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Offload
Pump
Soap
Pump
Fluid Waste collected
through Manifold Drain Valve
Waste Coupling
extends from Docker to
mate with Rover
Fluid Waste pumped
to hospital waste
water system
Fluid Waste System Theory of Operation
At the Docking Station, fluid waste is removed from the Rover’s Canisters and discarded into the hospitals waste water
system. This docking process proceeds automatically when the Rover is pushed into the Docking Station. The general fluid
waste transfer steps involved are:
The Docking Station connects to the dry break Waste Coupling on the bottom of the Rover
Waste Fluid is pulled from the Large Canister and discarded by the Docker’s Offload Pump
Waste Fluid from the Small Canister is dumped into the Large Canister by opening the Drain Valve
The Offload Pump continues running until all waste is removed
Canisters are washed and related water is offloaded in the same manner
Drain Valve
The Drain Valve between Canisters is a motor actuated Ball Valve connected to a motor control circuit. Its position (open/
closed) is determined by a hall sensor mounted to the front of the motor.
Small Canister Clogging
During the docking cycle, clotted blood may not drain from the Small Canister to the Large Canister by the force of gravity
alone. To increase the effectiveness of the offload process, the Large Canister is sealed as the Small Canister is drained.
This allows the Offload Pump to draw a vacuum (up to ~ 6 in-Hg) on the Large Canister. This vacuum, in addition to the
force of gravity, pulls clotted blood from the Small Canister through the Drain Valve.
Fluid Waste Handling System
Mechanical
Fluid Waste Subsystem-090622-SREA
Fresh Water System Theory of Operation
At the Docking Station, the Rover Canisters are washed using the normal hospital water supply pressure. Cleaning water is
transferred from the Docking Station to the Rover via dry break couplings. The flow of water within the system is controlled
by a Water Solenoid Valve in the Docking Station. The water’s destination (Small or Large Canister) is controlled by the
Diverter Valve (two solenoid valves) located in the Rover.
Prefill
To enable fluid volume measurement, both Canisters require a small amount of clean water be added after they are
offloaded. This prefill water also includes a small amount of detergent to aid in cleaning during the next docking cycle. At
the Docking Station, prefill water is added through the spray ball in each Canister
The Small Canister can be emptied into the Large Canister away from the Docking Station. This allows the user to fill the
Small Canister multiple times before returning to the Docking Station (i.e. multiple surgical uses between docking cycles). To
prefill the small canister away from the Docking Station, the Rover utilizes water stored in its internal Prefill Tank. Water is
pulled from the Prefill Tank by the Prefill Pump and added to the Small Canister.
Note that the plumbing configuration within the Rover ensures that the Prefill Tank is filled automatically during Docking.
Detergent Dispensing
Detergent is mixed with rinse water inside the Docking Station to improve Canister cleaning. Detergent is dispensed by the
Soap Pump at specific points during the docking cycle to maximize cleaning effectiveness.
Water Temperature and Pressure
Water temperature and the flow rate can significantly affect the ability of the system to clean itself. Since the system does
not control either of these parameters, it is important that the hospital plumbing be set up according the the system’s
installation instructions.
Warm water, up to 110°F, provides the best cleaning. Temperatures above this can ‘cook’ the blood in the system causing
offload problems. High temperatures can also damage internal plumbing components. Low temperatures tend to be less
effective at removing fats.
Solenoid Valve Sequencing
To prevent trapping high pressure water in the Rover and Docker Couplings, the solenoid valves are automatically opened
and closed in a specific sequence.
When turning the water on, the proper Diverter Valve is opened first, followed by the Docker Solenoid.
When turning the water off, the Docker Solenoid is closed first, followed by the Diverter Valve.
When extending or retracting Couplings, the Diverter Valve is opened to prevent pressure in the Couplings from stalling the
Coupling Actuator in the Docking Station.
Offload
Pump
Soap
Pump
Prefill
Pump
Prefill Tank
Fresh water in from
hospital water supply
Detergent drawn from
external bottle
Water Solenoid Valve
Backflow Prevention
Check Valve
Diverter Valve directs water
to either the Small or Large
Canister
Prefill
Tank
Spray Ball in
each Canister
Water Coupling
extends from Docker
to mate with Rover
Fresh Water Handling System
Mechanical
Fresh Water Subsystem-090504-SREA
Level Sensor Theory of Operation
In the Operating Room, the Rover monitors and displays the fluid level of each Canister to the user. Fluid levels are also
used to ensure the docking cycle is carried out correctly. The Level Sensing system is comprised of a Level Sensor Rod,
two magnetic Sensor Floats, and two Reference Magnets attached to the bottom of the Canisters.
To make a volume measurement, an electrical current Interrogation Pulse is sent from the Level Sensor electronics down a
wire inside the Level Sensor Rod. When this current pulse passes by each of the four magnets, a mechanical Return Pulse
is sent back up the Level Sensor Rod. The time between return pulses is used to determine the distance between each
Canister’s Sensor Float and Reference Magnet. This time is used to calculate the fluid volume. See the timing diagram
below for a visual description of this process.
Canister Calibration
Manufacturing variation between Canisters (i.e. canister shape, reference magnet position, etc.) is addressed by factory
calibration of each one produced. A Canister’s calibration information is stored in a permanently attached Canister
Calibration PCBA. This calibration information is read by the Rover’s Main Controller at every power up, preventing the need
for field calibration when canisters are replaced.
Float Calibration
Manufacturing variation between Floats (i.e. float weight, internal magnet placement, etc.) must be addressed by field
calibration. An especially heavy Sensor Float would sit lower in the canister fluid than a light one. This would result in a
different Float-Reference magnet distance for a given fluid volume. The Float Calibration Procedure must be performed any
time a Rover’s floats are changed.
Float calibration information is stored on the Rover Main Controller PCBA. Consequently, the F Float Calibration Procedure
must be repeated when this PCBA is replaced.
Since the time between return pulses is not dependent on which sensor is used, the Float Calibration Procedure does not
need to be repeated when the Level Sensor Rod is replaced.
Canister Temperature
The diameters of the Fluid Collection Canisters increase or decrease with temperature due to thermal expansion. Because
fluid volume calculations take this geometry change into account, the Canister Calibration PCBA’s also include sensors to
measure Canister temperature.
Volume Display
Level Sensor
electronics
Sensor Float
(magnetic)
Reference Magnet
attached to Canister
Canister
Calibration PCBAs
Sensor Float
(magnetic)
Reference Magnet
attached to Canister
Distance between magnets
corresponds to fluid volume
Large Canister
return pulses
V
Time (microseconds)
Interrogation
Pulse Sent
Return Pulse from
Small Canister Float
Return Pulse from Small
Canister Reference Magnet
Time between pulses
corresponds to distance
between Float and
Reference Magnet
Level Sensor System
Mechanical
Level Sensor Subsystem-090527-SREA
Smoke
Evacuator
ULPA
Filter
Smoke
Evacuator
Blower
Smoke collected
through filter inlet
Filtered Air exhausted
inside Rover
Cooling Air Inlet
Smoke Sensor included
in ULPA Filter
Smoke Evacuator Theory of Operation
The Rover’s Smoke Evacuation system is activated by pressing a button on the User Interface Panel. The Smoke Blower
speed can also be selected to offer the right trade-off between noise and smoke evacuation effectiveness.
Air containing smoke is evacuated from the surgical site and filtered before being discharged back to the room. The Smoke
Filter removes smoke particulate using ULPA rated filter media and captures other volatile chemicals with an activated
carbon bed.
Manual Mode
When operated in Manual Mode, the Smoke Evacuator Blower runs at a constant speed regardless of the level of smoke
present in the OR air.
Auto Mode
A Smoke Sensor is built into the ULPA filter for identifying when smoke is actually being generated at the surgical site.
When placed in Auto Mode, the Smoke Evacuator Blower defaults to a low speed to ‘sniff’ for smoke. This ‘sniffing’ speed
was selected to minimize the Blower’s audible noise.
If a smoke plume is generated, it is drawn into the ULPA filter and detected by the Smoke Sensor. The Blower speed is
immediately increased to more effectively evacuate the plume. When smoke is no longer detected, the Blower returns to
‘sniffing’ speed until additional smoke is generated.
Smoke Blower Speed Control
Circuitry controlling the Smoke Blower Motor is designed to ensure its speed is constant over the expected ranges of mains
line frequency and voltage. The Rover determines the line frequency (50/60 Hz) at power up and continuously monitors and
reacts to line voltage changes while running.
Cooling Air
If run with all of the ULPA Filter inlets closed, the Smoke Evacuator Blower requires cooling air to prevent overheating. This
air is provided by a restrictive porous plastic inlet located inside the Rover.
Smoke Evacuation System
Mechanical
Smoke Evacuator Subsystem-090504-SREA
Vacuum Pump
Muffler
Fluid
Suction
HEPA
Vacuum
Regulator
House Suction Ports
with internal Check
Valves
Check Valves
Vacuum Relief Valve
allows cooling air for
Vacuum Pump
Fluid Waste collected
through Manifold
Air removed from Canister
to create vacuum
Overflow Prevention Float
and Mist Collection Foam
Vacuum Regulator Theory of Operation
The on-board vacuum system is activated by a button on the User Interface and vacuum settings are selected for each
canister through dedicated dials. While there is only one Vacuum Pump in the Rover, the actual vacuum level in each
canister is controlled by two separate Regulator Valves. Each Regulator Valve attempts to maintain its canister at the user
selected vacuum setting by:
connecting the Canister to the vacuum source (Vacuum Pump) to increase it’s vacuum level
connecting the Canister to the atmosphere to decrease (vent) it’s vacuum level
sealing the Canister to maintain it’s current level of vacuum
See the diagrams below for a visual explanation of regulator function.
Regulator Valve position is controlled by a DC Motor driven by a Vacuum Control circuit. Valve position is determined by an
optical Encoder mounted to each Motor. Since the Encoder does not provide absolute position information, an initialization
sequence is performed each time the Rover is powered on. This sequence involves driving the Motor in each direction until
a hard-stop is reached.
Vacuum Measurement
The actual vacuum level of each Canister is monitored by PCB mounted Vacuum Sensors. Each Canister is monitored by a
Primary and Secondary Sensor. The readings from Primary and Secondary Sensors are constantly being compared to each
other to ensure accuracy and detect Sensor failure.
House Suction
The user also has the option of providing suction to the Canisters via the hospital’s wall suction. For this mode of use, the
Regulators do not attempt to control the Canisters’ vacuum level. The Rover must be turned on, however, to ensure the
Regulators are in a position that will allow house suction to work (i.e. not vented to atmosphere).
Check Valves in the House Suction Ports eliminate the need for capping these ports when not in use. Additional Check
Valves at the inlet to the HEPA filter prevent air from being drawn backward through the Vacuum Pump when House Suction
is used
Docking
Regulators are also used during docking to vent or seal Canisters. This facilitates offloading waste and prevents building
pressure while spraying rinse water.
Actual Canister Vacuum
above Set Point
To Vacuum
Pump or
House
Suction
Atmosphere
Vent
Fluid
Collection
Canister
Motor Actuated
Regulator Valve
Actual Canister Vacuum
below Set Point
To Vacuum
Pump or
House
Suction
Atmosphere
Vent
Fluid
Collection
Canister
Power Distribution PCBA
Primary
Vacuum
Sensor
Secondary
Vacuum
Sensor
Vacuum
ControllersActual Vacuum
Signal
Regulator Valve
Position Control
Motor Actuated
Regulator Valve
Actual Canister Vacuum
at Set Point
To Vacuum
Pump or
House
Suction
Atmosphere
Vent
Fluid
Collection
Canister
Motor Actuated
Regulator Valve
Vacuum System
Mechanical
Vacuum Subsystem-090504-SREA
Offload
Pump
Soap
Pump
Docker Coupling Actuator Theory of Operation
During docking, fluid connections are bade between the Rover and Docker to transfer fluid waste and fresh water for
cleaning. The Water and Waste Couplings on the Rover are stationary and mounted to the bottom surface. In the Docking
Station, they are mounted to a movable plate. This plate is raised and lowered by a Stepper Motor riding up and down a
stationary lead screw. Diagrams to the left illustrate the components involved, showing them in the fully extended and
retracted positions..
Coupling position is determined using two digital hall sensors. The Extended Hall Sensor is triggered by a metal Sensor
Flag when the couplings are fully extended. The Retracted Hall Sensor is triggered by the Flag when the couplings are fully
retracted.
The entire coupling mechanism is floated on springs to accommodate misalignment between the Rover and Docking Station.
Power Coupler
An inductive Power Coupler transfers power wirelessly from the Docking Station to the Rover during Docking. The Power
Coupler functions much like a transformer with a primary winding located in the Docking Station and a secondary winding in
the Rover. The two transformer halves are brought together when the Rover is pushed into the Docking Station, which
allows for power transfer.
Power Coupler
Water and
Waste Couplings
Lead Screw
Stepper Motor
Couplings shown extended
Sensor FlagExtended Hall Sensor
Retracted Hall Sensor
Couplings shown retracted
Coupling mechanism
shown in detail above
Movable
Coupling Plate
Springs to float
Coupling
Mechanism
Coupling and Actuation System - Docker
Electrical
Coupling Actuation Subsystem-090617-SREA
IV Pole Theory of Operation
The Rover’s IV Pole is raised and lowered in response to buttons pressed on the User Interface Panel. The Pole is driven by
a DC motor and associated control circuitry. The Motor contains an integral Brake, which when powered, holds the Pole at
the desired height. The mechanism connecting the IV Pole Motor to the IV Pole is illustrated in the diagram below.
Auto Down Feature
When power is removed from the Rover, the IV Pole Brake releases automatically. As the pole begins to drop under its own
weight (and the force of an internal Return Spring), the Motor is mechanically back-driven by the falling Pole. In this
instance, the Motor acts as electrical generator and provides power to run a speed control circuit. The speed control circuit
electronically brakes the Motor to limit the speed of the descending Pole.
Since the speed of Pole descent is controlled by the Motor, if it is electrically disconnected from the rest of the system, the
Pole will fall rapidly.
Moving IV Pole
Moving Pole
attached to Belt
Motor drives this Pulley, moving
Belt to raise or lower IV Pole
Integral Brake on Motor holds Pole
at desired height
Idler Pulley at top of
stationary Pole Support
IV Pole Motor with
integral Brake
Moving IV Pole
Stationary (outer) IV Pole
Stationary
Pole Support
IV Pole System
Mechanical
IV Pole Subsystem-090504-SREA
brown
Power
Switch / CB
red
white
black
gray
gray
blue
violet
violet
Power Distribution PCBA
0702-001-035
red
On/Off
Controlorange
violet
blue
blue
orange
orange
Data from/to
Docker
Power in
from Mains
red
black
brown
brown
red
black
yellow
blue
brown
gray
gray
white
white
3.3 VDC
Motor Pwr
5 VDC
12 VDC
24 VDC
125
18 VDC
Gnd
J10 1314
25.5 VAC2
25.5 VAC1
J10 76
14.4 VAC2
14.4 VAC1
J10 12
120 VAC1
120 VAC2
J10
98
120 VAC2
120 VAC1
J10
2 12
Motor P
wr
Gnd
J9
On/Off
Control
1 11
Motor P
wr
Gnd
J9 19 20
Motor P
wr
Gnd
J13
On/Off
Control
Speed
Control
13 14
Motor P
wr
Reverse
Motor P
wr
Reverse
J13 15 16
Motor P
wr
Forward
Motor P
wr
Forward
Speed
Control
Position
Sensing
13 14
5 VDC
0-5 VDC
Signal
J9 15
Gnd
20 19
Motor P
wr
Reverse
Motor P
wr
Forward
J9
black
red
red
black
23 24
Motor P
wr
Reverse
Motor P
wr
Reverse
J13 21 22
Motor P
wr
Forward
Motor P
wr
Forward
9 10
Motor P
wr
Reverse
Motor P
wr
Reverse
J13 11 12
Motor P
wr
Forward
Motor P
wr
Forward
Speed
Control
Speed
Control
Position
Sensing
Position
Sensing
black
black
gray
12
10
5 VDC
Smoke
Signal
J11
16
11
Gnd
Smoke
Pulse
13Gnd
95 VDC brown
white
blue
black
green
red
15
14
Logic Pwr
5 VDC
J11
52
3.3 VDC
Digital Com
3
Digital Com
1
Reset
8
Gnd
red
orange
white
green
blue
brown
black
129
Vac On/Off
150/60 Hz
Detect
J81011
Gnd
Vac On/Off
2
5
Smoke Sp
Settin
g
6
5 VDC
white
green
black
brown
blue
red
12
3
brown
12
3
Smoke Blower
Motor
Vacuum Pump
Assy
12
12
Cooling Fan
Cooling Fan
gray
gray
Prefill Pump
12
34
12
34
56
Smoke Sensor
(in ULPA Filter)
65
Isolated
Gnd
Digital Com
J12
43
Digital Com
Digital Com
2Digital Com
124 VDC
Level Sensor
12
34
56
7
green
black
blue
white
brown
18
4
Gnd
3.3 VDC(ID)
J9
98
Digital Com
Digital Com
103.3 VDC red
brown
green
white
black
Large Canister
Calibration PCBA
0702-001-803
12
3.3 VDC
Digital Com
J1
34
Digital Com
3.3 VDC(ID)
5
Gnd
16
5
Gnd
Gnd (ID)
J9
76
Digital Com
Digital Com
173.3 VDC red
Small Canister
Calibration PCBA
0702-001-803
12
3.3 VDC
Digital Com
J1
34
Digital Com
Gnd (ID)
5
Gnd
brown
green
white
black
1 2 3 4 5 6 7 8
Large
Regulator
Encoder
Large
Regulator
Motor
1 6
Gnd
Encoder
Pulse
J13 7 17
Encoder
Pulse
3.3 VDC
18
Encoder
Pulse
green
brown
red
blue
1 2 3 4 5 6 7 8
Small
Regulator
Encoder
Small
Regulator
Motor
5 3
Gnd
Encoder
Pulse
J13 4 8
Encoder
Pulse
3.3 VDC
2
Encoder
Pulse
black
orange
yellow
green
brown
red
blue
IV Pole
Brake
IV Pole
Motor
1 2 1 2
Large
Canister
Diverter
Small
Canister
Diverter
1 2 3 4
Drain
Valve
Motor
Position
Sensor
1 2 3 4 5
Volume Display PCBA
0702-001-844
Volume Display
65
Gnd
Reset
J143
Digital C
om
Digital C
om
2
3.3 VDC
1
5 VDC
black
brown
blue
white
green
red
red
orange
green
white
blue
brown
black
Power
Coupler Coil
black
black
DC/DC
ConverterLogic Pwr
Important General Diagram Notes:
- PRODUCT MALFUNCTION IS OFTEN DUE TO DAMAGED ELECTRICAL CONNECTORS. TAKE CARE NOT TO DAMAGE
CONNECTOR PINS WITH METER PROBES!
- CHECKING RESISTANCES AT THE AC POWER AND PD PCBA EDGE CONNECTORS VERIFIES CONTINUITY OF WIRE
HARNESS AND INTERNAL COMPONENT WINDINGS. THIS IS THE PREFERRED LOCATION TO BEGIN
TROUBLESHOOTING.
- Resistance and voltage values given are not specifications, but general expected values. These should be used primarily for
determining continuity or basic circuit function.
- Resistance measurements must be made with rover power off and control circuitry disconnected to avoid damage / false readings.
- All voltage measurements (other than transformer primary and secondary) must be taken with component plugged in to avoid false
readings. Needle type probes will be required to contact conductors inside mated connectors.
- Digital communication connections are indicated with dotted lines. Power, ground, and analog signal connections are indicated
with solid lines.
Specific Diagram Notes:
1. Brush motor resistance as measured with a volt meter can vary dramatically based on brush contact with the motor.
2. Resistance shown is the value if checked at the prefill pump with connector removed. A diode in the wire harness prevents
continuity checks at J10 of Power Distribution PCBA. To check continuity there, set meter to DIODE MODE. Attach positive lead
to pin 8 and negative lead to pin 9 of the wire harness. Diode drop measured should be ~ 0.6 VDC. Switch leads and ensure
meter reads “OL”.
3. Voltage applied to smoke blower motor depends on speed setting. It will be 0 VAC with smoke blower off. The speed setting is
communicated from Power Distribution PCBA to AC Power PCBA.
4. Cannot measure voltage at pump due to connector design.
5. Component is speed controlled, so applied voltage will vary rapidly. Volt meter measurements are not possible.
6. Motor Pwr can be checked via technician menu (TECHNICIAN MENU \ VACUUM \ REGULATOR) . It is shown as "PSVOLT". Its
value depends on the power source and should be ~18 VDC when powered by the Docker and 25 - 40 VDC when powered by
mains.
7. Logic Pwr depends on the power source and should be in the range of 18 – 20 VDC. Motor Pwr and Logic Pwr are the same
voltage when docking.
8. High frequency / high voltage signal cannot be measured with volt meter.
9. Actual voltage measured at component will be 2 - 8 volts lower than Motor Pwr.
10. Vacuum Pump On/Off signals are combined with an AND gate on the AC Power board.
11. The voltage supplied by mains may be either 120 VAC (60 Hz) or 230 VAC (50 Hz). Fuses F1 and F2 on the AC Power PCBA are
used to select which is provided. The autotransformer produces 230 VAC on its primary if 120 VAC is supplied. It produces 120
VAC on its primary if 230 VAC is supplied.
12. This voltage is electrically isolated from other voltages in the system. It must be measured using pin 6 as the ground reference.
13. Transformer voltages shown are for the fully loaded condition. Unloaded voltages will be 5-15 VAC higher.Power in
from Docker
Rover Power Coupler PCBA
0702-001-8061
3
Gnd
18 VDC
J3
12
VAC1
VAC2
J2
1 2
N/C
5 VDC
J1 3 4
3.3 VDC
Digital C
om
from Docker
5
Digital C
om
from Docker
6
Digital C
om
to Docker
7
Digital C
om
to Docker
8
Gnd
AC Power PCBA
0702-001-802
F1(230VAC selector)
F2(120VAC selector)
F4(6.3 A)
F3(10 A)
On/Off
Control
On/Off/
Speed
Control
4 9
Common
120 VAC
J2 20
230 VAC
523
Common
120 VAC
J2
14
22
Common
120 VAC
316
Common
40-65 VAC
J2
13
18
Common
230 VAC
J2
11
Common
Common
J2
11
12
120 or 230
VAC120 or 230
VAC
J2
65
5 VDC
Smoke Sp
Setting
J1
43
Vac On/Off
2
Gnd
2
50/60 Hz
Detect
1
Vac On/Off
1
blue
Position
Sensing
Smoke
Sensing
Calibration
Reading
Radio PCBA
0702-014-028
Note 3
Note 3 Note 10
Note 4
Note 7
Note 6
Note 5Note 5Note 5
Note 9Note 9
Note 5
Note 11
Note 11
IR
IR
S/N PCBA
0702-001-815
12
3.3 VDC
Gnd
J1
34
Digital Com
Digital Com
5Digital Com
6Digital Com
7Gnd
83.3 VDC
Rover Main Controller PCBA
0702-001-800
Main Display
76
Gnd
Reset
J4
54
Digital Com
Digital Com
33.3 VDC
25 VDC
1Logic Pwr
1 2
5 VDC
3.3 VDC
J3 4 3
Digital C
om
Digital C
om
5
Reset
6
Gnd
87
Gnd
Digital C
om
to Docker
J265
Digital C
om
to Docker
Digital C
om
from Docker
4
Digital C
om
from Docker
3
3.3 VDC
2
5 VDC
1
20 VDC
Note 7
Rover
Main
Controller
87
3.3 VDC
Gnd
J11
65
Digital Com
Digital Com
4
Digital Com
3
Digital Com
2
Gnd
1
3.3 VDC
12
3
15
28
46
73
Auto Power Xfmr
0702-001-830
Primary Secondary
120 VAC
14.4 VAC
25.5 VAC
Note 12
Note 8
EMC Filterbrown
blue
green/yellow
Component
Resistance
Chart:
Cooling Fans
Prefill Pump
Small Regulator Motor
Large Regulator Motor
Smoke Blower Motor
Vacuum Pump Motor
Component
Winding
Resistance
(Ohms)
5
1 - 10
285
30
1 - 20
1 - 20
See
Note
1
2
1
1
IV Pole Motor 1 - 20 1
IV Pole Brake 120
Small Canister Diverter 13
Large Canister Diverter 13
Drain Valve 1 - 220 1
Power Coupler Coil 0.5
Note 13
Edge Connectors and pin counting for Power
Distribution and AC Power PCBA’s
J1
1 3
4 6
J2
1 12
13 24
J13
1 12
13 24
J8
1 6
7 12
J9
1 10
11 20
J10
1 7
8 14
J11
1 8
9 16
This drawing shows sheet metal mounted
connectors, viewed from the back of the
rover with circuit boards removed.
1 3
4 6
J12
System Wiring Diagrams-090622-SREA
Docker Main Controller PCBA
0702-014-500
Power
Switch / CB
120 VAC
from Mains
62
N/C
N/C
J437
12.8 VAC 2
12.8 VAC 1
4
23 VAC 2
8
23 VAC 1
1
120 VAC 2
5
120 VAC 1
red
red
blue
blue
green
green
Actuator Stepper
Motor
Couplings
Extended
Hall Sensor
Couplings
Retracted
Hall Sensor
Coupling
Door Hall
Sensor
Data from/to
Rover
Power
Coupler Coil
black
black
Power out to
Rover
16
15
N/C
Gnd
J12
14
13
Gnd
3.3 VDC
125 VDC
1112 VDC
10Motor Pwr
9Motor Pwr
87
Digital Com
Digital Com
65
Digital Com
Digital Com
4
Digital Com
from Rover
3
Digital Com
from Rover
2
Digital Com
to Rover
1
Digital Com
to Rover blue
black
brown
green
white
tan
gray
purple
red
red
red
orange
yellow
black
black
pink
Electro-
magnet
Electro-
magnet
On/Off
Control
21
Gnd
Motor Pwr
J7
21
Gnd
Motor Pwr
J8
black
black
black
black
1 10
5 VDC
Signal
J10 4
Gnd
8 5
5 VDC
Signal
J10 11
Gnd
7 9
5 VDC
Signal
J10 2
GND
1 2 31 2 3 4 1 2 3 1 2 3 4
3 4
Motor P
wr/
Gnd
Motor P
wr/
Gnd
J3 2 1
Motor P
wr/
Gnd
Motor P
wr/
Gnd
green
green/white
red
red/white
Stepper
Motor
Control
Docker Main Controller
F3(6A)
F2(6A)
3 6
120 VAC1
120 VAC2
J91 4
120 VAC1
120 VAC2
J9 2 5
120 VAC1
120 VAC2
J9
purple
orange
1 2 31 2 3
orange
orange
gray
gray
On/Off
Control
On/Off
Control
On/Off
ControlD23 D30Coupling Test
Buttons
1 2 3 4
Soap
Pump
Water
Solenoid
Offload
Pump
87
3.3 VDC
Gnd
J11
65
Digital Com
Digital Com
4
Digital Com
3
Digital Com
2
Gnd
1
3.3 VDC
S/N PCBA
0702-001-815
12
3.3 VDC
Gnd
J1
34
Digital Com
Digital Com
5Digital Com
6Digital Com
7Gnd
83.3 VDC
D29 D17D22
Questra Controller
Docker Power Coupler PCBA
0702-014-510
12
VAC1
VAC2
J1
Power
Coupler
Driver
12
Digital Com
to RoverDigital Com
to Rover
J3
34
Digital Com
from RoverDigital Com
from Rover
5
Digital Com
6
Digital Com
7
Digital Com
8
Digital Com
910
Motor Pwr
Motor Pwr
11
12
12 VDC
5 VDC
13 3.3 VDC
14 Gnd
15 Gnd
16 N/C
IR
IR
3.3 VDC
5 VDC
12 VDC
DC/DC
ConverterLogic Pwr
Motor Pwr
D27
D26
D25
D21 D20 D18
15
26
48
37
12
34
Docker Isolation Xfmr
0702-014-520
Primary Secondary
12.8 VAC
23 VAC
120 VAC
Note 3
Note 4
Note 6
Note 5
Note 7
Note 8
120 VAC
120 VAC
brown
blue
D14
D28
yellow
purple
white
orange
blue
brown
red
green
black
Component
Resistance
Chart:
Soap Pump
Water Solenoid
Offload Pump
Actuator Stepper Motor
Power Coupler Coil
Electromagnets
Component
Winding
Resistance
(Ohms)
375
< 1.0
30
220
N/A
2
See
Note
2
1
9
Docker Main Controller Software
Status LEDs: (See Notes 11, 12)
LED Label
D25
D26
D27
System Condition / Defect
ON
ON
(dim)
ON
ExpectedQuestra Com
Lost
Power Coupler
PCBA Com
Lost
ON
FLASH
(10s / 10s)
OFF
ON
FLASH
(0.25s / 0.25s)
ON
Questra Controller
Software Status LEDs:(See Notes
11, 13)
LED Label
D21
D20
D18
System Condition
ON
ON
OFF
Expected(no ethernet
connection)
Expected(with ethernet
connection)
FLASH
ON
OFF
Important General Diagram Notes:
- PRODUCT MALFUNCTION IS OFTEN DUE TO DAMAGED ELECTRICAL CONNECTORS.
TAKE CARE NOT TO DAMAGE CONNECTOR PINS WITH METER PROBES!
- BOTH THE DOCKER MAIN CONTROLLER AND POWER COUPLER PCBA’S HAVE LARGE
CAPACITORS THAT RETAIN CHARGE FOR EXTENDED PERIODS OF TIME. POWER
MUST BE REMOVED FROM THE DOCKER FOR 3 MINUTES PRIOR TO CONNECTING OR
DISCONNECTING ANYTHING FROM THESE PCBA’S!
- CHECKING RESISTANCES AT THE CONNECTORS TO THE DOCKER CONTROLLER
PCBA VERIFIES CONTINUITY OF WIRE HARNESS AND INTERNAL COMPONENT
WINDINGS. THIS IS THE PREFERRED LOCATION TO BEGIN TROUBLESHOOTING.
- Resistance and voltage values given are not specifications, but general expected values.
These should be used primarily for determining continuity or basic circuit function.
- Resistance measurements must be made with docker power off and control circuitry
disconnected (unplug wire harness from PCBA) to avoid damage / false readings.
- All voltage measurements (other than transformer primary and secondary) must be taken with
component plugged in to avoid false readings. Needle type probes will be required to contact
conductors inside mated connectors.
- Digital communication connections are indicated with dotted lines. Power, ground, and analog
signal connections are indicated with solid lines.
Specific Diagram Notes:
1. The offload pump has an internal rectifier that prevents making resistance measurements. To
check continuity, put meter in DIODE MODE. Measured voltage drop through the pump should
be ~ 1.1 VDC when checked in both directions.
2. Resistance shown is the value if checked at the prefill pump with connector removed. A diode
in the wire harness prevents continuity checks at the Main Controller end of the wire harness.
To check continuity there, set meter to DIODE MODE and remove connector from J9 of the
PCBA. Attach positive lead to purple wire and negative lead to orange wire. Diode drop
measured should be ~0.6 VDC. Switch leads and ensure meter reads “OL”.
3. Cannot measure voltage at pump due to connector design. Voltage can be measured at
Docker Controller PCBA. With pump off, measured voltage will be < 100 VAC. With pump on,
measured voltage will be ~120 VAC.
4. Component is current controlled, so applied voltage will vary rapidly. Volt meter measurements
are not possible.
5. Motor Pwr depends on power source and should be in the range of 25 - 40 VDC.
6. Logic Pwr depends on the power source and should be in the range of 18 – 20 VDC.
7. High frequency / high voltage signal cannot be measured with volt meter.
Docker Main Controller Map:
Docker
Main
Controller
Software
Status
LEDs
Extend/Retract
Test Buttons
Retracted LED
(D23)
Extended LED
(D30)
J9
4 6
1 3
J4
85
41
Soap Pump LED
(D29)
Offload Pump LED
(D22)
Water Solenoid LED
(D17)
Electromagnet LED
(D14)
J12
9 16
1 8
J10
7 12
1 6
J3
4
1
J7
1
2
(D25)
(D26)
(D27)
Coupling Door LED
(D28)
Questra
Controller
Software
Status
LEDs
J8
1
2
(D20)
(D18)
(D21)0702-014-500
Revision Level
12
12
Note 10
Note 10
F4
Note 14
Note 15
Specific Diagram Notes (continued):
8. The voltage supplied by mains may be either 120 VAC (60 Hz) or 230 VAC (50 Hz). Input
voltage is selected by installing the appropriate wire harness P/N between the power switch and
transformer. The main diagram shows the Docker wired for 120 VAC mains.
9. The resistance of both stepper motor phases should be checked. Check resistance from green
wire to green/white. Check resistance from red wire to red/white.
10. Hall signal indicator LED’s are ON when hall sensors are un-plugged.
11. The software status LED states specified in this table apply after the Docker power up
sequence is complete and when no Rover is attached. The Docker power up sequence is
complete 90 seconds after power is applied.
12. Questra Com Lost condition requires replacing Docker Controller PCBA. Power Coupler Com
Lost condition requires troubleshooting of Power Coupler PCBA (check for power and continuity
of communication lines).
13. Conditions other than those shown may require replacing Docker Controller PCBA.
14. Fuse and fuse holder was not included in PCBA revisions prior to H.
15. Transformer voltages shown are for the fully loaded condition. Unloaded voltages will be 5-15
VAC higher.
Wired for 230 VAC mains
Power
Switch / CB
230 VAC
from Mains
12
34
Docker Isolation Xfmr
0702-014-520
Primary Secondary
12.8 VAC
23 VAC
120 VAC
120 VAC
120 VACbrown
blue
Hardware LED Indicators: (See Note 10)
Couplings Retracted
Soap Pump State
Offload Pump State
Water Solenoid State
Couplings Extended
Coupling Door
LED
Label
D28
D30
D23
D29
D22
D17 ON = ON
LED
Electromagnet State D14
Docker Main
Controller PCBA
Revision Level
ON = OFF ON = ON
ON = ON
ON = ON
A - F HLED Label
Triggered
Condition
Door Closed
Extended
Retracted
LED State
if Triggered
OFF
ON
ON
Signal if
Triggered
0 VDC
3.3 VDC
3.3 VDC
LED
System Wiring Diagrams-090622-SREA
Rover
RF Module
0702-014-028
Wireless
Controller
Docker
Docker Power Coupler PCBA
0702-014-510Docker Main Controller PCBA
0702-014-500
Rover Main Controller PCBA
0702-001-800
Power Distribution PCBA
0702-001-035
Volume Display PCBA
0702-001-844
Rover Main
Controller
EDMS
Ministamp
EDMS Main
Stamp
Docker Main
Controller
Docker
Power
Coupler
Controller
Smoke
Controller
Tank (Valve)
Controller
Level
Sensor
FPGA
Large
Vacuum
Regulator
Controller
Small
Vacuum
Regulator
Controller
IV Pole
Controller
Canister
Reader
Controller
Volume
Display
Controller
Rover Power Coupler PCBA
0702-001-806
IR
IRIR
IR
Data
Transfer
Power
Transfer
System Control Overview
Electrical
System Control Overview-090623-SREA
2 - Fluid_Waste_Subsystem-Thoery of Oper3 - Fresh_Water_Subsystem-Theory of Oper4 - Level_Sensor_Subsystem-Theory of Oper5 - Smoke_Evacuator_Subsystem-Theory of Oper6 - Vacuum_Subsystem-Theory of Oper7 - Coupling_Actuation_Subsystem-Theory of Oper8 - IV_Pole_Subsystem-Theory of Oper1 - System_Wiring_Diagrams-090622-SREA1a - System_Control_Overview-090623-SREA
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