Zoll Base Powercharger Service manual
ZOLL Base Powercharger
Service Manual
4x4
9650-0072-01 Rev. E
GENERAL INFORMATION
SECTION I
GENERAL INFORMATION
TABLE OF CONTENTS
DESCRIPTION SECTION
I. General Information
• Table of Contents .............................................................................I-1
• Safety Considerations ...................................................................... I-3
• How to Use This Manual .................................................................. I-5
• Symbols used on the Equipment......................................................I-7
• Service Policy ................................................................................... I-8
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
• Definition of Fault Code..................................................................III-4
IV. Functional Descriptions
• System........................................................................................... IV-2
• Common Circuitry Description....................................................... IV-3
• Bay Circuitry Description ............................................................... IV-5
• LED PCB ..................................................................................... IV-12
V. Schematic Drawings
• Display / Keyboard. ........................................................................ V-3
• System............................................................................................ V-4
VI. Component Layout Drawings
• LED................................................................................................ VI-3
• System .......................................................................................... VI-4
I-1
VII. Disassembly Procedures
• Removing the Base Pan................................................................ 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. Replacement Parts
• Field Replaceable Units .............................................................. VIII-2
APPENDIX A OPERATOR'S MANUAL
GENERAL INFORMATION
I-2
GENERAL INFORMATION
SAFETY CONSIDERATIONS
WARNINGS
General
• The following is a list of service related safety considerations. For
operation related safety considerations see the Base
PowerCharger
aware of all safety considerations prior to servicing the equipment.
• THE BASE POWERCHARGER
SERVICED BY QUALIFIED PERSONNEL ONLY! Unauthorized
persons should not attempt to service this device.
• The Base PowerCharger
radio frequency emissions typical of two-way radios used in
emergency service/public safety activities. Users of the Base
PowerCharger
environment of use for the possibility of radio frequency interference
from high-power sources.
4x4
Operator's Guide. Service Technicians should be
4x4
DEVICE SHOULD BE
4x4
is protected against interference from
4x4
should assess the devices’ performance in their
• 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 Personnel should disassemble the PowerCharger
4x4
.
A shock hazard exists. Refer all problems to ZOLL Technical
Service.
• Follow all recommended maintenance instructions. If a problem
occurs, obtain service immediately. Do not use the Base
PowerCharger
4x4
until the unit has been inspected by the appropriate
personnel.
• Do not place anything on top of the Base PowerCharger
4x4
. Doing so
may block the vents on the unit, preventing proper dissipation of heat
during operation.
• Do not sterilize the Base PowerCharger
4x4
.
• Do not use alcohol or ketones (MEK, acetone, etc.) on the Base
PowerCharger
• Always wait until the Base PowerCharger
4x4
.
4x4
has completed its
charge cycle before removing batteries.
• Repeated use of partially charged batteries will reduce their capacity
and operating life.
I-3
Operator Safety
GENERAL INFORMATION
• Do not operate the Base PowerCharger
4x4
in the presence of
flammable agents (such as gasoline), oxygen-rich atmospheres, or
flammable anesthetics. Using the device near the site of a gasoline
spill may cause an explosion.
• Do not immerse or set the Base PowerCharger
4x4
in fluid. Using the
device near or within puddles of water is a shock hazard to the
operator, patient, and nearby personnel.
Patient Safety
• Do not mount the device directly above the patient. Locate the Base
PowerCharger
harm the patient if they fall.
4x4
and ZOLL resuscitation devices where they cannot
Caution
• Do not discharge a PD 4410 battery pack except in a Base
PowerCharger
device.
• Safety and 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 ZOLL accessories such as disposable electrodes,
patient cables and batteries. ZOLL cannot make representations as
to safety and clinical effectiveness when a device is used with nonZOLL accessories. Users assume all responsibility for the safety and
effectiveness of ZOLL products if used with non-ZOLL accessories.
Further, ZOLL disclaims all implied and expressed warranties,
including warranties of fitness and merchantability, and all product
liability to the extent possible in the event of the use of a non-ZOLL
accessory.
4x4
or compatible ZOLL Battery Charging/Testing
• The equipment may only be used with disposables, accessories, and
consumable items when an agency, accredited for the testing of the
equipment, has established that those items, in their intended use,
meet its safety requirements.
I-4
Who it is for
GENERAL INFORMATION
HOW TO USE THIS MANUAL
The Base PowerCharger
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
(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
Service Manual. A separately bound copy should be kept with the Base PowerCharger
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
Service Manual is a basic technical reference document
4x4
to the sub-assembly
4x4
device.
4X4
4X4
Section II: Checkout Procedures
This section contains information you need in order to verify that the Base
PowerCharger
PowerCharger
4X4
is functioning properly, and procedures for checking the Base
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.
I-5
GENERAL INFORMATION
Section VI: Component Layout Drawings
Major component layout drawings are included for troubleshooting purposes.
Section VII: Disassembly Procedures
Step-by-step instructions are provided for removing subassemblies in the event of failure.
Refer to the Service Policy in Section I for return and repair information.
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 person to identify and
order replacement parts. No attempt to replace parts at the component level should be
attempted or the ZOLL warranty may be voided.
Appendix A: Operation
The Operator's Manual has been reproduced here for convenience and consistency. It
should be read and understood before attempting any service procedure.
I-6
GENERAL INFORMATION
SEE FILE PG7_C.PM5
FOR THIS PAGE AND ALL OF THE
SYMBOLS
I-7
SERVICE POLICY
WARRANTY
In North America: Consult your purchasing agreement for terms and conditions
associated with your warranty.
Outside of North America: Consult ZOLL authorized representative.
In order to maintain this warranty, the instructions and procedures contained in this
manual must be strictly followed.
For additional information, please call the ZOLL Technical Service Department at
1-800-348-9011 in North America
1-781-229-0020 outside of North America
SERVICE
GENERAL INFORMATION
The Base PowerCharger
4X4
will provide trouble free operation without periodic
recalibration or adjustment. However, it is recommended that the biomedical engineering
department perform routine tests of the device to verify proper operation. (See Section
II.)
U.S.A. customers
Should the Base PowerCharger
4X4
require service, contact the ZOLL Technical Service
Department to obtain a return claim number. The unit should be returned, in its original
container, to:
ZOLL Medical Corporation
32 Second Avenue,
Burlington, Massachusetts 01803-4420,
Attn: Technical Service Department
Loaner instruments are available for use while repairs are being completed. To request
loan equipment, contact ZOLL at 1-800-348-9011 (in Massachusetts: 1-781-229-0020).
Please have the following information available to expedite service:
• Unit serial number
• A description of the problem
• Department where equipment is in use
• A Purchase Order to allow tracking of loan equipment
• A Purchase Order for systems out of warranty
I-8
International Customers
GENERAL INFORMATION
Should the Base PowerCharger
4X4
require service, it should be returned, in its original
container, to the 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,
Burlington, Massachusetts 01803-4420, USA
Attn: International Sales Department
1-781-229-0020 (voice)
or
1-781-272-5443 (fax)
Attn: International Sales Department
I-9
GENERAL INFORMATION
I-10
CHECKOUT PROCEDURES
SECTION II
CHECKOUT PROCEDURES
ZOLL recommends that you check your Base PowerCharger
least once every six months.
This section contains information you need in order to verify that the Base
PowerCharger
Daily operational checks are described in Section 3, Maintenance and
TroubleShooting in the Operator's Guide.
4x4
is functioning properly.
4x4
for proper operation at
TABLE OF CONTENTS
1. Leakage Current Test......................................................................................................II-2
2. Functional Test ...............................................................................................................II-2
9650-0072 II-1 Rev. D
CHECKOUT PROCEDURES
9650-0072 II-2 Rev. D
LEAKAGE CURRENT
• Perform Leakage Current Test per your manufacturer's recommended procedure
found in the Operator's Manual of your Leakage Tester.
CHECKOUT PROCEDURES
Observe:
• After the test is complete, fill in the date , operator, and Base PowerCharger
serial number on the Test Data Sheet (Page II-4). Review the results against the
limits below for any test that failed. If any test fails, circle the failed test on the
Test Data Sheet and take corrective action.
• Record results on Test Data Sheet (Page II-4).
TEST 90 - 265 VAC LIMITS
Gnd Wire Resistance N/A
Line 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
Normal Pol. No/Ground
< 500 µA
< 500 µA
4x4
Reverse Pol. No/Ground
Reverse Pol. w/Ground
Ground Wire Leakage
Normal Pol. No/Ground
Reverse Pol. No/Ground
< 500 µA
< 500 µA
< 500 µA
< 500 µA
FUNCTIONAL TESTS
Continuity and Isolation Test
• Take a measurement of the Digital Volt Meter (in ohms) by shorting the two (2)
leads of the DVM.
• Record Results on Test Data Sheet (Page II-4).
• Place the red lead of the DVM on any part of the unit where there is exposed
metal, except for the battery terminals, and place the black lead of the DVM on
the ground part of the powercord.
• Record Results on Test Data Sheet (Page II-4).
• Subtract the two values and the difference should be less than 1 ohm.
9650-0072 II-3 Rev. D
• Record Results on Test Data Sheet (Page II-4).
MANUAL TEST
• Check to see that the unit is connected to live AC mains. The POWER light
• Remove all batteries from the Base PowerCharger
• Press each of the four (4) TEST buttons corresponding to each of the four (4)
• The unit will light all of the LED's associated with the compartment for a few
• Ensure that all of the FAULT indicators are off.
• If any of the FAULT lights are lit, the compartment is defective in some way. To
NOTE: The device under test should be at operating temperature before
CHECKOUT PROCEDURES
should be lit.
4x4
.
battery compartments.
seconds. This will be followed by a beep and then the TESTING and BATT.
READY LED's will light for a couple of seconds. Then all LED's extinguish.
identify the defect press and hold the TEST button. Illumination of specific
indicator lights together represent a specific defect. (Refer to FAULT CODES
TABLE on page III-3 to identify the fault and take corrective action).
checking/adjusting voltages. (Device powered up for a minimum of 20
minutes).
• Set the DVM to VOLTS DC.
• Test each battery compartment seperately by placing the Black lead of the DVM
on the left battery contact pin of the battery compartment and place the RED lead
of the DVM on the shrouded (middle) pin of the same battery compartment.
• The voltage measurement on the DVM should be 11.86 ± 0.10 VDC.
• Record Results on Test Data Sheet (Page II-4).
• If the voltage measurement is NOT 11.86 ± 0.10 VDC, adjust RV1 (on 9301-
0147) until the correct value is displayed.
AUTO TEST OPTION
• Install battery into any well and observe that the CHARGER ON and TESTING
LED’s are illuminated.
NOTE: The CHARGER ON and TESTING LED’s may go off within minutes,
depending on the charge state of the battery pack installed. (i.e., Fully
Charged)
QUICK CHARGE OPTION
• Install battery into any well and observe that the CHARGER ON LED remains
illuminated until the battery is “READY”.
• The TESTING LED will not
turn on by installing a battery into the charger.
9650-0072 II-4 Rev. D
CHECKOUT PROCEDURES
BASE POWERCHARGER
4X4
DEVICE CHECKOUT PROCEDURE
DATA SHEET
S/N___________ OPERATOR___________ DATE_________
COPY THIS FORM BEFORE USING
SECTION 1. LEAKAGE 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 µA
< 500 µA
< 500 µA
< 500 µA
YES or NO
YES or NO
YES or NO
YES or NO
1.2 Ground Wire Leakage
Normal Pol. No/ Ground
Reverse Pol. No/ Ground
< 500 µA
< 100 µA
YES or NO
YES or NO
SECTION 2. FUNCTIONAL TEST
Perform this Action: Look for : Circle the Result:
9650-0072 II-5 Rev. D
CHECKOUT PROCEDURES
2.1 Continuity and Isolation
Resistance measurement
of two (2) leads shorted
to one another.
Resistance measurement
with Red lead on metal
and Black lead on
powercord ground.
Subtract the two values
above.
Record value:
________ohms
Record value:
________ohms
Difference should be < 1 ohm
YES or NO
SECTION 3. MANUAL TEST
Perform this Action: Look for : Circle the Result:
3.1 Remove all batteries from
the Base PowerCharger
Press each battery
compartment TEST
button (4).
Set DVM to VOLTS DC.
Test each battery
compartment
4x4
All LED's illuminate
momentarily, the Batt. Ready
and Testing light illuminate
alone and then, all LED's go
off.
Ensure FAULT indicators are
all off.
Voltage is 11.86 ± 0.10 VDC
YES or NO
YES or NO
YES or NO
YES or NO
YES or NO
SECTION 4. AUTO TEST
For 4 x4 base chargers that are configured as auto test units.
Perform this Action: Look for : Circle the Result:
4.1 Install Battery into any
well .
9650-0072 II-6 Rev. D
Charger on and testing LED’S
illuminate.
YES or NO
TROUBLESHOOTING GUIDES
SECTION III
TROUBLESHOOTING
This section answers many of the common 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 CONTENTS
1. TroubleShooting Table.................................................................................................. III-2
2. Fault Codes Table .......................................................................................................... III-3
3. Definition of Fault Codes .............................................................................................. III-4
III-1
TROUBLESHOOTING TABLE
Symptoms TroubleShooting Method and Possible
POWER light does not illuminate.
CHARGER ON indicator light does not
illuminate when battery is inserted into
compartment.
TESTING light does not illuminate when
TEST button is pressed.
Battery fails test cycle. (FAULT light
illuminates with TESTING light).
TROUBLESHOOTING GUIDES
Causes
• Check that the unit is plugged into an
appropriate power source.
• Check for defective power cord.
• Plug unit into another power source.
• Check for blown fuse. Disconnect power
cord and open fuse holder to check fuses.
• Check that the battery is properly seated
in battery compartment.
• Check that battery contacts are clean and
not damaged.
• Check that unit is plugged into an
appropriate power source.
• Test the battery compartment for
functionality.
• Place another battery in the compartment.
• Check that the battery is properly seated
in compartment.
• Check that unit is plugged into an
appropriate power source.
• Remove the battery and press the TEST
button to perform a compartment self-test.
If it does not self-test the button is
defective.
• Verify that the battery compartment is fully
operational with no defects.
• Press and hold the TEST button to
determine the fault code. (See Fault
Codes Table on Page III-3).
• If all FAULT LED's are on most likely
there is a failure in the common circuitry.
When the unit does not follow the Power-Up sequence explained elsewhere in this
manual or if a fault light comes on at any time follow the steps listed below to identify
the fault.
Note: The unit can be run through it 's self-test at any time, as long as there is no
battery installed, by pressing the TEST button. When the self-test is invoked on a
single battery compartment the unit will respond by lighting all the LED's associated
with the compartment for a few seconds. This will be followed by a beep and then the
TESTING and BATT. READY LED's will light for a couple of seconds. Then all LED's
extinguish.
Faults that may endanger the reliable charging of a battery or the ability to
charge/test successfully are latching faults that can only be cleared by power cycling
after the fault is fixed. All other faults are self-clearing as soon as the fault condition is
removed.
III-2
TROUBLESHOOTING GUIDES
Fault Codes Table
When the FAULT indicator light illuminates, press and hold the TEST button. The
illumination of the following indicator lights together represent a specific defect
identified under the Fault Code column.
Charger On Batt. Ready Fault Testing Fault Code
ON
ON ON
ON ON ON
ON ON ON ON OverCharge
ON ON
ON
ON
ON
OFF
OFF OFF
OFF OFF OFF
OFF OFF OFF
OFF OFF
OFF
OFF
OFF
OFF
OFF OFF
ON ON ON High Battery
ON ON Low Battery
ON
ON ON Battery
ON Temperature
OFF
ON Shutdown
ON Charger
Constant
Current Voltage
Discharge
Discharge Time
Voltage
High Constant
Current
Voltage
Capacity
OFF
OFF
OFF
OFF OFF
NOTE: A battery that has failed a capacity test will display the TESTING & FAULT
LED's simultaneously. When the TEST button is pressed and held the LED pattern
will not change. This is a normal operating condition and does not reflect a fault with
the unit.
ON
ON
ON ON
OFF OFF
OFF
ON
III-3
ON Vcc Voltage
OFF
OFF
Constant
Voltage
Low Power
Supply Voltage
Low Constant
Current
Definition of Fault Codes
Constant Current The Constant Current compliance Voltage is below the specified
Voltage: range.
Discharge: Test discharge has been ineffective.
Discharge Time: The unit is unable to perform the discharge test.
OverCharge: The total delivered charge exceeds the specified range.
Temperature: Internal charger temperature deviated from specified range.
Low Battery The Battery Voltage measured was below specified range.
Voltage:
VCC Voltage: The internal 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 (shutdown).
TROUBLESHOOTING GUIDES
High Battery The Battery Voltage was measured to be above the specified
Voltage: range.
Battery Capacity: The battery's capacity was measured to be below the specified
range.
Charger: Safety shutdown (#1) is not operating properly (charge enable).
Constant Voltage: The Constant Voltage deviated from the specified range.
Low Power The charging voltage was measured to be below the specified
Supply Voltage: range.
Low Constant The amount of current during a charge was below specified
Current: range.
III-4
FUNCTIONAL DESCRIPTION
SECTION IV
FUNCTIONAL DESCRIPTIONS
This section describes the basic operation 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. System. ...........................................................................................................................IV-2
2. Common Circuitry Description..................................................................................... IV-3
3. Compartment Circuitry Description............................................................................. IV-5
4. LED PCB .......................................................................................................................IV-12
IV-1
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