ZOLL Base Powercharger 4x4 Service Manual
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ZOLL Base Powercharger 4x4 Service Manual

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4x4
ZOLL Base Powercharger
Service Manual
9650-0072-01 Rev. E

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Summary of Contents for ZOLL Base Powercharger 4x4

  • Page 1 ZOLL Base Powercharger Service Manual 9650-0072-01 Rev. E...

  • Page 2: Table Of Contents

    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.
  • Page 3 GENERAL INFORMATION 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.

  • Page 4: General Information

    • Only Qualified Personnel should disassemble the PowerCharger A shock hazard exists. Refer all problems to ZOLL Technical Service. • Follow all recommended maintenance instructions. If a problem occurs, obtain service immediately.
  • Page 5 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. •...

  • Page 6: How To Use This Manual

    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 device.
  • Page 7 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 and will allow the service person to identify and order replacement parts.
  • Page 8 GENERAL INFORMATION SEE FILE PG7_C.PM5 FOR THIS PAGE AND ALL OF THE SYMBOLS...

  • Page 9: Service Policy

    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...
  • Page 10 Should the Base PowerCharger 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...
  • Page 11 GENERAL INFORMATION I-10...

  • Page 12: Checkout Procedures

    CHECKOUT PROCEDURES SECTION II CHECKOUT PROCEDURES ZOLL recommends that you check your Base PowerCharger for proper operation at least once every six months. This section contains information you need in order to verify that the Base PowerCharger is functioning properly.
  • Page 13 CHECKOUT PROCEDURES 9650-0072 II-2 Rev. D...

  • Page 14: Leakage Current Test

    CHECKOUT PROCEDURES LEAKAGE CURRENT • Perform Leakage Current Test per your manufacturer's recommended procedure found in the Operator's Manual of your Leakage Tester. 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.

  • Page 15: Manual Test

    CHECKOUT PROCEDURES • 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 should be lit. • Remove all batteries from the Base PowerCharger •...
  • Page 16 CHECKOUT PROCEDURES BASE POWERCHARGER 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 < 500 µA Normal Pol. w/ Ground YES or NO <...
  • Page 17 CHECKOUT PROCEDURES 2.1 Continuity and Isolation Resistance measurement Record value: of two (2) leads shorted ________ohms to one another. Resistance measurement with Red lead on metal Record value: and Black lead on ________ohms powercord ground. Subtract the two values YES or NO above.

  • Page 18: Troubleshooting Guides

    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.

  • Page 19: Troubleshooting Table

    TROUBLESHOOTING GUIDES TROUBLESHOOTING TABLE Symptoms TroubleShooting Method and Possible Causes • Check that the unit is plugged into an POWER light does not illuminate. appropriate power source. • Check for defective power cord. • Plug unit into another power source. •...

  • Page 20: Fault Codes Table

    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 Constant...

  • Page 21: Definition Of Fault Code

    TROUBLESHOOTING GUIDES 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.

  • Page 22: Functional Descriptions

    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.

  • Page 23: System

    Product Overview The ZOLL Base PowerCharger (with QuickCharge or AutoTest) is a battery charger and testing system designed for management of PD 4410 battery packs used in ZOLL Medical Corporation resuscitation devices. The ZOLL Base PowerCharger (with QuickCharge or AutoTest) provides four battery charging/testing compartments.

  • Page 24: Common Circuitry Description

    FUNCTIONAL DESCRIPTION Standard Terms and Abbreviations Constant Voltage. Term applies to the type of charging technique used to charge a battery where a Constant Voltage is applied to the battery. Constant Current. Term applies to the type of charging technique used to charge a battery where a Constant Current is applied to the battery.
  • Page 25 FUNCTIONAL DESCRIPTION DC Power Bus Circuitry All four charging compartments share an unregulated 30V DC Power Bus which is used by each compartment as the power source for its switching power supply control circuit. This DC bus is created from a 24Vac input which originates from a chassis mounted transformer and enters the board via 2 pin connector J3.

  • Page 26: Compartment Circuitry Description

    FUNCTIONAL DESCRIPTION Temperature Measurement Circuitry Temperature measurement circuitry is provided in order to compensate for battery charge and capacity test variations due to temperature. The signal generated by voltage divider RT1 and R24 is buffered by amplifier U6B and routed to an A/D input of each microprocessor through R135, R235, R335, and R435 for isolation.
  • Page 27 FUNCTIONAL DESCRIPTION The microprocessor (U104) is a 87C752 running at 6.144 MHz with 16K of internal ROM and 64 bytes of internal RAM. It also includes a five bit I/O port (port #0; pins 6 - 8, 23 and 24) and two 8 bit I/O ports (port #1 and #3; pins 13 - 22 and 1- 5, 25 - 27). The lower five bits of port 1 are configured as analog inputs (pins 13 - 19).
  • Page 28 FUNCTIONAL DESCRIPTION Clock Test Circuitry Clock testing is provided by the R123 and C122 R/C network. As part of its start-up verification sequence the microprocessor drives the port pin low and then releases it to charge up to VCC. After a delay of approximately 110 uS it reads the voltage to determine if it has reached the 2/3 charge point or approximately 3.3 volts.
  • Page 29 FUNCTIONAL DESCRIPTION Charge Control Circuitry The microprocessor establishes one of three different voltage and current control settings to support CV and CC battery charging and battery test. The following paragraphs describe the voltage and current control functions in detail. A fail-safe charge enable circuit is provided which requires that the microprocessor is functioning properly before the current and voltage control limits are established.
  • Page 30 FUNCTIONAL DESCRIPTION Test Switch Interface Circuitry A simple interface circuit and a single input port line is used to monitor the test switch located on the LED PCB. An internal pull-up resistor in the microprocessor holds the input pin high (port P1.6) until the test switch is pressed causing this signal to short to ground.
  • Page 31 FUNCTIONAL DESCRIPTION Switchmode Power Supply Operation At the heart of each compartment is a switchmode power supply which establishes each of the charging configurations for the charging compartment. When a battery is inserted and charging is initiated, the switchmode power supply provides a constant voltage to charge the battery.
  • Page 32 FUNCTIONAL DESCRIPTION When no battery is present in a charging compartment, the voltage feedback amplifier with inputs at U103.1 and U103.2 dominates control of the loop. The negative input of the amplifier is tied to the temperature compensated reference through R103 for isolation purposes.

  • Page 33: Led Pcb

    FUNCTIONAL DESCRIPTION Battery Capacity Output (optional) Output control line P0.4 (U104.24) is used to develop an analog output that is proportional to the capacity of a battery that has been tested. The microprocessor's port line P0.4 is configured as a pulse width modulated output which is filtered by the R131 and C128 R/C network.

  • Page 34: Charge Mode

    FUNCTIONAL DESCRIPTION Charge Mode In this mode of operation the controller will perform a charging sequence on the battery. The CHARGER ON indicator will be turned on at this time. When the CV/CC charge sequence is completed the CHARGER ON indicator will be turned off and the BATT. READY indicator will be activated.
  • Page 35 FUNCTIONAL DESCRIPTION Battery Charging Algorithm The algorithm used to charge the battery in both the charge and test modes is as follows; • When a battery is installed the controller will begin charging operation in a CV charge mode. At this time a charge timer will be started. •...
  • Page 36 FUNCTIONAL DESCRIPTION I/O Signal Summary Pin No. Signal Name Definition Comments B1 + Battery Charge Pin B1 SENS + Battery Sense Battery #1 detection signal. B1 - Battery Return B2 + Battery Charge Pin B2 SENS + Battery Sense Battery #2 detection signal. B2 - Battery Return B3 +...
  • Page 37 FUNCTIONAL DESCRIPTION User Tests This mode occurs only if the test button is activated for two seconds with no battery installed. A self test will be performed which will include turning on all LED's for a brief period of time. If successful, the TESTING and BATT. READY indicator's will be turned on for a few seconds.

  • Page 38: Schematic Drawings

    SCHEMATIC DRAWINGS SECTION V SCHEMATIC DRAWINGS ZOLL Base PowerCharger 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 DRAWINGS Description Page 1.
  • Page 39 SCHEMATIC DRAWINGS...
  • Page 40 SCHEMATIC DRAWINGS ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE SCHEMATIC, PCB, DISPLAY/ KEYBOARD DWG NO. REV. 9301-0145-SC NONE SCALE...
  • Page 41 SERVICE MANUAL (NOT USED ON BASE POWERCHARGER ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE SCHEMATIC, PCB, SYSTEM, BASE POWERCHARGER DWG NO. REV. 9301-0147-SC NONE SCALE...
  • Page 42 SCHEMATIC DRAWINGS ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE SCHEMATIC, PCB, SYSTEM, BASE POWERCHARGER DWG NO. REV. 9301-0147-SC NONE SCALE...
  • Page 43 SERVICE MANUAL ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE SCHEMATIC, PCB, SYSTEM, BASE POWERCHARGER DWG NO. REV. 9301-0147-SC NONE SCALE...
  • Page 44 SCHEMATIC DRAWINGS NOTES: 1. ALL RESISTORS ARE 1% TOLERANCE UNLESS OTHERWISE SPECIFIED. 2. ALL CAPACITOR VALUES ARE IN MICROFARADS UNLESS OTHERWISE SPECIFIED. ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE SCHEMATIC, PCB, SYSTEM, BASE POWERCHARGER DWG NO.
  • Page 45 SERVICE MANUAL ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE SCHEMATIC, PCB, SYSTEM, BASE POWERCHARGER DWG NO. REV. 9301-0147-SC NONE SCALE...
  • Page 46 SCHEMATIC DRAWINGS ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE SCHEMATIC, PCB, SYSTEM, BASE POWERCHARGER DWG NO. REV. 9301-0147-SC NONE SCALE...
  • Page 47 SERVICE MANUAL ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE SCHEMATIC, PCB, SYSTEM, BASE POWERCHARGER DWG NO. REV. 9301-0147-SC NONE SCALE V-10...

  • Page 48: Component Layout Drawings

    COMPONENT LAYOUT DRAWINGS SECTION VI COMPONENT LAYOUT DRAWINGS ZOLL Base PowerCharger component layout drawings are included here to supplement the information presented in: • Section III, Troubleshooting • Section IV, Functional Descriptions • Section V, Schematic Drawings LIST OF DRAWINGS...
  • Page 49 COMPONENT LAYOUT DRAWINGS VI-2...
  • Page 50 COMPONENT LAYOUT DRAWINGS ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE ASSY DWG, PCB, LED, BASE POWERCHARGER DWG NO. REV. 9301-0145-AD NONE SCALE VI-3...
  • Page 51 SERVICE MANUAL ZOLL MEDICAL CORPORATION ZOLL 32 SECOND AVENUE BURLINGTON, MA. 01803 TITLE ASSY DWG, PCB, SYSTEM, BASE POWERCHARGER DWG NO. REV. 9301-0147-AD NONE SCALE VI-4...

  • Page 52: Disassembly Procedures

    DISASSEMBLY PROCEDURES SECTION VII DISASSEMBLY PROCEDURES This section is designed to assist in the removal and replacement of Base PowerCharger components. Assembly and disassembly should be performed on a soft, protected work surface to guard against scratches. WARNING • Lethal voltages exist within the Base PowerCharger .
  • Page 53 DISASSEMBLY PROCEDURES VII-2...

  • Page 54: Removing The Base Pan

    DISASSEMBLY PROCEDURES 1. REMOVING THE BASE PAN TOOLS REQUIRED: • No. 2 Phillips head screwdriver Remove the eight (8) screws as shown in the illustration. Lift Base Pan straight up and remove. INSTALLING THE BASE PAN TOOLS REQUIRED: • No. 2 Phillips head screwdriver Reverse steps 1 &...
  • Page 55 DISASSEMBLY PROCEDURES VII-4...

  • Page 56: Removing The Main Pcb Assembly

    DISASSEMBLY PROCEDURES 2. REMOVING THE MAIN PCB ASSEMBLY TOOLS REQUIRED: • Two (2) No. 1 Phillips head screwdrivers (Extended and Short shaft). • Needle Nose Pliers Remove the Base Pan as described on page VII-3. Disconnect Ribbon Cable from Main PCB. Disconnect the PCB Battery Harness (J1) from Main PCB.
  • Page 57 DISASSEMBLY PROCEDURES VII-6...
  • Page 58 DISASSEMBLY PROCEDURES VII-7...

  • Page 59: Removing The Heat Sink

    DISASSEMBLY PROCEDURES 3. REMOVING THE HEAT SINK TOOLS REQUIRED: • No. 1 Phillips head screwdriver • Adjustable Wrench Remove the Base Pan as shown on page VII-3. Remove the Main PCB as shown on page VII-5. Remove two (2) screws securing the Heat Sink to the Upper Housing. Lift Heat Sink straight out.
  • Page 60 DISASSEMBLY PROCEDURES VII-9...

  • Page 61: Removing The Transformer

    DISASSEMBLY PROCEDURES 4. REMOVING THE TRANSFORMER TOOLS REQUIRED: • No. 1 Phillips head screwdriver • Needle Nose Pliers Remove the Base Pan as described in VII-3. Disconnect the PCB Supply Harness fastons and the Power Supply Harness fastons from the top of the Transformer. Loosen four (4) screws from the upper mounting bracket of the Transformer.
  • Page 62 DISASSEMBLY PROCEDURES VII-11...
  • Page 63 DISASSEMBLY PROCEDURES VII-12...

  • Page 64: Removing The Power Entry Module

    DISASSEMBLY PROCEDURES 5. REMOVING THE POWER ENTRY MODULE TOOLS REQUIRED: • No. 1 Phillips head screwdriver • Adjustable Wrench Remove the Base Pan as described on page VII-3. Remove the Main PCB as described on page VII-5. Remove the Heat Sink as described on page VII-7. Remove the Transformer as described on VII-9.
  • Page 65 DISASSEMBLY PROCEDURES VII-14...

  • Page 66: Removing The Battery Harness And Contact Pins

    DISASSEMBLY PROCEDURES 6. REMOVING THE BATTERY HARNESS AND CONTACT PINS TOOLS REQUIRED: • No. 1 Phillips head screwdriver Remove the Base Pan as described on page VII-3. Remove the Main PCB as described on page VII-5. Cut two (2) tie wraps. Remove the twelve (12) Battery Contact Pins securing the Battery Harness the Upper Housing.
  • Page 67 DISASSEMBLY PROCEDURES VII-16...

  • Page 68: Replacement Parts

    This section contains a listing of the replacement parts available for the Base PowerCharger unit. Replacement parts may be ordered through your sales representative, distributor, or directly from ZOLL Medical Corporation. When ordering parts, please provide the following information: • the Base PowerCharger model and serial number •...

  • Page 69: Field Replaceable Units

    REPLACEMENT PARTS FIELD REPLACEABLE UNITS Description Part Number 1. Plastic Housing ......................9310-0123 2. Stabilizer Bracket ....................... 9320-0115 3. EMI Base Pan Gasket ....................9320-0117 4. Rubber Foot ....................... 0310-0057 5. Main PCB Assembly ....................9301-0147 6. PCB Power Supply Harness Assembly ..............9500-0075 7.
  • Page 70 REPLACEMENT PARTS 33. Locknut/Hex, 4-40 with 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 Tubing ......................0500-0204 40.
  • Page 71 REPLACEMENT PARTS VIII-4...
  • Page 72 Appendix A Converting PowerCharger to AutoTest WARNING • Lethal voltages exist within the Base PowerCharger . Units should 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. •...
  • Page 73 Base PowerCharger Operator's Guide...
  • Page 74 Appendix B Changing the AC Line Setting of the Base PowerCharger The voltage wheel can be found within the Power Module located on the rear plate of the Base PowerCharger . The Base PowerCharger can be set for line voltages of 100V, 120V, 220V, and 240V. To set the unit to a different line voltage than the voltage shipped perform the following steps: Open Door Here...
  • Page 75 Base PowerCharger Operator's Guide...

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