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GENERAL INFORMATION

I-5

HOW TO USE THIS MANUAL

Who it is for

The Base PowerCharger

4x4

Service Manual is a basic technical reference document

designed for biomedical engineering personnel whose responsibilities include
maintenance and repair of medical equipment.

Purpose

Its purpose is to provide the basic information needed to allow biomedical engineering
personnel to identify and/or repair the Base PowerCharger

4x4

to the sub-assembly

(printed circuit board) level.

Recommended Use

The Service Manual should be readily available in the facility's equipment maintenance
library. It will be used for preventive maintenance checks and for troubleshooting when
problems are reported.

The Operator's Guide, included as Appendix A, will be used in training new operators
and for operational reference. This copy should be kept with the Base PowerCharger

4X4

Service Manual. A separately bound copy should be kept with the Base PowerCharger

4X4

device.

The Service Manual consists of several key sections:

Section I: General Information

This section contains a number of important notices and reference material, including
safety warnings and ZOLL's warranty statement.

Be sure to review this section

thoroughly before attempting to use or service the Base PowerCharger

4x4

device.

Section II: Checkout Procedures

This section contains information you need in order to verify that the Base
PowerCharger

4X4

is functioning properly, and procedures for checking the Base

PowerCharger

4X4

.

For daily inspection and operational checks, see the Operator's Manual.

Section III: Troubleshooting Guides

This section contains an operational troubleshooting section, for use by non-technical
personnel to respond to common problems detected during Base PowerCharger

4X4

operational use.

Section IV: Functional Descriptions

This section provides a basic technical description of the Base PowerCharger

4X4

main

subassembly modules. The information should be thoroughly reviewed before servicing.

Section V: Schematic Drawings

Major circuit board schematics are included for troubleshooting purposes.

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Содержание Base Powercharger 4x4

Страница 1: ...9650 0072 01 Rev E ZOLL Base Powercharger 4x4 Service Manual...

Страница 2: ...II Checkout Procedures Leakage Current Test II 2 Functional Tests II 2 Manual Test II 3 Checkout Procedure II 4 III Troubleshooting Guides TroubleShooting Table III 2 Fault Codes Table III 3 Definitio...

Страница 3: ...VI 3 Removing the Main PCB Assembly VI 5 Removing the Heat Sink VI 7 Removing the Transformer VI 9 Removing the Power Entry Module VI 12 Removing the Battery Harness and Contact Pins VI 14 VIII Repla...

Страница 4: ...erence from high power sources Use only the AC power line cord supplied with the device Failure to use the proper line cord could result in excess leakage currents and reduced safety Only Qualified Pe...

Страница 5: ...d effectiveness data submitted to the Food and Drug Administration FDA under section 510 K of the Medical Device Act by ZOLL Medical Corporation to obtain approval to market is based upon the use of Z...

Страница 6: ...er4X4 device The Service Manual consists of several key sections Section I General Information This section contains a number of important notices and reference material including safety warnings and...

Страница 7: ...nformation Section VIII Replacement Parts This section contains a detailed listing of ZOLL part numbers for field replaceable parts available for the Base PowerCharger 4x4 and will allow the service p...

Страница 8: ...GENERAL INFORMATION I 7 SEE FILE PG7_C PM5 FOR THIS PAGE AND ALL OF THE SYMBOLS...

Страница 9: ...biomedical engineering department perform routine tests of the device to verify proper operation See Section II U S A customers Should the Base PowerCharger4X4 require service contact the ZOLL Technic...

Страница 10: ...nearest authorized ZOLL Medical Corporation service center To determine which authorized ZOLL Medical Corporation service center to use write call or fax ZOLL Medical Corporation 32 Second Avenue Burl...

Страница 11: ...GENERAL INFORMATION I 10...

Страница 12: ...er operation at least once every six months This section contains information you need in order to verify that the Base PowerCharger4x4 is functioning properly Daily operational checks are described i...

Страница 13: ...CHECKOUT PROCEDURES 9650 0072 II 2 Rev D...

Страница 14: ...ine Voltage Hot to Neutral N A Hot to Gnd N A Neutral to Gnd N A Current Consumption N A Chassis Leakage Normal Pol w Ground 500 A Normal Pol No Ground 500 A Reverse Pol No Ground 500 A Reverse Pol w...

Страница 15: ...ctive action NOTE The device under test should be at operating temperature before checking adjusting voltages Device powered up for a minimum of 20 minutes Set the DVM to VOLTS DC Test each battery co...

Страница 16: ...E TEST Perform this Action Limits Circle the Result 1 1 Chassis Leakage Normal Pol w Ground Normal Pol No Ground Reverse Pol No Ground Reverse Pol w Ground 500 A 500 A 500 A 500 A YES or NO YES or NO...

Страница 17: ...Result 3 1 Remove all batteries from the Base PowerCharger4x4 Press each battery compartment TEST button 4 Set DVM to VOLTS DC Test each battery compartment All LED s illuminate momentarily the Batt...

Страница 18: ...mmon problems or questions that arise during operation If trouble persists after consulting this guide contact the appropriate technical personnel or ZOLL Technical Service Department TABLE OF CONTENT...

Страница 19: ...defective Battery fails test cycle FAULT light illuminates with TESTING light Verify that the battery compartment is fully operational with no defects Press and hold the TEST button to determine the...

Страница 20: ...verCharge ON ON OFF ON Temperature ON OFF ON ON Low Battery Voltage ON OFF ON OFF High Constant Current ON OFF OFF ON Shutdown OFF ON ON ON High Battery Voltage OFF OFF ON ON Battery Capacity OFF OFF...

Страница 21: ...ternal five 5 volt supply deviated from specified range High Constant The amount of current during a charge was above specified Current range Shutdown Safety shutdown 2 is not operating properly shutd...

Страница 22: ...ation of the circuits and supplements the troubleshooting guides in Section III of this manual For additional information refer to the associated schematics found in Section V TABLE OF CONTENTS 1 Syst...

Страница 23: ...e of powering a PD 1400 D 1400 or PD 2000 D 2000 for approximately 2 0 hours in Monitor mode Fully charged batteries whose capacity is insufficient to power the devices for this period of time will ca...

Страница 24: ...the PD1400 1600 2000 Pacemaker Defibrillator family of products that are compatible with the Base PowerCharger4x4 S Microseconds 2 COMMON CIRCUITRY DESCRIPTION As shown in the attached Block Diagram...

Страница 25: ...final over voltage protection for the logic supplies For more details on buck converter operation see Switchmode Power Supply section Reference Voltages A two terminal 1 235V band gap reference U9 is...

Страница 26: ...for each battery detect op amp input to keep the working voltage range within the VCC supply voltage Each op amp within U5 is configured as a comparator with a 1 2V threshold reference presented to th...

Страница 27: ...Pin In Out Analog Digital Signal Name Description P0 0 D Not Used P0 1 D Not Used P0 2 D Not Used P0 3 O D WDO Watchdog output P0 4 O D CAPOUT PWM Capacity Level Indicator P1 0 I A V_BATT Battery Vol...

Страница 28: ...a power on reset circuit to insure that the microprocessor is held RESET until the 5 volt VCC power supply is stable The watchdog timer continues to monitor the power supply and drives RESET high if t...

Страница 29: ...d Diode D111 is provided to prevent the voltage transition which comes through C132 from exceeding the high and low input signal requirements of the CMOS logic at U107 9 and U107 10 One of two possibl...

Страница 30: ...he signal range within the input requirements of the op amp device U105A The resulting output signal at U105 1 ranging from 0 to 4 85 volts is read by the microprocessor at its analog input U104 13 Ca...

Страница 31: ...switch is closed When the switch is opened current starts to decrease through the inductor The voltage at the cathode of D113 clamps to 0 4V as the current through the inductor decreases V L di dt Wi...

Страница 32: ...mplifier U102A Operation of this amplifier is similar to that of U102A with resistor divider R118 and R101 providing a reference voltage to compare against the voltage generated across current sense r...

Страница 33: ...LED12 for charging compartment 3 and LED13 LED16 for charging compartment 4 All of the drive and interface electronics for these devices are located on the main PCB and are described in the Display Dr...

Страница 34: ...capacity is insufficient the TESTING and FAULT indicators will be activated at the end of the capacity test and the battery will be recharged if possible To abort this mode the user must either remove...

Страница 35: ...time T required to arrive at this CC charge point The controller will then switch to a constant current charging mode and charge the battery at a CC charge rate until the battery s voltage peaks i e...

Страница 36: ...ill be performed by the system to insure product safety and simplify assembly and test requirements Power Up As AC power is applied the controller will perform a series of internal tests to determine...

Страница 37: ...r supply is within tolerance OverCharge Timer test Performed during the CV CC charge sequence Limit the amount of time battery is subjected to charge to less than 4 AH Battery Voltage validity Perform...

Страница 38: ...rCharger4x4 schematic drawings are included here to supplement the information presented in Section III Troubleshooting Section IV Functional Descriptions Section VI Component Layout Drawings LIST OF...

Страница 39: ...SCHEMATIC DRAWINGS V 2...

Страница 40: ...SCHEMATIC DRAWINGS V 3 DWG NO SCALE NONE REV B SHT OF 9301 0145 SC ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 1 1 SCHEMATIC PCB DISPLAY KEYBOARD...

Страница 41: ...MANUAL V 4 DWG NO SCALE NONE REV B SHT OF 9301 0147 SC ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 1 7 SCHEMATIC PCB SYSTEM BASE POWERCHARGER4X4 NOT USED ON BASE POWERCHA...

Страница 42: ...SCHEMATIC DRAWINGS V 5 DWG NO SCALE NONE REV B SHT OF 9301 0147 SC ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 2 7 SCHEMATIC PCB SYSTEM BASE POWERCHARGER4X4...

Страница 43: ...SERVICE MANUAL V 6 DWG NO SCALE NONE REV B SHT OF 9301 0147 SC ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 7 3 SCHEMATIC PCB SYSTEM BASE POWERCHARGER4X4...

Страница 44: ...147 SC ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 7 4 SCHEMATIC PCB SYSTEM BASE POWERCHARGER4X4 NOTES 1 ALL RESISTORS ARE 1 TOLERANCE UNLESS OTHERWISE SPECIFIED 2 ALL CAP...

Страница 45: ...SERVICE MANUAL V 8 DWG NO SCALE NONE REV B SHT OF 9301 0147 SC ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 7 5 SCHEMATIC PCB SYSTEM BASE POWERCHARGER4X4...

Страница 46: ...SCHEMATIC DRAWINGS V 9 DWG NO SCALE NONE REV B SHT OF 9301 0147 SC ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 7 6 SCHEMATIC PCB SYSTEM BASE POWERCHARGER4X4...

Страница 47: ...SERVICE MANUAL V 10 DWG NO SCALE NONE REV B SHT OF 9301 0147 SC ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 7 7 SCHEMATIC PCB SYSTEM BASE POWERCHARGER4X4...

Страница 48: ...owerCharger4x4 component layout drawings are included here to supplement the information presented in Section III Troubleshooting Section IV Functional Descriptions Section V Schematic Drawings LIST O...

Страница 49: ...COMPONENT LAYOUT DRAWINGS VI 2...

Страница 50: ...COMPONENT LAYOUT DRAWINGS VI 3 DWG NO SCALE NONE REV B SHT OF 9301 0145 AD ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 1 1 ASSY DWG PCB LED BASE POWERCHARGER4X4...

Страница 51: ...SERVICE MANUAL VI 4 DWG NO SCALE NONE REV A SHT OF 9301 0147 AD ZOLL ZOLL MEDICAL CORPORATION 32 SECOND AVENUE BURLINGTON MA 01803 TITLE 1 1 ASSY DWG PCB SYSTEM BASE POWERCHARGER4X4...

Страница 52: ...hould be serviced by qualified personnel ONLY Before removing any components be sure the unit is unplugged and all batteries have been removed from the unit Be sure to observe anti static precautions...

Страница 53: ...DISASSEMBLY PROCEDURES VII 2...

Страница 54: ...2 Phillips head screwdriver 1 Remove the eight 8 screws as shown in the illustration 2 Lift Base Pan straight up and remove INSTALLING THE BASE PAN TOOLS REQUIRED No 2 Phillips head screwdriver 1 Rev...

Страница 55: ...DISASSEMBLY PROCEDURES VII 4...

Страница 56: ...ve two 2 screws securing the Stabilizer Bracket 7 Remove eight 8 screws securing the Main PCB to the Upper Housing 8 Remove five 5 screws securing the four 4 resistors and one 1 bridge rectifier from...

Страница 57: ...DISASSEMBLY PROCEDURES VII 6...

Страница 58: ...DISASSEMBLY PROCEDURES VII 7...

Страница 59: ...NK TOOLS REQUIRED No 1 Phillips head screwdriver 1 Reverse steps 2 thru 7 above CAUTION When reconnecting the components to the Heat Sink check the following That there are no burrs nicks or scratches...

Страница 60: ...DISASSEMBLY PROCEDURES VII 9...

Страница 61: ...crews from the upper mounting bracket of the Transformer 4 Remove the upper mounting bracket and screws 5 Remove the Transformer INSTALLING THE TRANSFORMER TOOLS REQUIRED No 1 Phillips head screwdrive...

Страница 62: ...DISASSEMBLY PROCEDURES VII 11...

Страница 63: ...DISASSEMBLY PROCEDURES VII 12...

Страница 64: ...Remove two 2 screws securing the Rear Plate to the Upper Housing 8 Remove the Rear Plate and Power Entry Module together as a unit 9 Remove grounding screw from the Rear Plate 10 Remove two 2 screws...

Страница 65: ...DISASSEMBLY PROCEDURES VII 14...

Страница 66: ...Cut two 2 tie wraps 4 Remove the twelve 12 Battery Contact Pins securing the Battery Harness to the Upper Housing 5 Remove the Battery Harness INSTALLING THE BATTERY HARNESS AND BATTERY CONTACT PINS T...

Страница 67: ...DISASSEMBLY PROCEDURES VII 16...

Страница 68: ...rt number Description of the replacement part ZOLL reserves the right to substitute different parts to reflect modifications and improvements in ZOLL BasePowerCharger4x4 circuitry and design To order...

Страница 69: ...163 0912 13 Sem Screw 4 40x1 4 0163 0900 14 Sem Screw 6 32x1 4 0163 0910 15 Sem Screw w Int 6 32x1 2 0163 0940 16 Keycap Test Switch 9310 0279 17 Earth Ground Main Assembly 9500 0073 18 Earth Ground B...

Страница 70: ...h Nylon Insert 0163 0044 34 HeatSink 9165 0002 35 HeatSink Mounting Base 9320 0047 36 Label Screw Cover 9305 0101 37 Slow Blow Fuse 2A 250V 0180 0003 38 Label Fuse Warning 9305 0258 01 39 Shrink Tubin...

Страница 71: ...REPLACEMENT PARTS VIII 4...

Страница 72: ...om with the latest revison level Refer to diagram for correct orientation of the software proms 4 Remove JP3 from Pins 1 and 2 5 Carefully place JP3 on Pins 2 and 3 Refer to diagram for correct locati...

Страница 73: ...A 2 Base PowerCharger4x4 Operator s Guide...

Страница 74: ...oor Make sure the voltage setting appears in the window of the door External Fuses Voltage Drum Door Appendix B Changing the AC Line Setting of the Base PowerCharger4x4 The voltage wheel can be found...

Страница 75: ...B2 Base PowerCharger4x4 Operator s Guide...

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