Service Manual

Dräger X-dock 5300 / 6300 / 6600

V1.2, October 2013 (EN Version / AA included)
Inhalt

1.  Introduction.......................................................................................................................... 4 

1.1  The Dräger X-dock 5300 / 6300 / 6600 .............................................................................. 4 

1.2  About this document ........................................................................................................... 5 
2.  Functional Test .................................................................................................................... 6 

2.1  The Self-test ....................................................................................................................... 6 

2.2  Event logger ....................................................................................................................... 6 
2.2.1  Overview of the event logger .............................................................................................. 7 
2.2.2  Read-out of the event logger .............................................................................................. 8 
2.2.3  Read out of X-dock Manager / DX Manager event logger ................................................. 8 
2.3  Info Screen ......................................................................................................................... 8 
2.4  The X-dock Station’s service menu .................................................................................... 9 
2.5  The X-dock Firmware ....................................................................................................... 11 
2.5.1  Concept Master and Module Firmware ............................................................................ 11 
2.5.2  Updating the X-dock Firmware ......................................................................................... 11 
2.6  Test scenario .................................................................................................................... 12 
2.6.1  S1 Self-test ...................................................................................................................... 12 
2.6.2  S2 Pump function ............................................................................................................ 13 
2.6.3  S3 Test calibration and alarm test ................................................................................... 13 
2.6.4  S4 Network functionality .................................................................................................. 14 
3.  Maintenance mechanics ................................................................................................... 15 

3.1  Required tools / working materials ................................................................................... 15 

3.2  Replacement of simple components / wearing parts ....................................................... 15 
3.2.1  Remove / Add a X-dock Module....................................................................................... 15 
3.2.2  Replacement of the sealing cartridge (X-am and Pac) .................................................... 16 
3.2.3  Replacement of screen protector ..................................................................................... 17 
3.2.4  Replacement of instrument cradles (X-am, X-am+ and Pac)........................................... 18 
3.2.5  Replacement of instrument module’s brackets ................................................................ 19 
3.2.6  Replacement of pneumatic module connector and module ending (non AA-Version) .... 20 
3.2.7  Replacement of valve nozzle ........................................................................................... 21 
3.3  Replacement of interior components................................................................................ 22 
3.3.1  Disassembly of the X-dock Master ................................................................................... 22 
3.3.2  Layout Master circuit board .............................................................................................. 24 
3.3.3  Tubing layout of the Master .............................................................................................. 25 
3.3.4  Assembly of the X-dock Master........................................................................................ 26 
3.3.5  Master components .......................................................................................................... 26 

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3.3.6  Dismantling the X-dock modules ...................................................................................... 32 
3.3.7  Layout module PCB (PR4 revision).................................................................................. 33 
3.3.8  Tubing layout module (non AA-Version) .......................................................................... 34 
3.3.9  Peculiarities X-am+ Module and Pac Module .................................................................. 34 
3.3.10  Assembly of X-dock Modules ........................................................................................... 34 
3.3.11  Module components ......................................................................................................... 35 
4.  Module deviations “AA-Version” ..................................................................................... 40 

4.1  AA-Version in general....................................................................................................... 40 

4.2  AA-Version in general....................................................................................................... 40 
4.3  Service on AA-Versions ................................................................................................... 41 
5.  Maintenance Software ...................................................................................................... 42 

5.1  Software repair with use of “scripts” ................................................................................. 42 

5.2  Software repair in general ................................................................................................ 42 
5.3  Error messages ................................................................................................................ 43 

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1. Introduction
1.1 The Dräger X-dock 5300 / 6300 / 6600

The Dräger X-dock Station is a modular calibration and data management system.

X-dock can be used as an autonomous station for bump tests and calibration as well as a system
with networked stations, which documents (on a single server) and offers an extensive reporting by
PC software.

Technical details:

Weight approx. 1500g (Master) approx. 960g (Modules)

Electricity supply 9 … 24V via power supply or car charging adapter
Approvals CE marking
Ambient conditions 0°C to 40°C (32°F to 104 °F)
3 x 2.0 USB (Type A)
Connections 1x USB-Host (Type Mini-B 5-pin (standard))
LAN (RJ 45)
1x fresh air inlet
Gas connections 1x exhaust outlet
3x test gas inlet (X-dock X300) 6x test gas inlet (X-dock 6600)

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1.2 About this document

This document is the Service Manual for the X-dock family. Repair measures and the configuration
of the station are described in here. In addition to this and in case of discrepancy the Service
Information of the X-dock family issued in the DORIS and Lotus Notes when necessary prevail.
The Product Management Portable Gas Detection is responsible for the preparation.

The Service Manual is a component of the Dräger X-dock document collection:

 Service Manual: Repair guidelines and configuration aids
 Sales Manual: USPs, competition and market positioning
 SIs: Service Information (DORIS / Lotus Notes)
 TNs: Technical Information (D-World / DORIS)
 IfU: Instruction for Use (DORIS and D-World)
 TH: Technical Handbook (DORIS and D-World)
 PC-SW IfU: Installation and configuration instructions of the network
components and the customer software „X-dock Manager“
 Software Online help: X-dock Manager (CD)
 Spare Parts List: Allocation and order information of the spare parts (DORIS /
Lotus Notes)

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2. Functional Test
2.1 The Self-test

With each system start a detailed self-test is run. This test contains the following test steps:

1. Module identification

2. SD cards identification

3. Data base identification

4. Software Version Master and Module alignment

5. Testing the internal tightness (this test does not occur directly after the start-up, but before
the first test which will be performed following this. And subsequently again before the first
test after 24h, if not switched off)

6. Test pump

7. Tightness of test gas lines

Notice:
For test step 5 a test gas cylinder must be connected to a gas valve and the gas
configuration set.

An error during the self-test will be directly shown. Also, the results of the self-test will be recorded
in the files custom.log and service.log, which are stored in the station. The file custom.log can be
read out by an export of the event logger.

2.2 Event logger

The event logger can be read out via the menu and copied on an USB stick. Connect an USB stick,
log in and store via the data administration the event logger on the stick.

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2.2.1 Overview of the event logger
The X-dock station creates different Log files which are necessary for the traceability and error
analysis. There are:

 Costumer event logger – custom.log

 Service event and error logger (Master) – service.log

 Service event and error logger (Module x) – servicex.log

 Measured value logger – mmeasval.log

All files should be opened via the Windows standard program “Wordpad” as the program “Notepad”
shows the files incorrectly. Furthermore it is important that the station does not use the customers
date and time settings on this level, but the internal system time which is based on the UTC time
zone. This leads to a deferred time stamp of all events, e.g. for Germany -2 hours.

Below is an example of a customer event logger. The real point of time of the first recognizable
event was for Germany the valid GMT +1 or MEZ so 12:06:47 p.m.

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2.2.2 Read-out of the event logger
Connect the USB stick with the station and select in the settings the point „Event Logger X-dock“
under the data management. In the following menu the USB stick can be selected and the
customer event loggers copied on the USB stick by “OK”.

Note
Log in as a service user as well to read out the service logger. Otherwise, only the
data of the customer event logger will be transferred.

2.2.3 Read out of X-dock Manager / DX Manager event logger

Even the X-dock Manager as well as the X-dock DxManager file event logger, but only for an error
analysis. In case issues occur, whether it is a crash, a license error or issues during the installation,
these logger can be copied and transferred to the next support authority and there analyzed.

The files are available in the following folder:

under WinXP: C:\Documents and Settings\All Users\AppData\Draeger\X-dock\files

under WinVista/Win7: C:\ProgramData\ Draeger\X-dock\files

(%AllUsersProfile\Draeger\X-dock\files)

2.3 Info Screen

The Info Screen is located in the instrument setting under the “System Configuration”. It contains
information about the versions, the installed APP version, the hardware version, the kernel version
as well as the firm MAC address and the allocated IP address.

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2.4 The X-dock Station’s service menu

To unlock the service menu it is necessary to log in as a service user. For this, do not select a user
in the login screen and enter the following password:

471352

Now additionally, the item „Service“ is available on the system menu. Behind it there are two sub
menus:

 Operating hours counter

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 Statistical data about the use of the X-dock station, as operating hours and number of
closing the Module flaps. This information can be called up individually for each module. It
is possible to swap between the master and the modules via a pop-up menu.

 Hardware Test

For each module and for the master the parameter will be displayed individually. The
valves as well as the pump can be switched manually for test purposes. Additionally, it is
possible to activate manually the charging function for the X-am+ modules here.

Notice
If the module flap is open, the valve will not switch on test gas although the valve
switches are activated. The firmware prohibits the exposure of test gas to an open
module.

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2.5 The X-dock Firmware

2.5.1 Concept Master and Module Firmware

If the firmware of master and module differ, the X-dock Master will create an error message that a
new / unknown FW version has been found and that an update for the FW is necessary.
In this case a USB update should be done. All system component (master and all modules, even if
not displayed yet) will be updated.

2.5.2 Updating the X-dock Firmware

The updating of the firmware is provided for the Dräger Service as well as for the customer. The
required update file is available on the X-dock’s product pages in the Internet as a download. It has
to be saved on an USB stick (highest folder level) and the stick has to be plugged into the X-dock.
The update process can be started via the menu under the “system configuration” and there
“update”.

Notice
Version 01.01.01 – 01.02.27: The file must be unzipped and copied on the stick

Version >SU2 (>=01.03.xx): The *.xup file must copied on the stick.
SU2 master (>01.04.xx) is necessary.

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2.6 Test scenario

The test of all functions of the X-dock Station is ensured using the following scenarios. Within the
remedial measures it will be referred to one or more of the below described scenarios to be
performed according to the necessity.

Necessary tests

S1 S2 S3 S4

Testing the station the following means / tools are necessary:

 Calibration gas, e.g. mixed gas CH4, O2, H2S, CO

 X-am 2000/5X00 with CH4, O2, H2S, CO sensors and FW 6.3 (X-am 5X00),
FW 6.0 (X-am 2000) or higher.

 Pac 7000 with O2 or H2S or CO sensor with FW 3.2 or higher.

 USB stick, at least 8GB

 Laptop with Windows7 or XP

 RJ 45 patch cable (LAN)

2.6.1 S1 Self-test
After the start of the initial test following the power-up, the X-dock dock will run and record a self-
test automatically. Additionally, this test will be repeated at least every 24 hours even when the
instrument is not switched-off (again before the start of the selected test).

Accordingly, for this scenario the gas supply must be connected, a system start and any test to be
performed. See also Chapter 2.1 and Chapter 5.1.

Additionally, for all X-am+ Modules the charging function must be tested. For this, start the
charging function via service menu manually and insert an X-am device. The flash of the charging
LED indicates the charging of the X-am instrument and shows its correct function.

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2.6.2 S2 Pump function
Via the service menu under “Hardware Test” the pump will be started manually directly at the
master. Now, by flagging the check box for the output valve (V1) this valve will be closed. Take the
readings of the appearing positive pressure in the hose system (P [mbar] bottom left). The pump’s
capacity will be sufficient if the generated pressure will be >50 mbar.

2.6.3 S3 Test calibration and alarm test

To check the tightness of the tubing to the module and the sealing cartridge this test scenario is to
be performed. First, an appropriate test for this must be defined in the test configuration. Select a
test program and configure it in the following way:

 Mode: extended bump test

 Alarm test ON

 Purge ON

 All further options OFF

Now, calibrate a test unit with an external calibration cradle manually.

With the extended bump test this test unit will be checked in the modules. If it passes, the test will
be successful. Simultaneously, the alarm elements can be tested exemplary.

Use for all tests the same test gas cylinder!

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2.6.4 S4 Network functionality
Connect the X-dock Station with a PC via a network cable (RJ45). The PC and the X-dock must be
in the same subnet. Which means, the first 3 IP areas must be identical the last part can differ (e.g.
192.168.78.xxx). With the command “cmd” typed in the field “execute” (WinXP) or directly in the
“search” function (Windows Vista & 7) the prompt can be started. Now, when “ping” is typed in
followed by a blank and the IP address of the X-dock Station to be tested a test signal will be sent
to the station. If the program reports that all 4 data packages are sent and received successfully
the network test will be successful.

Notice
This test only examines the first three layer of the OSI model. It is still possible that a
for example a firewall blocks the data movement on one port. In this case the station
won’t reach the data base, although the ping command has been performed
successfully.

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3. Maintenance mechanics
3.1 Required tools / working materials

2.0 mm and 2.5 mm hex key with torque control

8 mm jaw spanner or box wrench
17 mm jaw spanner
Slot screwdriver (approx. 3-4 mm width)

If screws get lost during the mending (or generally not available any more), parts of the tubing must
be replaced or bits and pieces like case feet and the model numbering are missing there following
spare parts are available apart from the main components:

8321971 Spare set screws

8321967 Spare set hoses

8321974 Spare part pad

8321839 Module numbering 1 – 10 (sheet)

3.2 Replacement of simple components / wearing parts

Note
Ensure that all test gas cylinders are closed and the hose connections are detached
as well as the X-dock is de-energized before starting the repairs.

3.2.1 Remove / Add a X-dock Module

To remove or add a random module the station’s right side part must be disconnected. For this,
loose the three lateral hex Allen screws and the two grub screws at the bottom (all 2.5 mm hex
key).

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To disconnect modules and/or master the metal connectors at the station’s bottom and back side
must be loosened. Unscrew at least one of the two hex screws per connector.

Now, the modules can be separated or an additional module affixed. To connect two modules
always a pneumatic module connector is necessary for the tubing, which has to be attached (see
3.2.6).

New modules or the removal of modules will be identified automatically by the master and will be
operative after the start of the station. There is no additional configuration necessary.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X

3.2.2 Replacement of the sealing cartridge (X-am and Pac)

The sealing cartridge is fixed on two sides. To remove it, the two levers must be pushed together.
Now, the seal can be pulled forwards and the two hoses can be removed.

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Insert the new seal, attach the hoses again (take care of the correct slot) and insert the sealing
cartridge.

Note
The hose must be attached properly and are therefore marked. Follow the arrows!

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X

3.2.3 Replacement of screen protector

When a screen protector is already affixed, first remove it carefully. Before attaching the new foil
the display should be deep cleaned from dust and grease residues. Then apply one of the narrow
sides and starting from there and paste it on lengthwise to avoid air pockets.

S1 S2 S3 S4

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3.2.4 Replacement of instrument cradles (X-am, X-am+ and Pac)
First, loosen the center hex screw. Then pull out the instrument cradle starting with the lower part
to the top and away from the retaining flap out of the station. The cradle can now be exchanged.

1 2

For the reassembling, all three cradle types must be attached to the module housing firstly with the
head position below the retaining flap. Then carefully seat the lower part until the cradle sits flush
with the module housing. Then fix again the hex screw with a tightening torque of 35N/cm.

Note
The IR diode for the Pac cradle is located directly in the cradle. The X-am charging
cradle is as well connected by a cable with the PCB to control the charging contacts.
To exchange these two cradles disconnect the cable from the PCB and connect it to
the new one (see picture – Pac instrument cradle).

In case the instrument cradle was marked with a number label before, it has to be replaced and
affixed to the new cradle.

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 Note
The charging contacts for the instrument cradle charging are not available individually,
only in conjunction with the instrument cradle itself.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X (only alarm test)

3.2.5 Replacement of instrument module’s brackets

In some cases the broken bracket can be pulled out of the closed module easily and exchanged
with a new one. When this is not possible any more follow the description below:

First, loosen the instrument cradle as described in 3.2.4 and remove it. Now, unfasten the bracket
from the module housing by pushing in the holders on both sides. The bracket can now be
exchanged.

To reintegrate the instrument cradle see again at 3.2.4.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X (only alarm test)

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3.2.6 Replacement of pneumatic module connector and module ending (non AA-Version)
Each module must be connected by a pneumatic module connector either to the neighboring
module or to the master module. The accurate positioning is set by an indentation.

For the last module the gas inlets must be closed by a pneumatic module ending. Again, the
accurate positioning is set by the footprint of the rubber part.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X

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3.2.7 Replacement of valve nozzle
In case one of the valve nozzles has been broken or is somehow damaged, the left side part has to
be removed to exchange it. In case the nozzle is torn off directly at the thread, it can be screwed
out of the valve block using a slot screwdriver.

Check whether the o-ring is in its place between the nozzle and the valve block before the new
valve nozzle is built in. Additionally, check whether the sealing surface is dust and dirt-free.
Assemble the new nozzle using an 8 mm jaw spanner or box wrench with a tightening torque of 35
N/cm, then assemble the side part again.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X

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3.3 Replacement of interior components

Note
Ensure that all test gas cylinders are closed and the hose connections are detached
as well as the X-dock is de-energized before starting the repairs.

3.3.1 Disassembly of the X-dock Master

Disconnect the master from the modules as described in Chapter 3.2.1 and loosen the two hex
Allen screws at the bottom. Additionally, loosen the three hex Allen screws at the handle and the
two grub screws at the bottom to separate the left side part from the master.

Now, carefully separate the top housing with the bottom part from the rail and lift it upwards
completely from the lower housing. For a first overview the top housing can be put aside still wired.

After having opened the housing and loosened the left side part as well, all electrical and
pneumatic plug-in connections which are connected with the PCB can be loosened now.

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 Note
At first, unlock the flat ribbon cable for the touch display and the keyboard film then it
is possible to take the cable out of the socket without resistance.

Now, the single components can be removed and exchanged. See also the following chapters.

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3.3.2 Layout Master circuit board

Mains supply

HD26 D-Sub
Module com-
munication

Pressure
sensor
1x USB
Typ B 5-pin Loud speaker

3xUSB
Type A Pump control

RJ 45

I/O (without use)

Touch display

Valve control
(1-8)

SD cards (2)

tactile switch Li battery

port

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3.3.3 Tubing layout of the Master

Pump connection

[2]

[1]

[1]

[2]

to valve block

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3.3.4 Assembly of the X-dock Master
The assembly has to be carried out in the reverse order of the disassembly. Ensure with every step
the stability and the mentioned torque of the screw connections, especially after an exchange of
components. Reconstruct the cable and tubing layout according to the original condition.

3.3.5 Master components

3.3.5.1 Replacement of the 3/2 & 2/2 – way valve

For this working step, detach the top of the master housing and put it aside. Loosen now the two
hex Allen screws, the tubing and the control contact and take off the valve.

The 6gas version has got seven 2/2 way valves and the 3gas version four 2/2 way valve (green
marking). Both valve block versions are additionally equipped with a 3/2 way valve (blue marking).
Important is the type of valve to be exchanged, pay attention to exchange it with the corresponding
one.

The new way valve will be delivered with two spare screws and spare o-rings. Exchange the o-
rings and take care of the correct positioning of the o-rings. An indentation in the valve block
defines its seat. Ensure that the sealing surfaces are absolutely dust and dirt-free.

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Finally, fasten the new valve with the two screws and a tightening torque of 25 N/cm and
reconstruct all pneumatic and electrical connections again.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X

3.3.5.2 Replacement of the valve block

To replace the entire valve block, first the control contact plug has to be loosened and the PCB as
described in 3.3.5.3 dismantled. Now, detach carefully the tubing from the valve block, unscrew the
two hex Allen screws (orange marking) and then remove the old valve block.

Once the new valve block is installed and the tubing according to the tubing layout 3.3.3 restored,
assemble the PCB again. Be aware that the thin tubes leading to the pressure sensor are placed
through the notch and are not seized. When connecting the PCB follow the screws’ order according
to 3.3.5.3.

Now, reconnect all control contacts (according to the assignment) and check again all plug
connections on the PCB for firm and correct seating before the housing is closed.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X

3.3.5.3 Replacement of the PCB

Disconnect the PCB from all pneumatic and electrical connections as described in 3.3.1. Loose the
four hex Allen screws and remove the PCB.

Equip the new PCB with the two SD cards. The slots are at the board’s bottom. Normally, the two
SD cards of the old PCB can be used again so that the station’s database is also available after the
PCB’s exchange in its previous state. The SD cards can be easily relocated.

Note
To use the old SD cards on the new PCB, ensure that they are located in the same
slots as on the old PCB!

SD cards may never be ejected during normal operation!

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In case of problems with the old SD cards and the new PCB, each spare PCB will be delivered with
two new SD cards programed to the factory setting.

Additionally, the SD cards can be formatted (FAT32) and programed with an update package. As a
result, an update is performed after starting the station and the SD cards are activated.

First, bolt the new PCB together with the housing’s underside (red marked screws first, then the
orange marked one) and reconstruct all plug connections. The correct wiring of the valve controller
can be seen in the picture. All the other plugs are marked directly on the PCB. Otherwise see PCB
layout 3.3.2. The flat ribbon cable must be placed again in the socket, which has to be locked.
Check the firm fit by a slight traction on the cable.

After having closed the housing first connect the mains and then switch on the X-dock. The
configuration of the new SD cards will be done automatically and will take some time.

8 7 6 5 4 3 2

1
8 7 6

5 4 3 2 1

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X X X

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3.3.5.4 Replacement of the touch display
To change the display, open the housing and remove the wiring of the speaker, the pump, the
button and of course the display (flat ribbon cable, see 3.3.5.3). The tubing to the pump can remain
connected.

Now, lay the top housing aside scratch protected on a flat surface and loosen the four hex Allen
screws of the display frame. Now, remove the old display. The new display’s spare part set will be
delivered apart of the display also with sealing, the frame, the flat ribbon cable and four hex Allen
screws. For the new display, it is mandatory to replace also all the other mentioned parts
accordingly. Use these parts for the new touch display only.

Once the new display is positioned over the display frame and fixed by the hex Allen screws
reconstruct the plug connection to the PCB. To this, push the cable coming from the valve block
and with the blue stripe in direction to the PCB through the slot of the cable routing and into the
prior unlocked plug. Lock it and check the firm fit by a slight traction on the cable.

Finally, reconnect all plug connections and test the station after the assembly. Calibrate the display
when necessary (see Chapter Fehler! Verweisquelle konnte nicht gefunden werden.)

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X

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3.3.5.5 Replacement of the pump
Open the housing and put the top part aside. Take off the two hose connections and the plug
connection from the PCB. The pump is clamped in position by a plastic nose of the housing. Pull it
slightly outwards and withdraw the pump out of the housing. Bring the new pump in the same
position, the plastic nose will snap in. Reconstruct the tubing and plug connection and finally check
the pump flow of the new pump during normal operation.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X

3.3.5.6 Replacement of the tubing

The spare part “Hose set” (8321967) contains the 1.5 x 0.75 mm Viton hose for the connection of
the pressure sensor as well as the 3.0 x 1.0 mm FPM standard hose for all other hose connections.
Cut to length as required or for the appropriate position.

1.5 x 0.75 mm Viton 193 mm 140 mm

3.0x1.0 mm FPM 309 mm 140 mm 74 mm 3x 61 mm 2x 56mm

As an aid to install or place the hoses correctly take the pictures from Chapter 3.3.2 and Chapter
3.3.3.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X X

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3.3.5.7 Replacement of the housing set
The spare part set “housing set Master” (8321972) contains apart from the top housing as well the
two side parts and the display frame (see picture).

The replacement of the display frame is described in Chapter 3.3.5.4. To change the top housing,
disassemble the pump, the loud speaker, the hosing and the exchange display from the old top
housing. They will be used for the new housing as well as the thread for the dust filter, which is not
included in the set and has to be reused also.

Included in the housing set is a type label. It has to be fixed on the master’s backside and the part
and serial number of the present instrument has to be entered by hand.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X

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3.3.6 Dismantling the X-dock modules
After having removed the module as described in Chapter 3.2.1, the two hex Allen screws below at
the modules’ front have to be loosened. Now, lift the front carefully and disassemble the module
housing from the rear support rail and put it aside.

To disassemble the top housing completely remove the sealing cartridge from both hose lines as
described in 3.2.2 and if necessary unlock the plug connections to the PCB.

Now, the module PCB, the non-return valve and the 3/2 way valve as well as the entire top housing
are in access.

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3.3.7 Layout module PCB (PR4 revision)

IR Diode

3/2 way valve

control

Slot SD card

Module switch
X-am / Pac

Pac Diode
connection

X-am
Contact
charging
charging PCB
contact

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3.3.8 Tubing layout module (non AA-Version)

3.3.9 Peculiarities X-am+ Module and Pac Module

The instrument cradles of these two modules are connected via a plug connection to the PCB. The
X-am+ Module links the charging contacts with the PCB. The IR diode at the Pac Module is located
in the module cradle. Therefore, it must be connected to the PCB by the plug. The wiring is to be
considered during the disassembly and assembly.

Furthermore, the X-am+ Module contains an additional charging PCB. Directions for the
replacement of this component are available in Chapter 3.3.11.2.

3.3.10 Assembly of X-dock Modules

The assembly has to be carried out in the reverse order of the disassembly. Ensure with each step
the stability and the mentioned torque of the screw connections, especially after a change of
components. Reconstruct the wiring and the hosing according to the original condition.

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3.3.11 Module components

3.3.11.1 Replacement of the housing set

The housing set contains the locking flap including the spring, the basic housing as well as the fiber
optics, everything preassembled. Attached is a blank label. Record the module’s part and serial
number by hand on it.

Remove the instrument cradle according to 3.2.4 and the sealing cartridge according to 3.2.2.
Install these components into the new housing and reconstruct all pneumatic and electrical
connections again.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X

3.3.11.2 Replacement of the PCB (incl. charging PCB for X-am+)

Disassemble the module according to 3.3.6and remove the top housing. Loosen the cable for the
valve control and the four hex Allen screws and lift the PCB out of the housing. Take care for the
tubing and the valve block. Remove the plastic guide rail and reuse it for the new PCB.

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In case it is an X-am+ Module with charging function and a failure of the charging PCB can be
excluded, it could be reused. Loosen the plastic discs with a slot screwdriver and the plug
connection underneath.

Ensure that a SD card is inserted again before building in the new PCB. Use either the old SD card
or a new SD card, which is now available as a spare part and insert it at the bottom of the PCB.
After that, use the guide rail again for the new PCB.

Now, link the charging PCB of the X-am+ Module and hand tight the plastic screws.

Place the PCB now in reverse order in the housing and fix it with the four screws with a tightening
torque of 35 N/cm. The orange marked screw is the last one to tighten.

Finally, configure the PCB to the appropriate module according to the following switch positions
(the PCB’s switch positions see 3.3.7).

Note:
The DIP layout has been changed. Older PCBs in the field have a different jumper
setting! The current design is using two 3-dip-switches.
The old layout used one 3-dip-switch and two 1-dip-switches.

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Layout with two 3-dip-switches (current layout):

X-am / X-am+ Module Pac Module

Layout with one 3-dip-switche and two 1-dip-switches (first/old layout):

X-am / X-am+ Module Pac Module

Note
A configuration of the new PCB by software is not necessary. A firmware is
preinstalled. The part number and the altered serial number of the module are
available on the insert. The SD card will be configured automatically as well.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X

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3.3.11.3 Replacement of the 3/2 – way valve
For this work step only the top housing has to be removed and put aside. Then, loosen the two hex
Allen screws of the valve, the tubing and the control contact and lift off the valve. The new 3/2 way
valve will be delivered with two spare screws and spare o-rings. Exchange the o-rings and pay
attention to the correct positioning. It is defined by an indentation in the valve block.

Finally, fix the new valve with the two screws and a torque of 25 N/cm and reconstruct all
pneumatic and electrical connections.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X

3.3.11.4 Replacement of the valve block

When a change of the entire valve block is necessary, the complete chapters of 3.3.11.2 for the
disassembly and assembly of the PCB must be considered. After having removed the PCB detach
the tubing and unscrew the valve block.

Fix the new valve block (see picture) with the two hexagon screws with a tightening torque of 35
N/cm and reconstruct the tubing (see tubing layout module 3.3.8). Now, assemble again the PCB,
link the valve control with the PCB and assemble the module again.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X

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3.3.11.5 Replacement of the non-return valve
Open the housing according to 3.3.6 and remove the old non-return valve from the hose of the gas
recirculation. Now insert the new valve. Pay attention to the flow direction. The small arrow on the
valve must point in the direction of the valve block / PCB (see pictures).

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X

3.3.11.6 Replacement of the tubing

The spare set “Hoses“ (8321967) contains the 1.5 x 0.75 mm Viton hose for the pressure sensor’s
connection as well as the 3.0 x 1.0 mm FPM standard hose for all the other hose connections. Cut
to length as required or for the appropriate position.

3.0 x 1.0 mm FPM 290 mm 125 mm 100 mm 4x 56 mm

As an aid to install or place the hoses correctly take the pictures from Chapter 3.3.8.

Necessary tests (see Chapter 2.6)

S1 S2 S3 S4
X X

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4. Module deviations “AA-Version”
4.1 AA-Version in general

The AA-Version has a slightly different module-to-module connector. Instead of using the rubber
connector the hoses must be attached manually. To reach the hoses an additional plate at the
bottom was introduced which can be opened and closed.

The master is always the same but the modules have a different connection on the right side.

4.2 AA-Version in general

The AA-Version has a slightly different module-to-module connector. Instead of using the rubber
connector the hoses must be attached manually. Furthermore a plate offers the necessary access.

The following picture shows the plate:

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After removing the plate the hoses can be seen:

The hoses must directly be connected to the connector block as seen in the picture.

The last module needs to be treated differently:

Hose 1 and 4 need an end plug.

Hose 2 and 3 must be connected with a special connector.

Please refer to the training videos and the assembly instructions for further information how to
assemble and disassembly the AA-Version.

4.3 Service on AA-Versions

There is not a big difference in the service on the AA-Versions. The repair instructions are the
same but with a slightly different assembly and disassembly.

Two additional spare parts exist:

Bottom cover with screw: 8321954

End plugs and hose connector: 8321963

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5. Maintenance Software
5.1 Software repair with use of “scripts”

The service may (currently no script is released) get script files which will be necessary for the
correction of more in-depth software problems. This procedure is intended for special actions which
will be announced by a service information when necessary.

To run them, save the file you want to use on an USB stick and put it in a switched off station.
Now, start the station and press the start button for additional 30 seconds. The station will now
search for a script file and will run it.

Note:
There must not be more than one script file on the plugged in USB stick. Otherwise,
the station will not run any file.

5.2 Software repair in general

Please refer to the Doris service information and D-World news for current known issues and how
to repair.

E.g. the SD card update (service information no. 2) will fix nearly all known non-systematic
software issues but all data/configuration is lost on the X-dock itself.

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5.3 Error messages

Occurred error Action

Certificate creation for test %s in Check SD card: Plugged in? Full?
module %u failed: %s Check MSD, when not accessible exchange SD

Database error: Tidy up the database via menu (attention: test data
will be lost)
Errors in EEPROM data Reinstall SW, exchange PCB when necessary
Error when mounting the first SD Check SD card: Plugged in?
partition If yes exchange SD
Error when mounting the second SD Check SD card: Plugged in?
partition If yes exchange SD
Error receiving device data from Check plug connection.
module %u Exchange Module PCB when necessary
Error retrieving test results. Check plug connection.
Exchange Module PCB when necessary
Error sending message to database: Tidy up the database via menu (attention: test data
will be lost)
Error sending message to module: Check plug connection.
Exchange Module PCB when necessary
Error sending message to user Restart the station, at repeatedly occurrence
interface: reinstall SW, exchange Master PCB when
necessary
Error: leakage with fresh air line: %s Check pneumatic connections.
Exchange connection components when necessary
Error: leakage with test gas line: %s Check pneumatic connections.
Exchange connection components when necessary
Error: pressure sensor offset: %s Check pneumatic connections.
Exchange Master PCB when necessary
Error: pressure span with compressed Check pneumatic connections. Check fresh air
air: %s supply.
Exchange Master PCB when necessary
Error: pressure span with pump: %s Check pneumatic connections.
Check filter.
Exchange pump or Master PCB when necessary

Error: pressure span with test gas: %s Check pneumatic connections.

Check test gas supply.
Exchange Master PCB when necessary
Error: leakage with fresh air line: %s Check pneumatic connection.
Exchange connection components when necessary
Error: leakage with test gas line: %s Check pneumatic connection.
Exchange connection components when necessary
Error: pressure sensor offset: %s Check pneumatic connection.
Exchange Master PCB when necessary
Error: pressure span with compressed Check pneumatic connections.
air: %s Check fresh air supply.
Exchange Master PCB when necessary

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Error: pressure span with pump: %s Check pneumatic connections.
Check filter.
Exchange pump or Master PCB when necessary

Error: pressure span with test gas: %s Check pneumatic connections.

Check test gas supply.
Exchange Master PCB when necessary
Expected software version %s not Perform SW Update
found in module %d. Installed software
version: %s.
Internal error during self test Restart the station.
Reinstall SW, exchange Master PCB when
necessary
Internal error: Restart the station.
Reinstall SW, exchange Master PCB when
necessary
Internal error: Module %d reset. Restart the station.
Reinstall SW, exchange Module PCB when
necessary
Invalid device data received: Update instrument SW, clean IR Diode, exchange
Module PCB when necessary
Invalid test parameters: no favorite Check favorites configuration
selected
Invalid test type Check favorites configuration
Leak test failed. Check pneumatic connections.
Exchange connection components when necessary
Leakage test with fresh air Check pneumatic connections.
Exchange connection components when necessary
Leakage test with test gas Check pneumatic connections.
Exchange connection components when necessary
Reset of master detected Reinstall SW, check SD cards, at repeatedly
occurrence exchange Master PCB

Module %d exceeded boot time. Try to Restart the station. SD cards plugged-in?
reboot. Exchange Module PCB when necessary
Module %d not found. Try to reboot. Restart the station. SD cards plugged-in?
Exchange Module PCB when necessary
Module reset. Restart the station, SD cards plugged in?
Exchange Module PCB when necessary, in case of
unknown modules add each module and test it
individually
More than %d modules detected. Disassemble module
Operation not possible.
No tests found in favorite list. Check favorites configuration
Pressure sensor offset test Check pneumatic connections.
Exchange Master PCB when necessary
Pressure sensor span test with Check pneumatic connections.
compressed air Check fresh air supply.
Exchange Master PCB when necessary
Pressure sensor span test with pump Check pneumatic connections.
Check pump.
Exchange pump and /or Master PCB when
necessary

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Pressure sensor span test with test gas Check pneumatic connections.
Check test gas supply.
Exchange Master PCB when necessary
Self-test not passed, Station error %d, Perform software update when necessary
%s
Self test timed out Restart the station, at repeatedly occurrence
reinstall SW.
Exchange Master PCB when necessary
Test configuration Check configuration
Test gas configuration for valve Check configuration
The current station status does not Restart the station
allow tests: %s
Time-out Restart the station
Too many modules found. The Disassemble the module
maximum number is %d.
Unrecoverable device error Start master only, afterwards add each module
individually.
Exchange affected PCB when necessary
Wrong module count during self test. Check electrical connections. Connect modules
step-by-step and restart in between.
Exchange PCB when necessary in case the
module is faulty

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