The issue date for the X Series Service Manual (REF 9650-001356-01 Rev. D) is November, 2013.
0123
ZOLL Medical Corporation
269 Mill Road
Chelmsford, MA USA
01824-4105
ZOLL International Holding B.V.
Newtonweg 18
6662 PV ELST
The Netherlands
If more than 3 years have elapsed since the issue date, contact ZOLL Medical Corporation to det ermine if
additional product information updates are available.
9650-001356-01 Rev. DZOLL X Series Service Manualiii
TABLEOF CONTENTS
iv9650-001356-01 Rev. D
Overview
Preface—Contains safety warnings and an overview of the manual’s contents. Be sure to
review this section thoroughly before attempting to use or service the X Series unit.
Chapter 1—Maintenance Tests describes step-by-step procedures for various maintenance
tests.
Chapter 2—Troubleshooting provides a listing of error messages to help the service
technician detect faults and repair them.
Chapter 3—Disassembly Procedures describes step-by-step procedures for disassembling
modules in the X Series unit.
Chapter 4—Replacement Parts List displays a complete list of ZOLL part numbers for field
replaceable parts available for the X Series unit, allowing the service person to identify and
order replacement parts from ZOLL.
Preface
The ZOLL® X Series™ Service Manual is intended for the trained biomedical technician
whose responsibility is to identify malfunction s and/or make repairs at the subassembly level.
The X Series Service Manual has five main sections and two appendixes.
Chapter 5—Functional Description provides technical descriptions for the X Series major
subassembly modules.
Appendix A—X Series Electrical Hardware Interconnect Diagram and X Series Signal and
Power Interconnect Schematic.
Appendix B—Contains simulators and settings that may be used to assess the performance of
the NIBP module.
9650-001356-01 Rev. DZOLL X Series Service Manual1
PREFACE
Safety Considerations
The following section describes general warnings and safety considerations for operators and
patients. Service technicians should review the safety considerations prior to servicing any
equipment and read the manual carefully before attempting to disassemble the unit. Only
qualified personnel should service the X Series unit.
Federal (U.S.A.) law restricts this unit for use by or on the order of a physician.
Safety and effectiveness data submitted by ZOLL Medical Corporation to the Food and Drug
Administration (FDA) under section 510(K) of the Medical Device Act to obtain approval to
market is based upon the use of ZOLL accessories such as disposable electrodes, patient cables
and batteries. The use of external pacing/defibrillation electrodes and adapter units from
sources other than ZOLL is not recommended. ZOLL makes no representations or warranties
regarding the performance or effectiveness of its products when used in conjunction with
pacing/defibrillation electrodes and adapter units from other sources. If unit failure is
attributable to pacing/defibrill ation e lectrodes or adapter units not manufactured by ZOLL, this
may void ZOLL's warranty.
Only qualified personnel should disassemble the X Series uni t.
WARNING! This unit can generate up to 2775 volts with sufficient current to cause lethal shocks.
All persons near the equipment must be warned to “STAND CLEAR” prior to dischargin g the
defibrillator.
Do not discharge the unit’s internal defibrillator energy more than three times in one minute or
damage to the unit may result.
Do not discharge a battery pack except in a ZOLL SurePower
Do not use the X Series in the presence of flammable agents (such as gasoline), oxygen-rich
atmospheres, or flammable anesthetics. Using the unit near the site of a gasoline spill may
cause an explosion.
Do not use the unit near or within puddles of water.
Additional Reference Material
In addition to this guide, there is a X Series Operator’s Guide which is a comprehensive
reference work that describes all the user tasks needed to operate the X Series.
TM
Charging Station.
29650-001356-01 Rev. D
Conventions
Conventions
WARNING! Warning statements describe conditions or actions that can result in personal injury or death.
CautionCaution statements describe conditions or actions that can result in damage to the unit.
Note:Notes contain additional information on using the defibrillator.
Service Policy Warranty
In North America: Consult your purchasing agreement for terms and conditions associated with
your warranty. Outside of North America, consult a 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 1-800-348-9011 in North America.
Technical Service
If the ZOLL X Series unit requires service, contact the ZOLL Technical Service Department:
Telephone: 1-978-421-9655; 1- 800-348-9011
Fax: 1-978-421-0010
Email: techsupport@zoll.com
Have the following information available for the Te chnical Service representative:
• Unit serial number.
• Description of the problem.
• Department where equipment is used.
• Sample chart recorder strips or electronic log files documenting the problem, if applicable.
• Purchase Order to allow tracking of loan equipment.
• Purchase Order for a unit with an expired warranty.
If the unit needs to be sent to ZOLL Medical Corporation, obtain a service request number
(SR#) from the T e chn ic al Service representative. Return the unit in its original container to:
ZOLL Medical Corporation
269 Mill Road
Chelmsford, Massachusetts 01824-4105
Attn: Technical Service Department (SR#)
Telephone: 1-800-348-9011; 1-978-421-9655 FAX: 978-421-0010
9650-001356-01 Rev. DZOLL X Series Service Manual3
PREFACE
Technical Service for International Customers
International customers should return the unit in its origin al co nt ain er to the neare s t aut hor ize d
ZOLL Medical Corporation Service Center. To locate an authorized service center, contact the
International Sales Department at ZOLL Medical at the above address.
49650-001356-01 Rev. D
X Series Overview
This chapter includes step-by-step procedures for various maintenance tests. At a minimum, a
trained biomedical technician must perform a CO
once per year. A CO
calibration. It is necessary to perform maintenanc e tests after a module is repaired to ensure that
the functions of the X Series unit work properly . Use the checklist at t he back of this document
(ZOLL X Series Maintenance Tests Checklist) to record your results of the maintenance tests.
Because the X Series units must be maintaine d ready for immediate use, it is important for
users to conduct the Operator’s Shift Checklist procedure at the beginning of every shift. This
procedure can be completed in a few minutes and requires no additional test equipment. (See
the ZOLL X Series Operator’s Guide for the Operator’s Shift Checklist.)
Chapter 1
Maintenance Test s
calibration and an NIBP calibration check
calibration check may be performed at any time to verify the CO2
2
2
9650-001356-01 Rev. DZOLL X Series Service Manual5
CHAPTER 1MAINTENANCE TESTS
This chapter describes the following maintenance tests:
• 1.0 Physical Inspection of the Unit
• 2.0 Operational TestsOperational Tests
• 3.0 Leads T e st
• 4.0 Heart Rate Display Test
• 5.0 Heart Rate Alarm Test
• 6.0 Power Supply Test
• 7.0 Leakage Current Test
• 8.0 Shock Test
• 9.0 Advisory Test
• 10.0 Synchronized Cardioversion Test
• 11.0 Pacer Test
• 12.0 Printer Test
• 13.0 Treatment Report Test
• 14.0 SpO2 Test (for SpO
• 15.0 SpO2, SpCO, and SpMet Test (for SpO
• 16.0 EtCO2 Calibration (required for annual calibration)
• 17.0 EtCO2 Calibration Check
• 18.0 EtCO2 Test
• 19.0 IBP Test
• 20.0 NIBP Calibration Check
• 21.0 NIBP Leak Test
• 22.0 Deflation Test
• 23.0 Inflation Test
• 24.0 NIBP Test
• 25.0 Temperature Test
• 26.0 Wi-Fi Test (Optional)
• 27.0 Audio Recording Test (Optional)
feature without SpCO and SpMet)
2
feature with SpCO, or SpCO and SpMet)
2
Before You Begin the Maintenance Tests
• Assemble the tools listed in following section, “Equipment You Need to Perform the
Maintenance Tests.”
• Keep an extra fully charged X Series battery available.
• Schedule an hour to conduct the entire maintenance test.
• Perform the tests in the order presented.
• Perform all the steps of each test procedure.
• Complete all the steps of the procedure before evaluating the test results.
69650-001356-01 Rev. D
Equipment You Need to Perform the Maintenance Tests
The equipment listed below is used in the maintenance procedures in this chapter. You can
substitute an equivalent device; however, not all simulators and analyzers will produce the
same results. Be sure to follow the manufacturer’s recommendations for conducting the
maintenance tests.
BP Pump/Dynatech Nevada Inc. part number 3010-0378)
• ECG simulator
• Fluke Index 2 SpO
• IBP/Temp simulator
• NIBP simulator
• 5% CO
• CO
• Stop watch
• Battery Current Test Fixture 9100-3055-TF
• Agilent E3633A Power Supply
• Agilent 34401 Digital Multi-meter
calibration gas cylinder with CO2 sample line (kit available from Scott Medical
2
Products, PN 4653ORF-BD)
sampling line airway adapter
2
simulator
2
X Series Overview
Accessories You Need for the X Series Options Maintenance Tests
• 3-lead, 5-lead and 12-lead ECG cables. (12-lead cable needed if 12-lead option is
installed.)
• Dual lumen NIBP hose
• IBP cable
• SpO
• EtCO
• Paddles
• Printer paper
• Battery
• Auxiliary power source
• USB thumb drive
• PC w/ Windows media player and speakers
cable and sensor
2
cable and sensor
2
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CHAPTER 1MAINTENANCE TESTS
Maintenance Tests
1.0 Physical Inspection of the Unit
Observe this...Pass/Fail
Housing
1.1
Is the unit clean and undamaged?
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1.2 Does the unit show signs of excessive wear?
1.3 Does the handle work properly?
1.4 Does the recorder drawer open and close properly?
1.5 Are input connectors clean and undamaged?
1.6 Are there any cracks in the housing?
1.7 Does the front panel have any damage or cracks?
1.8 Are there any loose housing parts?
1.9 Paddles (if applicable)
Do the adult and pedi plates have major scratches or show signs of damage?
1.10 Do the adult shoes slide on and off easily to expose the covered pedi plates?
1.11 Are the paddles clean (e.g., free of gel) and undamaged? (if applicable)
1.12 Cables
Are all cables free of cracks, cuts, exposed or broken wires?
1.13 Are all bend/strain reliefs undamaged and free of excessive cable wear?
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1.14 Battery
Is the X Series battery fully charged?
1.15 Is the battery seated in the battery well correctly?
1.16 Is battery housing free of cracks and damage?
1.17 Are connectors free of damage and excessive wear?
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2.0 Operational Tests
The X Series unit comes equipped with routine operational tests that can be performed
periodically. With the exception of the Physical Inspection of the Unit test, these tests contain
instructions within them that provide guidance during the tests.
The operational tests on the unit can be accessed by doing the following:
1. Turn on the X Series unit.
Note:If the unit is in AED mode, press the Manual quick access key to go into manual
mode. Use the navigation keys to sel ect th e fou r di gits in the Manual Mode pass code.
Press SAVE when you are finished. If the unit has not been config ured to enter a pass
code, the message Exit to Manual Mode is displayed. Use the na vigation ke ys to select Yes.
2. Press the More () then the Setup () quick access keys.
3. Use the navigation keys to select Supervisor>Service>Device Tests. The operational tests
are displayed. Use the navigation keys to select one of the tests.
Note:You need a supervisor passcode to enter the Supervisor menu .
Maintenance Tests
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CHAPTER 1MAINTENANCE TESTS
2.1 Keypad Test
This test checks all the front panel buttons on the unit to make sure they are working correctly.
Follow the instructions and use the navigation keys to move around the display and make
selections.
Note:To exit screen after test is complete, press the “Enter” button 3 times to display arrow.
2.2 LED Test
This test checks all the Light Emitting Diodes in the unit to make sure they are working
correctly.
Follow the instructions and use the navigation keys to move around the display and make
selections.
Note:The speed of the flash varies by color.
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Maintenance Tests
2.3 LCD Test
This test checks the colors of the Liquid Crystal Display on the unit.
Follow the instructions and use the navigation keys to move around the display and make
selections.
2.4 RFU Indicator Test
This test checks the Ready For Use Indicator on the unit to make sure it is working correctly.
Follow the instructions shown on the display.
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CHAPTER 1MAINTENANCE TESTS
2.5 Audio Test
This test checks the audio tones on the unit to make sure they are working correctly.
Follow the instructions and use the navigation keys to move around the display and make
selections.
2.6 Printer Test
This test checks the printer to make sure it is working correctly.
Follow the instructions shown on the display.
129650-001356-01 Rev. D
2.7 Battery Test
This test checks the battery to make sure it is working correctly.
Follow the instructions on the display.
Maintenance Tests
2.8 Fan Test
This test checks the fan in the unit to make sure it is working correctly.
Follow the instructions and use the navigation keys to move around the display and make
selections.
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CHAPTER 1MAINTENANCE TESTS
2.9 USB Test (Optional)
Note:Before starting this test, contact the ZOLL Technical Service Department to obtain a
test file, or create a file (see instructions below). Once you have obtained a copy, save
it on a USB thumb drive.
This test allows you to perform the USB test to make sure it is working correctly.
Follow the instructions and use the navigation keys to move around the display and make
selections.
When these tests are completed, use the navigation keys to exit out of the Service menu.
Creating a Test File
1. Create a Text file using Microsoft Notepad.
2. Open new file in Notebook.
3. Click in the first line of the file and type “Thunderbolt Testfile".
4. Save file as Tbolt_usb.txt.
149650-001356-01 Rev. D
Maintenance Tests
3.0 Leads Test
Equipment3-lead, 5-lead, and 12-lead cables, Fluke Impulse 7000DP Analyzer
Note:Test each cable separately.
Test SetupConnect the lead wires appropriate for each test to the Fluke Impulse 7000DP Analyzer or
equivalent, then connect the ECG cable to the X Series unit.
Do this...Observe this...Pass/Fail
3.1 Turn on the X Series unit.
Note: Make sure the lead is not
displayed.
3.2 Disconnect one lead from the
simulator.
3.3 Reconnect the lead. Repeat step 2
with the remaining leads.
3 .4 Repeat steps 2 and 3 for 5 lead and 12
lead cables.
No ECG LEAD FAULT message
displayed.
The ECG LEAD F AULT message displays
within 3 seconds (if configured).
Wa it for ECG LEAD FAULT message to
clear from the display (if configured).
Note: If heart rate alarm sounds, on the
X Series unit:
Press the More quick access key () key
to access the second set of quick access
keys.
Press the Alarm quick access key ().
Press the Alarm Cancel quick access key
().
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CHAPTER 1MAINTENANCE TESTS
4.0 Heart Rate Display Test
EquipmentFluke Impulse 7000DP Analyzer
ECG Cable (3-lead, 5-lead or 12-lead)
Test SetupPress Lead quick access key until II displays.
Connect the ECG leads to the ECG studs on Analyzer.
Do this...Observe this...Pass/Fail
4.1 Set the ECG Simulator to 120BPM.The Heart Rate displays as 120 +/- 4 bpm.
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5.0 Heart Rate Alarm Test
I, II,
III...
EquipmentFluke Impulse 7000DP Analyzer
Do this...Observe this...Pass/Fail
5.1
Press the Leads quick access key
() on the X Series unit and
select lead II.
5.2 On the X Series unit:
• Press the More quick
access key () key to
access the second set of
quick access keys.
• Press the Alarm quick
access key ().
• Press the Limits softkey.
5.3 On the X Series unit, select HR/PR
Alarm in the Alarm Settings menu
and use the navigation keys to do
the following:
• Set the Upper Limit Enable
to ON.
• Set the Lower Limit
Enable to ON.
• Set the Lower limit to 35.
• Set the Upper limit to 150.
Use the navigation keys to exit the
Alarm Settings menu.
5.4 On the X Series unit, press the
Alarm Cancel quick access key
().
5.5
Remove a lead wire from the
simulator
.
ECG
Maintenance Tests
II displays next to the Leads quick
access key.
The Alarm Settings menu displays.
The red alarm suspension timer
displays at the top of the screen next
to the message area.
T
he ECG LEAD FAULT message
displays.
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5.6
On the X Series unit, press .
5.7
Reattach ECG Lead wire to
ECG
simulator.
5.8 Set simulator to 30 BPM or lower.
5.9
On the X Series unit, press .
The Alarm Suspend key flashes
The ECG LEAD FAULT message no
longer displays.
Heart Rate Value is highlighted and
the alarm tone sounds. The HR/PR LOW ALARM message displays.
The Alarm Suspend key flashes.
.
The
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red alarm suspension timer displays
at the top of the screen next to the
message area.
5.10 Set the simulator to 120 BPM.
5.11
On the X Series unit, press .
9650-001356-01 Rev. DZOLL X Series Service Manual17
Alarm is enabled. The alarm suspend
key flashes. The alarm suspension
timer disappears.
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CHAPTER 1MAINTENANCE TESTS
Do this...Observe this...Pass/Fail
5.12 Set simulator to 160 BPM or higher.
5.13
On the X Series unit, press
the
Alarm Silence/Reset button
()
.
Heart Rate Value is highlighted and
the alarm tone sounds. The HR/PR HIGH ALARM message displays.
Alarm is suspended for 90 seconds.
The alarm suspension timer appears
in black.
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Maintenance Tests
6.0 Power Supply Test
EquipmentBattery Current Test Fixture (P/N 9100-3055-TF), Power Supply, Digital Multi-meter.
Test Setup
1. Set the Power Supply to 12V VDC 10 A.
2. Turn off the Power Supply output.
3. Connect the positive (PS+) post of the Power Supply to t he p ositiv e (PS+) post (PS Red) of
the Battery Current Test Fixture.
4. Connect the negative (PS-) post of the Power Supply to the negative (PS-) post (PS Black) of
the Battery Current Test Fixture.
5. With the Battery Current Test Fixture out of the battery well, turn on the Power Supply
output.
6. Set the Digital Multi-meter to measure DC I DC Amps.
7. Set the rear/front switch on the Digital Multi-meter to rear.
8. Connect the Digital Multi-meter (I+) terminal of the Battery Current Test Fixture to the red
terminal (I) on the back of the Digital Multi-meter.
9. Connect Digital Multi-meter (I-) terminal of the Battery Current Test Fixture to the black
terminal (LO) on the back of the Digital Multi-meter.
Do this...Observe this...Pass/Fail
6.1 Install the Battery Current Test
Fixture into battery well and wait
about five seconds.
6.2 Make sure the X Series unit is
turned off.
6.3 Press the I Measure switch on the
Battery Current Test Fixture.
6.4 Turn on the X Series unit, and wait
about ten seconds until the power
has stabilized.
Verify that the reading on the digital
multi-meter is between
0.583mA-0.770mA.
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CHAPTER 1MAINTENANCE TESTS
Do this...Observe this...Pass/Fail
6.5 On the X Series unit, do the
following:
• Press the More () then the
Setup () quick access keys.
• Use the navigation keys to
select Supervisor>Display/
Configuration>Device Info
and select Restore All Factory
Defaults.
Note: You need a supervisor
passcode to enter the Supervisor
menu. Also the unit will reboot
during the of restoring factory
defaults.
6.6 Press the I Measure switch on the
Battery Current Test Fixture.
Observe the current measurement on
the DMM, and verify that the reading
is between 0.47A-1.25A.
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Maintenance Tests
7.0 Leakage Current Test
EquipmentSee the manufacturer’s instructions or supplied specifications for the leakage tester you use.
SetupSee the manufacturer’s instructions or supplied specifications for the leakage tester you use.
Repeat leakage test with accessories: MFC, external paddles, internal paddles, and anterior/
posterior paddles. Perform these tests at the line-power voltage and frequency used in your
installation.
Maximum Leakage Acceptance Limits
Patient LeakageMains on Applied Part
NormalSingle FaultSingle Fault
ECG10
MFC10
Earth Leakage2500
50 100
50 100
NormalSingle Fault
5000
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CHAPTER 1MAINTENANCE TESTS
I, II,
III...
8.0 Shock Test
WARNING!Take the necessary precautions to guard against shock or injury before you start
conducting the defibrillator tests.
Keep hands and all other objects clear of the multi-function cable connections and
defibrillator analyzer when discharging the defibrillator.
Before you discharge the defibrillator, warn everyone near the equipment to STAND
CLEAR.
8.4 Connect the X Series MFC connector to the
pads connection.
8.5 On the X Series unit, apply power to the unit
using a battery or an AC adapter.
8.6 Connect the MFC cable to the X Series unit.
8.7 Turn on the X Series unit, and press the
Leads quick access key
PADS.
8.8 On the X Series unit, set energy level to 5J
by pressing the Energy Select DOWN arrow .
8.9 On the X Series unit, press the CHARGE
button.
8.10 On the X Series unit, press the Shock button.
8.11 On the Analyzer, observe and record the
energy measurement.
() to select
The unit charges to 5J, the red
Shock button illuminates and a
ready tone sounds.
Energy is delivered at 5J. Verify
that the delivered energy is within
15% based on the values in the
table “Delivered Energy at 200J
Defibrillator Setting into a Range
of Loads” on page 24.
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8.12 On the X Series unit, set the energy level to
50J by pressing the Energy Select UP arrow.
8.13 On the X Series unit, press the CHARGE
button.
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The unit charges to 50J, the red
Shock button illuminates and a
ready tone sounds.
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Maintenance Tests
Do This...Observe This...Pass/Fail
8.14 On the X Series unit, press the Shock button.
8.15 On the Analyzer, observe and record the
energy measurement.
8.16 On the X Series unit, set energy level to 100J
by pressing the Energy Select UP arrow.
8.17 On the X Series unit, press the CHARGE
button.
8.18 On the X Series unit, press the Shock button.
8.19 On the Analyzer, observe and record the
energy measurement.
8.20 On the X Series unit, set energy level to 200J
by pressing the Energy Select UP arrow.
8.21 On the X Series unit, press the CHARGE
button.
Energy is delivered at 50J. Verify
that the delivered energy is within
15% based on the values in the
table “Delivered Energy at 200J
Defibrillator Setting into a Range
of Loads” on page 24.
The unit charges to 100J, the
Shock button illuminates and a
ready tone sounds.
Energy is delivered at 100J.
Verify that the delivered energy is
within 15% based on the values in
the table “Delivered Energy at
200J Defibrillator Setting into a
Range of Loads” on page 24.
The unit charges to 200J, the red
Shock button illuminates and a
ready tone sounds.
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8.22 On the X Series unit, press the Shock button.
8.23 On the Analyzer, observe and record the
energy measurement.
8.24 On the X Series unit, press the CHARGE
button.
8.25 When the X Series unit is charged, start the
stop watch.
8.26 Turn off the X Series unit.
Energy is delivered at 200J.
Verify that the delivered energy is
within 15% based on the values in
the table “Delivered Energy at
200J Defibrillator Setting into a
Range of Loads” on page 24.
The unit charges to 200J, the red
Shock button illuminates, and a
ready tone sounds.
Verify that after 50 seconds the
tone changes and within 10
seconds the unit does an internal
discharge and displays
DISARMED TIMEOUT.
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CHAPTER 1MAINTENANCE TESTS
Delivered Energy at 200J Defibrillator Setting into a Range of Loads