Technical Data

Housing dimensions: H650mm x W335mm x L600mm

Compressor J9 J2 J3 J12 J6 J10

Figure 2 (Blockdiagramm 115V/230V device)

7.1.2. Low Cooling Power

7.1.3. “Condensate container full” message appears on the display

7.1.4. “Clean filter” message lights

7.1.5. Error Messages

Possible error messages:

7.2. Service Report

Customer: .............................................................. Date: ............................

Occurrence of fault: once several times frequent always with

Under the following conditions: after switching on with a warm device

Special environmental conditions:

Humidity:............... Temperature:............... Power connection:........…………………………..................................................

Prior repairs and installed spare parts (name, serial number):

Please enter password:

9.2. Freeze-over Simulation

9.3. Hour Meter

9.4. Manual Component Control

Kom 60°C VER -15°C KRE 30°C PCB 22°C

KOM = 0 CLR = 16 TLR = 2 HZG = 0

P=0 ExO = 0 ExI = 0 ExS = 0

Legend for Figure 6:

10.1. Starting Problems

II. Refrigeration test

III. Refrigeration test

10.2. Problems without error message

10.3. EEPROM write error

10.4. WATCHDOG error

10.5. Temperature Sensor (Evaporator)

10.6. Refrigeration System Temperature Sensor

10.7. Incorrect Mains Frequency <45Hz or >65Hz

11. Assembly and Service

Spare Part List:

Link Part number Part name

11.2.1. Spare Parts Handling

All boards must be inspected before installation (shipping damage, etc.).

11.2.2. Required Equipment

11.2.3. Safety Notice

Caution! - Do not touch parts!

11.3. Removing and Attaching the Therapy Tube

11.4. Opening the Housing

1. Unplug power cable from power source.

11.5. Closing the Housing

1. Installing metal housing:

11.6. Test Run

12. Repairs and Component Replacement

12.1.1. Mains Supply Side

12.1.2. Low-voltage Side

12.1.4. Board Replacement