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ZOLL Base Powercharger Service Manual

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4. GDS 4 OPEN D114 TO 220 OPEN 9163 H A F101 BUZ27 1 Lion WV rp 104 Ir zb o UNREG DC AND MI 2 SASA 4 BIBAT C133 2 0A JP 101 ATuH de R139 1 1 2REF 2 67K 1 29 L stoy Gaba 6800 Sa vec D109 P R138 1000uF D 1N4745A 22 1 TT R133 16V L 200K MPSAOS Ge P c119 VOLTAGE 14 3K c127 VIOUT E R103 D108 MUR 1 10 R128 i s 1 MONITOR 4 75K D112 611K aL V 8 R34 R35 EF N UIO5A 1 OZK OZK VREF 1N4 148 MURS 10 OPZ95 3 R115 Bis V_BAT 1 1 g 1 R3 a RN M 16 Ye C117 100 1W N INSTALL D113 BAT 18 18 2 se CRE SEHR ojo lt te2 STT RIS LOAD R110 P 86 6K HS1 b SWITCHING rer 115K 4TpF i U103 1 o Dp E RI32 T 5 OWER R105 nee lt A 1 15 4K TVIO1 t VREF VCC lt R118 c SUPPLY 18 2K E368 c108 ue 68 1K 14 1 4 TP 102 CONVERSION O1 x x DS 13 2 RIOZ jpC126 01 1 02K T VBAT TPlO2 TVS328 b S II 1 i SOLER RIZO se A AY 21 gk c106 001 3306 ARY U n 10 3 8v G DS 1 s fi vec R129 EY LOAD TEST atou C194 R119 12 2 7V 2
5. hdc ec lt B2T5W B4 B4 BASENS REF ERENCE FLT DRV TP403 TPAQA TP 1 LINLINT L vec AENE A TRIS UPS B318W 5 GENERATORS D 25 TST_DRV 1 235 VOLTS RN2 BABAT 24 17 E BaBAT USB m 15 ki a 13 LM324 r1 12 S 4 f 4 5 6 Ti uz lt BZBDET fela 100K 12 7 10 26 25 a 11 f 8 E 2419 6123 Z R18 CZ3I 2213 9121 ATpF T 1OOK T vec RNZ7O 20 E 1_2REF 1 JP6 1812 0117 C15 Ds a 123 o v 470F C20 TP12 R17 1619 9115 S IN52298 vcco 14159113 1219 8111 83 83 WZ 4 3v 274 10 RS 9 TP303 TP 304 26 8 T 1 d 123 JP1 123 P4 619 Sis A Y EN I A 3 3 3REF 1 18 1 16 212 1 cis B1CHRG El IA V OA 17 2 15 ino B3BAT ur BIRDY 3 IB e OB 16 4 5 TA Ta B1151 ic oc BSBAT pF 4 15 a 13 DEL Fa B ID OD TA 5 12 R21 B2TST IE OE LM324 SZ 6 13 6 Ti 10 B2FLT ZE o Hz E To p 1 B2RDY His oc HS i 5 lt B3BDET usc y BOK B2CHRG IH D OH A RNE7 SS R20 C30 14 3K ve o JE S a 100K yon m ULN 2803 123 1 ZREF 017 ds 1 fe vec lt BZTSW v ATpF dia 1N52298 RI BiT
6. 4e OPEN D214 TO 220 OPEN 0203 JA F201 PUZZ7I 3 LZOL N7 rezos T EG DC D TMIN AT UNREG DC AND n BZBAT 2 OA JP201 A7UH 8 R239 1 SESI le 2 67K 1 2W L Hszoli 1 2REF ze e vce 6800 gt R238 R233 DG 22 1 c224 200K 16V 100DUF T c219 R211 R203 D209 D213 VZOUT QUE VOLTAGE SSR 4 75K IN4745A MUR110 e c226 TPeoz S MONITOR n y EE M Ce 511K zi vzosa ja 295 SS w URS 16 INSTALL D213 EE L 8 R ZW ZW 4 OR D212 V_BAT2 1 R5 12V0 A 4 16 10 e R210 a 47pF 86 6K LIGA nsa Lt ZBEE gt 47pF 115K a U203 1 SWITCHING SE H 2 POWER R205 0202 m an R232 R218 12 VREF vcc c SUPPLY 18 2K BOTTOM D 15 4K ayagi o 68 1K y 14 A 1 ZA TP202 CONVERSION o1 xz VN 1V5328 R VBAT TP202 13 d zul 202 C206 T C229 01 1 02K c218 Bass dec ACAV NZ CA 47 21 5K gt gou 309K 10 3 8V G D S NC Hd c204 VRC on m f EN o201 5 R a 833295 lote eyn 3 A RaRa eom 165K 0202 15 0 TV D204 Es 1 1 82K 1 33k TNOGO4N3 LA 1 ki 0201 MC34060 8 8 3 N Kana BOTTOM Q204 R221 1N4 148 2 3 CT RT G 3 TNOBO4N3 EA U207A 10 2K a 1 Z 5 e 7 c21 A E AG gt i R230
7. FAULT TESTING BATT READY CHARGER PWRCHGR 4X4 e e e ED 13 ED 14 ED15 ED 16 NA NZ SZ NA BAY 4 M Y Y Y HLMP S8301 HLMP S301 HLMP S500 HLMP S30 1 SWA PD4420 PWRCHGR AXA 1LL o TES FAUL 1 TESTING BATT READY CHARGER PWRCHGR 4X4 e 9 e e LED9 LED 10 LED 11 LED 12 SAYS X NZ Z A u 5094 a Y Y Y Y AI a NA NA ALMP S301 IHLMP 8301 HLMP S500 HLMP S30 1 sw3 y O O d HLMP S500 HLMP S500 TES 4420PLUS PWRCHGR 4X4 PWRCHGR 4X4 im ONLY OWER OWER ei e e e PA GND ES C1 C2 FAULT TESTING BATT READY CHARGER PWRCHGR 4X4 O e e amp e O Q cd LED5 LED6 LED7 LEDS O VCC NA KA SZ RZ 4 O O 6 OO Y Y x 2 60 gt Y y Y E ALMP S301 HLMP S30 1 HLMP S500 HLMP S30 1 188 BAY 2 4 Ga Swe 2 O O Ge TEST PWRCHGR 4X4 ONLY FAULT TESTING BATT READY CHARGER PWRCHGR 4X4 9 e 9 LEDI LED2 LEDS LEDA ZOLL MEDICAL CORPORATION 32 SECOND AVENUE 4 SN ka 1 SZ KA RZ RZ ZOLL BURLINGTON MA 01803 Ji di TITLE SCHEMATIC PCB ALMP S301 HLMP S30 1 HLMP S500 HLMP S30 1 Sw 1 an O Q TEST 9301 0145 SC PWRCHGR 4X4 uem n i V 3 SERVICE MANUAL Hee ESP I 20 a A
8. l WE O BRACK L 1 PLACE URING GROUND WIR REW e Z Ek o POWER NTRY MODULE SEC S 2 U w ES f UL SCR 2 PLA VII 11 DISASSEMBLY PROCEDURES JUUVU O AJ Z U 0 GE E U BLACK GND GREEN WHITE H lt gt TRNSFRMR h BLUE LE 5 8 BRKT Ks GRND STUD HEAT BROWN SINK POWER IN MODULE O SE DS WIRING DIAGRAM SCREWS 2 PLACES NUTS 2 PLACES VIl 12 DISASSEMBLY PROCEDURES 5 REMOVING THE POWER ENTRY MODULE TOOLS REQUIRED e No 1 Phillips head screwdriver e 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 BO p gt Remove four 4 screws from the lower mounting bracket of the Transformer Remove the Lower Bracket of the Transformer Remove two 2 screws securing the Rear Plate to the Upper Housing 6 7 8 Remove the Rear Plate and Power Entry Module together as a unit 9 Remove grounding screw from the Rear Plate
9. mm BASE POWERCHARGER 4X4 BLOCK DIAGRAM AC FILTER ALARM 30VDC BAT BAT DET Fi EE gt BATTERY 1ST_SW Tal B i T 2 j CS TEMP CHARGE AY ej zl d INTERCONNECT TO 4 v REF 4 ee ES BATTERY WELLS 4 24 VAC V REP Sage BA ERY p 3 TERMINALS EACH 9 EE J3 SHEET 4 UIO2 UlO7 INT RFAC 19 ja IN HOUSING SHIELD 12 E AC TO DC CIRCUITRY a POWER E SHEET 3 US J1 CONVERSION BATTERY SHEET 3 BRI US U4 CHARG R AY f rz AUDIBLE LED SHEET 5 veo U207 ALAR KEYBOARD TEMPERATURE CIRCUITRY amp DISPLAY S S SHEET 3 G1 ul LSI ASSEMBLY SHEET 3 USB M T BATTERY T
10. eeennnannnnnnnnnnnn nn aaa panna a ann na kg KH cnn ad BE SH anne 111 4 Ill 1 TROUBLESHOOTING GUIDES TROUBLESHOOTING TABLE Symptoms TroubleShooting Method and Possible 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 POWER light does not illuminate heck that the battery i ly seat CHARGER ON indicator light does not vec Hale Pavel ie proper sealed in batt rt t illuminate when battery is inserted into H OT a a 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 TESTING light does not illuminate when TEST button is pressed 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 Battery fails test cycle
11. P32 O D TSTLED TestiED P358 O D FALTLED FautiED P34 O D SHUTDWN ChargeShutdown P35 O D CHRG ENB Charge control circuit enable P356 O D SSELO _ Chargestateselectbit0 alt ee SSEL1 Charge state select bit 1 Summary of the Battery Test and Charging Voltage and Current Settings 1 1 Discharge Battryvotage 0 21 Discharge Batteryvoltage 1 0 CCChage 0500Amps 16 5Vols CV Charge 1 0 Amps 11 75 Volts actual value changes with temperature IV 6 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 If it perceives the value to be outside acceptable limits it may be because the crystal oscillator circuit Y101 C103 C102 is out of specification In this event the microprocessor will revert to a fault condition to prevent improper operation VCC Test Circuitry A VCC test is provided by the 3 3V voltage reference circuit which was presented in the Common Circuitry section The microprocessor reads the reference value through its A D port U104 14 If it perceives the value to be outside acceptable limits
12. GDS OPEN D314 TO 220 e OPEN um y BAT F301 BUZZTI L301 r2 2 UNREG_DC ANA es 3 ED PON 4 4 B3BAT 2 0A JP30 1 3 47UH R339 1 C333 2 67K 1 2W L HS301 1 2REF x A lo vec Sado ZN R338 C324 R333 6 22 1 i gp R311 200K 7 kav ovoul D309 14 3K D313 V3OUT VOLTAGE Rapa VN SA MUR 1 10 Tp3oz Jl MONITOR 4 7BK A D312 R328 mae a 8 OP295 XX 7 VREF MUR8 10 INSTALL D313 511K cT U305A 3 R315 OR D312 v BAT3 1 RB 16 12V0 c309 H 1 1 16 2 317 E R310 cato R312 ATTER al pu ATPF 86 6K B yL HS i 6 D S RS fi 47pF LOAD N N 7 R332 U303 H SWITCHING ME ae POWER R305 12 vrer ve 2 SUPFEY 18 2K 0302 C311 R318 t R308 BOTTOM c3oa TV301 14 1 XN TV3328 68 IK SEE TP3 01 RI 25V 4 13 loa efi 0366 14222017 1 02K cate R320 VBAT TP302 Z H 047 H 001 9 A AN LOAD TEST 21 5K 309K CONTROL LA 10 6V 6 D S nc px z c304 V C R304 Bde 11 3 2V 4 R329 165K 0302 12 Z 7V 2 DTE PNM 3 4 1 B2K 1 33k 15 0 7V BSS295 me TNO604N3 D304 R322 je 0301 MC34060 v 1 kelli e D301 e 0304 3 Ra2 1 K BOTTOM U3CZA d INA 14 10 2K CT RT G 1N4 148 i p 2 3 TNOBO4N3 2 U307A i N 8 3 K o 5 DIE 10 2K 3 5 6 7 25 A Ls 1 c305 OP295 c313 R330 F Zw psos d Pri n a D 10 2K TAHC 132 U306F ee EE E RSS c325 Z SZ ZS 0307 TARA 5 6V 91 V 1N4734A 0033 3 48K 5 CURRENT LIMITER 5 6v MODE CONTROL l resos LOSIS B3BAT T R307 R306 TP30 CONVERSION
13. Power Up As AC power is applied the controller will perform a series of internal tests to determine if the electronics are functional The following tests are performed Timer Accuracy Verify that the internal clock timing function has not shifted fundamental frequency e Memory Validity Verify that all of the embedded processor s internal memory locations RAM and ROM are functional e Power Supply Accuracy Verify that the logic power supply is within tolerance e LED Test Turn the four LED s on for a short period If any of the first three functional tests fail the controller will revert to the Fault mode see Fault Mode section It will be left to the user to verify that the LED s are functional IV 15 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 If a failure is detected the FAULT indicator will be turned on and left on This test will also be run automatically after a battery is removed The following tests will be performed Timer Accuracy Verify that the internal clock timing function has not shifted fundamental frequency Memory Validity Verify that all of the imbedded processor s internal memory locations RAM and ROM are functiona
14. 1 CONTROL BSS295 DIC PWNI 3 n l R104 33K 165K 9102 15 0 7V D 104 R122 a I 1 82K TNO604N3 11 1 116 0101 MC34060 8 NZ m Q104 3 N BOTTOM D 101 TNOBO4N3 kr R121 INA 148 10 2K 3 CT RT G 1N4 148 1 z 3 2 ULOTA 2 Z gt d 10 2K 1 ki 7 C105 3 as 3 7 U106F US U102A C113 R130 TAHC 14 os R116 Ai ATpF a OP295 10 2K T4HC 132 ARA 10 OK m 61267 Y 4TpF Ke 3 5 6v O1 NZ CURRENT D 167 3 48K LIMITER 0033 INAT34A MODE CONTROL 5 6V LOGIC i ji TP 103 i STE m BAT R107 1 O2K C115 utozs TP101 CONVERSION 1 5 PN 7 IBAT TP101 e 1 1 02K 154 SPE un D OA av U 1078 U 1070 1a SUE OP295 TE1OI Q 1A 237V 74HC132 74HC 132 R117 RIO RIZ e 110UT O 5A 1 19V 44 2K 2 74K e O tuF 4 vec 1 04 2 37V SENSE kwa RI26 23 2K c 1a 2 0A 4 75V SENA EF NOTES pi UNREG DC d A E 5 a es R135 R125 CURRENT c i SZ NHI SSEL 10 1 ALL RESISTORS ARE 1 TOLERANCE UNLESS OTHERWISE SPECIFIED YU 1 02K MONITOR m ere e 5 U 1O7C D110 2 ALL CAPACITOR VALUES ARE IN MICROFARADS UNLESS OTHERWISE SPECIFIED AAA THERM gt 9 1N4 148 WATCHDOG CHARGING SHTDWN 4 m 8 10 d s b o vec HI D103 vec R136 U106E Dioz SSEL 11 N 1N4 148 o GEREF 14 Lo TAHC 132 3 TOL INA 148 d ksz il 5 Hon 1 02K 74HC 14 H ENSA Soti cist ide x PF5 _ R124 Ss cas ta WSSE v BATI c132 IN o 487K 6 2 Rare d 10 2 AD1 P1 1 E R142 01 9 6V xT 15 B wa E WDO ADZ P1 2 5 R143 1 O2K SU R123 5 C123 ve AD3 P 1 3 HS ISOK GND 1 H REF ADA P1 4 c v
15. A d ke Ba pas LAMP DISPLAY R214 T 7AHC 14 SELECT LINES R223 c202 _ 475 bas ET e GHGENB 100K Y ZOLL MEDICAL CORPORATION 10 AP SSEL e v201 ii 63 5 28 SSELZ l ZOLL 32 SECOND AVENUE SAP 6 144Mhz 870752 CLOCK TEST 4 BURLINGTON MA 01803 y R234 TITLE Y ies ES BETAW SCHEMATIC PCB SYSTEM 1 475 eee Du e 4 us m BASE POWERCHARGER TA D206 Z IE ATpF CHARGE SELECTION TABLE 1N4734A SE DISPLAY PATTERN SZ DWG NO NA SSEL2O SSEL21 CHARGE MODE 9301 01 47 SC B o CV CHARGE S o D 1 ENABLE TEST LOAD CHARGE RATI FAULT 1 o CC CHARGE EADV 1 1 ENABLE TEST LOAD m l SHT 5 OF 7 SCALE NONE PWRCHGR 4x4 V 8 SCHEMATIC DRAWINGS y O 2 EE AY 3 BOTTOM TIT OPTIONAL INDUCTOR BUCK CONVERTER WITH JP301 SHORTED OR XFMR FLYBACK WITH JP3OT OPEN
16. U206F EN DE05 1N4734A As zu L 47pF x 10 2K 74HC132 74HC 14 S eU 4 A L KN gt ozor Ze TE m quar TEL 0033 3 48K 5 CURRENT 3 1 B LIMITER 5 6V rezos MODE CONTROL LOGIG 4 4 A B2BAT R207 R206 C215 5 N U2OZB TP201 TP201 CONVERSION 6 1 02K 102K 47pF e 7 BAS len U207B U207D S Q OA OV R227 _ 6216 OP295 120UT TA OSSTU TAHC 132 7AHC 132 R217 R20 O 1 OHM poz 44 2K Z TAK s ENT O lur ves O 5A 1 19V CURREN ILQA 2 37V R226 23 2K cz 14 SENSE V 2 0A 4 75V R225 SZ UNREG DC EES AE R241 ZE R235 1 02K CURRENT Y SSEL20 RI MONITOR 01 85 I THERM R242 O2K 5 U207C Dato 1 02K gl IN4148 WATCHDOG CHARGING SHTDWN 8 4 1 vec uzol D203 vce R236 UZOBE DZOZ SSEL21 o 1N4 148 o 3 3REF 11 10 74HC 132 3 c INA 148 edm 5 1 02K aida ZO D211 c231 A316 x Llps __ res 13 V_BATZ INAFZHA oil 487K per 5 8 R224 RST ADO P1 O 145 5 8V l ADI P1 1 Fiss RZ43 U208A u x TB ge WDO 10 2 AD2 P1 2 12 1 02K 7 lt gt SH AD3 P1 3 16 19 REF AD4 P1 4 17 1 z BZCHRG 4 8 e a e GND vec ovog E INTo P 1 5 l 69 BZALRM RE WAXT232 INT1 P1 6 l l U206B ER SI MAX 1232 FT202 O 4 1 18 REF ro pt 7 ZZ B2BDET 74HC 14 3 P C223 BZRDY FTZO1 O S po ovas 11 PO 1 0E 288 SBE 6 PROD SEL PO 2 VP 23 po 3 5 5 veco U204 U296 U29 1 U207 Bo AWA U206D 28 14 8 14 c203 Z Es 5 74HC 14 vec c212 c228 c201 c230 33pF a g 8 6 1 1 sd 1 yi P3 1 BZFLT e 1 A gt
17. eR Apre eRZ10 0 6 ID29 edg310 e 6 D307 0 61D407 0 109 D o ETz8 o 9209 du205P eqczz7re D C309 dyzos e C327ho I g D oftaz7 o T er ap oRIZ31IHO E zeig P Rz31 E es gb O0 R33 10 B eS d r oAR431HO B o o a ej e o q D ce b RT1321o 0 EE b exo d illhoq p o Razzho eicaire b ekRize d ofi sikigspo ET EE 8233 R31 S R333 6 RATT R433 eRe Cu o RZ 12 o o R312 o eR o L 42L eRiisre eJD104 R213 eipbzote 413 c IP3040 R413 eJ 404 o RI22L Cr 0301 AR3221 0 Razz O TIG Qi 0401 proje vio e4D203 o 303 6 G ID403 0 ei lo J20 TV201 v301 TV401 NTO H HO 30 e ro 40 Gi ro t 45 OS 5 Allos te OK H 0000 e R3ZFo co kO G C15 Onooo ee b 1P4 CIO TGI3LO 616 t c TP13 P14 TP15 9 66 O elas te b 108 e Q Q U9 H HR US 04 oLRI3 b 6 RT8 Lomp E ES EA R44 172810 9999 STI eJ Ro b 6 RI6 O ela LO eop 99 e23 Ho 99 9 Da E e ae C31 o SEP 2 H R5 o 6 RZO l o L ue PE Ls us DEL R ee DIT Oe LSC Biggs Ee BEES s E SEE D Zsssssse 6666 8 R R R30 O JO O ui A RIZ re 290 TP LET bL 1r 66 b 6 b bh RVI 6 e R31 Ao DIOE g pO A RO o Orp ou Di li TP9 Ld A 06 O Ee ZOLL MEDICAL CORPORATION i s a EEO O ZOLL 32 SECOND AVENUE amp Dr 158 BURLINGTON MA 01803 e R55l eTR3rP c R38F6 e R4T TITLE ei R34 ed R36 6 HRIH HRIH 63 Wille O ASSY DWG PCB SYSTEM ne RIO O BR BASE POWERCHARGER DWG NO REV 9301 01
18. 1 Phillips head screwdriver 1 Reverse steps 3 thru 5 above Install the Main PCB as described on page VII 5 Install the Base Pan as described on page VII 3 Note Screws above to be torqued 7 9 inch pounds VII 15 DISASSEMBLY PROCEDURES VII 16 REPLACEMENT PARTS SECTION VIII 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 e the Base PowerCharger model and serial number e Field Replaceable Unit part number e Description of the replacement part ZOLL reserves the right to substitute different parts to reflect modifications and improvements in ZOLL BasePowerCharger circuitry and design To order directly from ZOLL Medical Corporation address your request to ZOLL Medical Corporation Telephone 800 348 9011 32 Second Avenue 781 229 0020 Burlington MA 01803 FAX Sales 781 272 5578 Attention Technical Service Department Service 781 229 0758 Current replacement part pricing is available from your sales representative or distributor You may also contact ZOLL s Technical Service Department for price quotations VIII 1 REPLACEMENT PARTS FIELD REPLACEABLE UNITS Description Part Number 1 PlastiGs AOusinG 2 ipe Ei da 9310 0123
19. 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 1 Insert screwdriver into slot on the PowerModule and twist to open the door Voltage Drum External Fuses Door 2 Remove voltage drum from Power Module by pulling straight out Set voltage drum to appropriate voltage setting by turning the voltage drum 3 Place voltage drum back into Power Module Close door Make sure the voltage setting appears in the window of the door B1 Base PowerCharger Operator s Guide B2
20. 2 stabilizer Bracket x a Rn e epe et 9320 0115 3 EMIiBase Parn Gasket 4 aaa anie eege ii d 9320 0117 4 Rubber Foot rr Lr tbe A 0310 0057 5 Main POB Assembly ii icio ET br ada inde rc adiri ped 9301 0147 6 PCB Power Supply Harness Assembly 9500 0075 7 PCB Battery Harness Assembly 9500 0115 8 PCB Supply Harness Assembly 9500 0074 Q LED POBzza ii y madi At lehnen nr 9301 0145 10 Battery Contact Pin euet ag a en rin 9330 0100 11 Hex Standoff M F 6 32x2 5 Lena rna ta 0160 0250 12 Sem Screw ET 0163 0912 13 SemiScrew 4 40x1 4 nn nt O rte ne ded Sr tee neces 0163 0900 14 Sem A oiii hoe ns M RA b ebd teet 0163 0910 15 Sem Screw W lrit 6 32X UU ite hane eem ae ao 0163 0940 16 Keycap Test Switch ei ieli tea dele RR ehe 9310 0279 17 Earth Ground Main Assembly 9500 0073 18 Earth Ground Bonding Assembly e eee 9500 0018 19 Label Set RowerCharger i p ere ende edet eds 9305 0095 01 20 EMI Housing Gasket net rare ea Rail 0500 0460 21 T amp B MiniBase 4 Wa y need Eed AER cote padan kab di dak pas ie abaco ga 0501 0016 22 Keps NUt 5 ento deme m Le i e e d e d Ee 0163 0284 237 Cable lie e o ad e o ues 0501 0001 24 Trans Sil Insulator Pad 1 ee 0165 0024 29 Rubber Sil Insulator zas e lidia 0165 0027 RE te 9141 0034 27 Top Transformer Bracket 9320 0057 28 Bottom Transformer Bracket 9320 0058 29 Screw 10 322 3 anale tat tak ga d odii et rui a nl l 0163 0238 980 Rear Plate nu te etu ete i
21. 200K MPSAO6 16V R411 D409 ld 14 3K 1N474BA D413 C428 V4OUT VOLTAGE A R403 4 75K D408 MUR I 10 R428 4 TP402 MONITOR VREF 4 KI D412 511K zle V 8 oP295 Bao kan 3 1N4 148 MURS 10 INSTALL D413 CASSAR SE nr w Zw Kis OR D412 V_BAT4 1 12v ave Rod NA f esos 12 a a 1 10 2 CAME mn S 6 D R4 10 ze Sale BATTERY il la HS 1 Mik Te gt W 47eF 115K la fore eee LOADL E o SWITCHING T a U403 15 4K g POWER R405 eee m 9 SUPPLY n VREF VCC 18 2K R408 c408 ZO 1V8328 68 JK 5 5 1 1 TP402 CONVERSION N7 28v a R402 C406 c429 D1 1 02K KZ LOAD TEST 3 2 41 4 A yon ll e d wo RAZO Sec la Pu CONTROL R 21 5K Foa 10 3 8V I a NE cava VQC m Pus 11 3 2v 0401 1 s DTC PVMI 3 T R404 5 336 165K 0402 TEL Bss2o5 2 fir if 1 82K TNOGO4N3 15 O TV DAOA RA22 IS MC34060 8 NZ 1 5 3 s 1 ji BOTTOM E D401 U402A 0404 4 R421 N 10 2K 1N4 148 2 3 a UAOTA INA 148 3 es TNOGO4N3 1 1 SZ Mia 19 2K 3 1 H i 4 5 2 C413 R430 ka D405 E TAHCIS2 BAOSF T 1N4734A 4 10 2K R416 47pF dj 74HC 14 BBY IGOK SZ ZE D407 a 1N4734A 1 5 CURRENT 0033 Sek LIMITER 5 6V MODE CONTROL f 77403 LOGIC A A A A BABAT R407 R406 TP401 CONVERSION B A T a e 5 I V402B TP401 IBAT TP401 7 ES LT ew C418 C415 b IAOUT U4O7B U407D RA 17 R401 RET oP295 O 5A 1 19V TAHC 132 TAHC 132 44 2K 2 74K 0 1 OHM 0 1uF TC 1 0A 2 37V CURRENT P 2 0A 4 75V SENSE R426 23 2K BE qoe RAZS 7 i RE 9 e UNREG DC I
22. 6 1 B A T m 5 usoesB TP301 IBAT TP301 7 OODA S OU U307B U307D 1 02K 1 02K D a 74HC 132 74HC 132 BARY C316 130UT O 1A 237V R301 G315 O BA 1 19V R317 2 0 1 OHM 44 2K 2 74K gt O 1uF VOC 1 0A s 2 37V CURRENT 47pF PA 2 4 RSW SENSE V7 ES R325 K7 5 4 47pF R341 UNREG DC i SSEL30 R335 1 02K CURRENT Si RZ BE palo THERM DA R342 1 OZK MONITOR Ax mat NATAS 4 9 1 02K 8 N WATCHDOG 4 CHARGING SHTDWN 10 Y m U306E SSEL31 vec D303 D3oz TAHC 132 o IN4 148 vec B SREF No 11 10 len gt R336 AN ZDD311 0331 R340 E 5 TSA TAHC 14 aT L l RST L uss iC 1N4734A ai 487K gt FE Raq by 6 R324 2 RST Apo P1 o H3 V BAT3 AAS 5 6v 10 2 AD1 P1 1 T 4 R343 x 2 TD L 7 WDO AD2 P 1 2 H amp 1 O2K BE SE v sT c323 15 AD3 P1 3 HS i 4 GND 8 1 REF AD4 P 1 4 20 B3CHRG 6332 b o VCC 9 vec INTO P1 5 21 B3ALRM U306B E oi MAX 7123 18 INT Ie Ede 7AHC 14 SA FT302 O REF TO P1 7 B3BDET 3 4 8 B3RDY FT301 O PO O AS BO GE os TAHC 14 PROD SEL 23 PO 2 VP 5 5 237 PO 3 B3TST PO 4 PWM U306D c303 SZ e3 0 LS TAHC 14 vcc 8331 ud ti P3 1 i 2 B BSFLT x1 P3 2 i T 2 LAMP DISPLAY U304 U3p6 U39 U397 E Ss R314 ES 1 74HC 14 SELECT LINES R323 YEGO ez 475 F3 8 Z7 CHGENB 100K 28 14 8 14 T 1 xa P53 aL2 SSEL30 c312 c328 c301 c330 T 870752 25 SSELS 1 1 1 1 go VES PEUT ie A T a T 33PF 6 144Mhz CLOCK TEST TEST SWITCH 4 Tee SZ RON PA R334 c322 ZOLL MEDICAL CORPORATION ONT NEL pos For ZOI
23. 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 Difference should be 1 ohm SECTION 3 MANUAL TEST 3 1 Remove all batteries from YES or NO the Base PowerCharger Press each battery All LED s illuminate compartment TEST momentarily the Batt Ready YES or NO button 4 and Testing light illuminate alone and then all LED s go off Ensure FAULT indicators are all off Set DVM to VOLTS DC YES or NO Test each battery compartment Voltage is 11 86 0 10 VDC YES or NO SECTION 4 AUTO TEST For 4 x4 base chargers that are configured as auto test units Perform this Action Circle the Result YES or NO 4 1 Install Battery into any Charger on and testing LED S YES or NO well illuminate 9650 0072 Il 6 Rev D 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 ss III 2 2 Fault Codes Table noui 0010 101516081664 cau oe tc Fake ee awa ta a RR andere EO OBRA fe 111 3 3 Definition of Fault Codes
24. FAULT light illuminates with TESTING light 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 Il 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 E Tena todo Current Voltage WM SN a ER w o o o blschageTme o o o on owrchage o o or o Temperature OFF Low Battery Voltage High Constant mg OFF High Battery Voltage Battery Capacity MUCH EC ON ME M UN nl OFF OFF OFF Constant Volt
25. Figure 1 Buck Mode Switching Regulator When the switch is closed current builds through inductor L101 inducing a magnetic field The amount of energy stored in the inductor depends upon how long the 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 With catch diode D113 now forward biased there is a path for the energy stored in the inductor to be transferred to the load The cycle repeats itself with the ON and OFF time of the switch determined by a feedback control loop The PWM control device U103 operates at a 100KHz switching frequency which is determined by the C107 and R118 R C network An internal open collector transistor switch at U103 9 turns Q103 on through a series gate resistor R138 by pulling one end of R137 to ground D109 clamps the gate source voltage of Q103 to acceptable levels and the network consisting of Q105 D108 and R139 speeds up the turn off time of Q103 There are three error feedback amplifiers that control the ON and OFF time of the internal switch two of which are internal to the PWM control device and one control amplifier U102A that is external All three amplifiers are OR ed together at pin 3 of U103 The internal amplifiers are tied together and brought out to pin 3 of U103 and the external amplifier U102A is diode OR ed through D101 such that the a
26. T xl TAHC O TES KBUB ING287A AO 5 m mra i 27V U x BTALRM ii TA Ri y HSZ FR O Qt 10 2K A KI A 10 1 BOTTCM IM MPSAO6 B3ALRM x RB RT NZ ES B4ALRM gt c A 2 61K 301 AST LINK ADJ VIN 6 Z4420BY1 SCH Kir Z4420BYZ SCH a e UNREG DC Z4420BY3 SCH i mm HS m Z4420BY4 SCH AST sen D Y E VCC SUPPLY AOTM TPS Si TOUR ZOLL MEDICAL CORPORATION Fa DA 1N4004 R9 LTIOTSCT 5 R33 OPEN SENSE VIN 32 SECOND AVENUE 5 4 m awa A e B RLINGTON MA 01803 10 2w Tr GND OSR re na TILE SCHEMATIC PCB SYSTEM Th ID vsw HA T vcc 3 3 3 UC ees Ga m BASE POWERCHARGER E e e 1 ALL RESISTORS ARE I TOLERANCE UNLESS OTHERWISE SPECIFIED cs c3 7 R11 3 NUS l EZOUF 220uF 1 508 D3 ZN cs 1 FA ALL CAPACITOR VALUES ARE IN MICROFARADS UNLESS OTHERWISE STATED DWG NO MUR 1 10 330 9301 01 47 SC B cz 3 EITHER JA OR J5 CAN BE UTILIZED TO CONNECT THE TEST PCB 033 T D2 ee SHT 3 OF 7 SCALE NONE 5 61 DV V 6 SCHEMATIC DRAWINGS LA D D w O Win CE AY hd aies OPTION 1 INDUCTOR BUCK CONVERTER WITH JP101 SHORTED AND INDUCTOR INSTALLED mm OPTION 2 FLYBACK CONVERTER WITH JP101 OPEN AND XFMR INSTALLED
27. TEST t CHARGER BAY 4 Je m T 3 4 2 KR CHRG VOLTAGE 3 R NC SHEET amp U301 U307 KEVBOA D 7 KR READY Boum DISPLAY o SEIS SHEET 3 USA USB US 12 KR TEST 13 14 15 BATTERY OST 7 ax LT CHARGER BAY u x VOLTAGE d A p L li REFERENC 25 COMPENSATED SE Jeans IST sw bcd SHEET 3 U2 J7 V2 EM SHEET 3 U3A 9301 0145 MAIN ELECTRONICS ASSEMBLY 9301 0147 SC P J4 OR J5 n ds di 4420 PLUS P d OPTION ON PD4420 CONTROL ANEL g NOT USED ON BASE Le RFAC POWERCHARGER P Pd 9301 0146 SC P Pd X P bm w di ZOLL MEDICAL CORPORATION LAST USED R44 Q1 JP8 YXO 1 ZOLL 32 SECOND AVENUE BURLINGTON MA 01803 RX43 QXO5 JPXO L1 TITLE DI TP15 RN2 LXO 1 SCHEMATIC PCB SYSTEM DX14 TPXO4 RVI LS1 POWERCHARGER o L CX33 TVXO1 JB EXO 9301 0147 SC UXO r BA ERY VOLTAGE SCHEMATIC DRAWINGS BATT CONTROL CIRCUITRY U103
28. a prom remover or appropriate pointed tool carefully remove four 4 proms indicated 3 Carefully place the four 4 new software proms supplied with Service upgrade Kit Part Number 7777 0251 in the appropriate locations U104 U204 U304 U404 The proms are marked with appropriate part number and revision level The correct prom to be installed in the device is always the prom 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 location 6 Place base pan on Base PowerCharger Install the eight 8 screws into the base pan NOTE Screws to be torqued 7 9 inch pounds 7 Carefully remove the label located on the front upper right corner of the device with an exacto knife and replace with AutoTest label 9305 0406 01 8 Connect the Power Cord of the Base PowerCharger to live AC mains 9 Place battery in each well and confirm the CHARGER ON and TESTING LED s illuminate simultaneously H SCREWS 8 PLACES cr A ZZ gt Nave 4 PLACES gt a A1 Base PowerCharger Operator s Guide A2 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
29. ability to perform under load To apply the test load the microprocessor asserts SSEL1 high at U104 25 which places the load resistor R3 across the battery via the output of U106 12 through R122 to the transistor Q101 As the load is applied across the battery the power supply is caused to shut down via the current flow through diode D104 Diodes D 105 provides static discharge protection for the gate of the load control FET Q101 IV 11 FUNCTIONAL DESCRIPTION Battery Capacity Output optional Output control line PO 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 PO 4 is configured as a pulse width modulated output which is filtered by the R131 and C128 R C network The resulting DC voltage is buffered by amplifier U105B and bussed to connector J101 2 R113 is a current limiting resistor inserted for protection against accidental shorts C121 is an RF bypass capacitor 4 LED PCB The LED PCB assembly provides the user interface to each of the four charging compartments within the Base PowerCharger system A ribbon cable running from J2 ofthe main PCB to P4 on the LED PCB carries the signals that drive the status LED s and test switches for each charging compartment Located on this assembly are four test switches SW1 SWA one for each charging compartment a power on indicator LED171 or 172 and four sets of status in
30. amplifier UBB C25 is an RF filter capacitor A second temperature compensated reference is created from device U9 to set the constant voltage mode output of each charger compartment The positive input of amplifier USA is referenced to the sum of U9 and the voltage across signal diode D10 Resistors R25 R26 R28 and potentiometer RV1 set the nominal gain of the amplifier to a range of 1 48 1 72 C24 and C27 provide RF filtering C23 provides power supply filtering and bypassing The voltage developed across the silicon diode varies inversely to ambient temperature This diode characteristic causes the reference circuit to automatically adjust the CV charge voltage down as temperature rises which is in accordance with the recommendations of the lead acid battery manufacturer Amplifier U6A along with gain resistors R22 and R23 are used to create a third 3 3V reference voltage C18 and C19 provide RF filtering C20 provides power supply bypass and filtering This reference voltage is bussed to an A D input of each charger compartment s microprocessor and used to verify the accuracy of the VCC supply voltage refer to VCC Test Circuitry Section for more details This self test feature insures that all A D readings are accurate and not corrupted by a faulty VCC supply voltage IV 4 FUNCTIONAL DESCRIPTION Temperature Measurement Circuitry Temperature measurement circuitry is provided in order to compensate for battery charge and capacity te
31. e RIZ4 e R305 o 1P307 R343L Od HR405 o fPabw R44340 RAZA CHC 104 La TP 101 8127 FerP201o R227 e C304 FO P301 PA ar amp Bi cano ki ISV ao CR L101 UZOZ N L201 U3oz G L301 Q U102 R e A L401 CTS 09 mn CAS 9 9 bra S e 414 99 CHS L pup C215 lai P204 oLC315 p Fu P304 C415 j ER TP40 C116 RIS O C216 RN O pLc3iee kk O C416 RR O cios e RTE EE C205 1k206F0 QUA c305 0 1R306 0 BIN R4660 Ye cR 66 JP 101 ofR207 o 66 JP201 oARIOTO 06 JP361 RA07Po 00 JP401 Dol Q pit F9 O 0212 IS O rre TPA03 D412 CRUSH TP103 RZT5T TP203 R317 D312 RIH e Rol RUES 13 tos Jo Rz o o Polo JEE Re ei Le 0103 Lo 9203 2 1 Lo 0303 31 H l o 0403 o P2T3o 6TR102 oC 117 1 oo Hie Sao EM 9 id e R302 o C317 9 IT 9 Ho pas pwe N td N 2113 O R37 po uzo3p SIS oi R237 Le usosp QIS oi R337 EE ex o f BIS And b Sj amd b Se 31 k E DT S E 5 IPZ08 RE b gt GHDZOE 0 5 o 1D403 0 GA IL 5 G R118 edic 127 9 1090 GRISES fd p e RZIBFe 0102280 9 edlbzog e edRz38 e PT p e R3IEFo S4C3Z6kO p c ID309 0 R338 0 edR418Fo edC426Fe 9 l409 edR438Fe RZ 8ZZBL RIZE RIZE AC1 8 0 Bee ol Rise p 0218F oso oi R39 Lo p e4C318ro flo EI e R339 Lo e4C418ro Mr E el R439 Lo A eR H Ri3oLe A ej C207 Ho RZ RBH LO e C307 ro GR3T9 oR33010 IN a RA19 o otrazoro B Slog ORo 102 e Sa aie GROS Rezofo 0800 2 GRIS o ORo eo Z 5 a mS oRazopo 9402 ige CRITIC Ey 0194 05 e czos o SEL CD 0204 7 o c308 o RE C 7 0504 CI O EE
32. failure the microprocessor will continuously attempt fault recovery In the event of a battery voltage failure the microprocessor will stay in the fault mode until the battery is removed If the microprocessor is disabled the charge circuitry will revert to CV charge operation and the FAULT indicator will flash to indicate this condition to the user IV 16 SCHEMATIC DRAWINGS SECTION V SCHEMATIC DRAWINGS ZOLL Base PowerCharger schematic drawings are included here to supplement the information presented in e Section III Troubleshooting e Section IV Functional Descriptions e Section VI Component Layout Drawings LIST OF DRAWINGS Description Page 1 Display Keyboard PCB aaa aaa aaa Tnhh k t V 3 MERCI V 4 V 1 V 2 SCHEMATIC DRAWINGS SCHEMATIC DRAWINGS
33. 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 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 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 GENERAL INFORMATION SEE FILE PG7 C PM5 FOR THIS PAGE AND ALL OF THE SYMBOLS GENERAL INFORMATION 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 The Base PowerCharger will provide trouble free operation without periodic re
34. 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 The operating frequency is derived from the external crystal circuit Y101 C103 C102 R114 connected to the processor at U104 10 and U104 11 R124 and C123 provide the reference voltage for the internal A D C112 C101 C129 C130 are bypass capacitors associated with various IC s located within each compartment circuitry For a summary of the microprocessor I O pin assignments and Battery Test Charging Voltage and Current Settings see the following tables below apin out miga Name Description 0 ELM Pin Out IDigital Name Description D Notused Ec mmn M MY ee T ee P02 D I NotUsed Pos O D WDO Watehdogoutput _P04 O D CAPOUT PWM Capacity Level Indicator PO 1 A VBATT Battery Voltage P11 I A vTST VCCTest Pi2 A TEMP Temperature P3 1 A SENSE OurentSese P14 A FREQ ClockTest P15 P15 D l NotUsed P1 6 TEST Enable support diagnostics not available in all versions of code release P17 D BAT DET Battery Detection P30 O D CHRGLED ChageLED P31 O D RDYLED ReadyLED
35. 0 milliohm resistor R127 The gain of the circuit is established by resistor values R125 and R126 The resulting output signal SENSE at U102 7 ranging from O to 4 85 volts is read by the microprocessor at its analog input U104 16 Capacitor C120 provides noise filtering while and capacitors C114 C115 and C116 provide RF interference and static discharge protection R 106 is a balancing resistor in the non inverting input line to the amplifier A D Current Battery Current 2 37 IV 9 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 As the battery charges up and the input current into the battery falls below a predetermined level the battery charging mode is changed by the microprocessor to a constant current charge until the battery is fully charged Upon completion of the constant current charge sequence a timed overcharge is applied to insure that the battery has been fully recharged U103 is a fixed frequency pulse width modulation control IC that contains the building blocks for the power supply As shown in Figure 1 U103 is configured in a buck orientation with power FET Q103 being the switch shown in the diagram 30VDC Q Q Q
36. 0103 CURRENT CU NI VOLTAGE VOLTAGE TEST LIMIT LIMITE LIMITER MONITOR LOAD CIRC RY BACK UP CIRCUITRY CONTROL UIO5A U102A R116 R118 RI28 Ri19 0102 ifa ne Er 30V GND BATT lt SHUTDONW N CHARO CONTROL LE JARRE CIRCUITRY MONITOR D101 D102 U 105 U102B VOC CHARGING sli ISPLAY E MICROPROCESSO ge READY TEM CONTROLLER Para U106 FAULT U 104 SWITCH TECTION LA SN ZOLL MEDICAL CORPORATION ZO LL 32 SECOND AVENUE BURLINGTON MA 01803 WATCHDOG OSCILLATOR R134 D106 ME EM BOE SYSTENI U101 Y101 BASE POWERCHARGER BAII DETECI u5 DWG NO REV 9301 0147 SC V 5 SERVICE MANUAL KEYBOARD DISPLAY PWRCHGR 4X4 JPI JP2 JP3 JP4 JP5 JP6 CONNECT 1 2 INTERFAC l VOLTAGE BATTERV
37. 1 1 0 Remove two 2 screws securing the Power Entry Module to the Rear Plate 1 Remove the Power Entry Module by sliding through the Rear Plate INSTALLING THE POWER ENTRY MODULE TOOLS REQUIRED e No 1 Phillips head screwdriver e Adjustable Wrench 1 Reverse steps 2 thru 11 above 2 Install the Base Pan as described on page VII 3 NOTE e Screws above to be torqued 7 9 inch pounds The two screws securing the Power Entry Module to the rear plate should be torqued 4 5 inch pounds VII 13 ES RY CONTACT 12 PLAC PINS DISASSEMBLY PROCEDURES BATT ES WRAPS 3 PLAC T ESS RY HARN BATT e N S NIKL ii NO BLACK BLACK BLACK BLACK RED ORANGE BAY 1 RED ORANGE BAY 2 RED ORANGE BAY 3 RED ORANGE BAY 4 VII 14 DISASSEMBLY PROCEDURES 6 REMOVING THE BATTERY HARNESS AND CONTACT PINS TOOLS REQUIRED e No 1 Phillips head screwdriver 1 Remove the Base Pan as described on page VII 3 2 Remove the Main PCB as described on page VII 5 3 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 TOOLS REQUIRED e No
38. 32 SECOND AVENUE E d DISPLAY PATTERN sos 28 BURLINGTON MA 01803 1N4 7 34A RZ ES TILE SCHEMATIC PCB SYSTEM CHARGE BATT FAULT H 7 H READY N7 CHARGE SELECTION TABLE SSEL 3Q EL31 CHARGE MODE PWRCHGR 4X4 DER BASE POWERCHARGER o o CV CHARGE DWG NO i BERG 9301 0147 SC B 1 ENABLE TEST LOAD SERVICE MANUAL OPTIONAL G D INDUC T OR GAY 4 CK CONVERT ER WITH P401 SHORTE u 0405 E aa OR XFMR FLYBACK WITH JP401 OPEN GDS OPEN D414 TO 220 as 2 OPEN 0403 AN F401 BUZ271 Lao Y Jrpsoa B d UNREG DC No Ss 3 Z D i BABAT 2 0A L JP401 47uH R439 1 2433 2 67K 1 2W U Hs40 4 A v 1 2REF Es LS G R438 ERE R433 Bud 22 1 caza
39. 47 AD VI 4 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 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 Be sure to observe anti static precautions whenever the unit is open NOTE Cable paths and connector locations should be noted prior to disassembly If cables are run in locations other than those indicated by the manufacturer the unit may exhibit HI POT failure fuse blowing or may not close properly Torque specifications for screws are provided under the installation instructions VII 1 DISASSEMBLY PROCEDURES E PAN BAS s Y e WS 8 PLAC p VII 2 DISASSEMBLY PROCEDURES 1 REMOVING THE BASE PAN TOOLS REQUIRED e No 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 e No 2 Phillips head screwdriver 1 Reverse steps 1 amp 2 above NOTE e Eight 8 screws to be torqued 7 9 inch pounds VII 3 DISASSEMBLY
40. Do not place anything on top of the Base PowerCharger Doing so may block the vents on the unit preventing proper dissipation of heat during operation Do not sterilize the Base PowerCharger Do not use alcohol or ketones MEK acetone etc on the Base PowerCharger Always wait until the Base PowerCharger has completed its charge cycle before removing batteries Repeated use of partially charged batteries will reduce their capacity and operating life GENERAL INFORMATION Operator Safety Do not operate the Base PowerCharger 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 in fluid Using the device near or within puddles of water is a shock hazard to the operator patient and nearby personnel Patient Safety e Donot mount the device directly above the patient Locate the Base PowerCharger and ZOLL resuscitation devices where they cannot harm the patient if they fall Caution e Donotdischarge a PD 4410 battery pack except in a Base PowerCharger or compatible ZOLL Battery Charging Testing 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 accessor
41. HARGE ENABLE TEST LOAD V 10 B COMPONENT LAYOUT DRAWINGS SECTION VI COMPONENT LAYOUT DRAWINGS ZOLL Base PowerCharger component lavout drawings are included here to supplement the information presented in e Section III Troubleshooting e Section IV Functional Descriptions e Section V Schematic Drawings LIST OF DRAWINGS Description Page 1 LED PCB Base PowerCharger cian VI 3 2 AMA ete eut dp quet impete iube VI 4 VI 1 COMPONENT LAYOUT DRAWINGS VI 2 COMPONENT LAYOUT DRAWINGS ED4 lt ED8 o LED12 lt lt LED16 A ED5 LED 11 LED9 LED 15 ED13 IP3 E SWI SII mu sw2 4 SW3 q EHO SWA LH D 2 A 6000000000009 HI ED172 lt A P20000000000000 lt N ZOLL MEDICAL CORPORATION 32 SECOND AVENUE ZO LL BURLINGTON MA 01803 TILE ASSY DWG PCB LED BASE POWERCHARGER DWG NO REV 9301 0145 AD VI 3 SERVICE MANUAL
42. PROCEDURES 2 PLACES HEAT SINK SCREWS PART OF 5 PLACES SECURING 4 RESISTORS AND BRIDGE RECTIFIER 1 SCREWS 2 PLACES PCB BATTERY HARNESS FOR STABILIZER BRACKET STABILIZER BRACKET SCREWS RIBBON CABLE SCREWS 8 PLACES FOR MAIN PCB P e GROUND WIRE PART OF HEAT SINK REMOVAL HARNESS PCB SUPPLY SCREW VII 4 DISASSEMBLY PROCEDURES 2 REMOVING THE MAIN PCB ASSEMBLY TOOLS REQUIRED e Two 2 No 1 Phillips head screwdrivers Extended and Short shaft e 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 Disconnect grounding wire at spade SP1 on Main PCB Disconnect the PCB Supply Harness J3 from the Main PCB Remove two 2 screws securing the Stabilizer Bracket Remove eight 8 screws securing the Main PCB to the Upper Housing o NO mF ob gt Remove five 5 screws securing the four 4 resistors and one 1 bridge rectifier from Heatsink 9 Before removing the Main PCB loosen by slightly twisting the four 4 resistors and one 1 bridge rectifier mounted on the heat sink with needle nose pliers 10 Remove the complete Main PCB assembly INSTALLING THE MAIN PCB ASSEMBLY TOOLS REQUIRED e No 1 Phillips head screwdriver 1 Reverse steps 2 through 10 above 2 Ins
43. Sw j e 10 0K B2 B2 4 3v TPt1 p s c23 JP3 vac TP203 TP204 O d 33 2K 2 8V NOMINAL 1 Ex 3 TP14 INCREASES O2V FOR B2SENS pum SZ EACH 5 DEGREE C RISE PROD SELS ip 3 HIGH PWRCHGR 4X4 lt BZBAT cz4 jn SN lt BZBAT 12 N ES m LM324 5 AQ 7 VW D10 A E z INA TAE EST BRIT x B2BDET T lt se p iode 8 am vec e12 3 5 ti E A5 RIS DM ee rl CONTROL PANEL es ta ai SH T pes o ANODE RZE TI 1 1 2REF NC us ZS 4 75K 5K POT FLT_ORV Tal T7 aci SZ SEGA D7 25 St 4T pi cael LM385Z 1 2 4 INTERFACE 16 SE Bs INS2298 G 5 TP 103 TP104 NY a 3v 1 ue NZ RZ6 B4TST 8 BOTTOM 10 0K ta SZ R28 U10A U10B J4 BIBAT i VCC 4 75K 1 A 7AHCOO R29 vec LT TPA TPS T 3 4 2 BTBAT B 1SENS B3SENS RZ 2 5 10K THERMISTOR U 1 D 47 2 10K e 25 74HC O TAHCOO 12 a SS f 11 vec E S TP 3 B4RDY 13 ele BAT ERY o TEMPERATURE 5 4 S NOT 3 c13 t DETECTOR oO 2 5V NOMINAL 74HC TEST CE E m E INCREASES 2V FOR PASSED K IT INTERCONNECT LM358 EACH 5 DEGREE C RISE EAbrT 19 x 12 v JP7 1 TO 2 12V POWER FROM MAIN SUPPLY e uMs a E R14 2 TO 3 12V POWER FROM AUX SUPPLY i ZS 4 JPB CONNECTED CAPACITOR DISCHARGE ON SZ Ts US 100K DISCONNECTED CAPACITOR DISCHARGE OFF B4TSW A Aet A R13 mE 47pF i 100K T 1 E i RI ud De 1 UNUSED SZ Kl 12V ACORN ATpF 1N52298 Ls N74 3V d UNREG DC TPI z Al 550KAS 1 2REF g UIB E 16 S AUDIBLE ALARM L A 12 21 VIN vout Le 4 12V LK E B C p BRI TVI
44. ZOLL Base Powercharger Service Manual 9650 0072 01 Rev E GENERAL INFORMATION SECTION I GENERAL INFORMATION TABLE OF CONTENTS DESCRIPTION SECTION l General Information e Table of Contents l 1 e Safety ConsiderafiOnS nn a Tnhh ky l 3 e How to Use This Manual l 5 e Symbols used on the Equipment l 7 e Service Policy 5 ite nn eant l 8 II Checkout Procedures e Leakage Current Test art ad Il 2 e Functional Tests ccs ot A a gi ete to i ga mat Il 2 e Mantal Festi ii ii idee te pe ide RA aie de Il 3 e Checkout Procedure nn Il 4 Ill Troubleshooting Guides e TroubleShooting Table n III 2 e Fault Codes Table nn IIl 3 e Definition of Fault Code 111 4 IV Functional Descriptions AS O si d dE a IV 2 e Common Circuitry Description nn IV 3 e Bay Circuitry Description nn IV 5 e EED POB U ii ce ee niei Eua IV 12 V Schematic Drawings e Display Keyboard eorr tiere aies te eee V 3 AS E iei tube i RER tA rr EE V 4 VI Component Layout Drawings s LED A Enos mde m aa VI 3 9 O cien eren t Renate T l VI 4 GENERAL INFORMATION VII Disassembly Procedures e Removing the Base Pan eee aaa E aoina VI 3 e Removing the Main PCB Assembly e sese VI 5 e Removing the Heat Sink enn VI 7 e Removing the Transformer Vl 9 e Removing the Power Entry Module VI 12 e Removing the Battery Harness and Contact Pin
45. age OFF Low Power Supply Voltage OFF OFF Low Constant Current NOTE A battery that has failed a capacity test will display the TESTING amp 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 IIl 3 Definition of Fault Constant Current Voltage Discharge Discharge Time OverCharge Temperature Low Battery Voltage VCC Voltage High Constant Current Shutdown High Battery Voltage Battery Capacity Charger Constant Voltage Low Power Supply Voltage Low Constant Current TROUBLESHOOTING GUIDES Codes The Constant Current compliance Voltage is below the specified range Test discharge has been ineffective The unit is unable to perform the discharge test The total delivered charge exceeds the specified range Internal charger temperature deviated from specified range The Battery Voltage measured was below specified range The internal five 5 volt supply deviated from specified range The amount of current during a charge was above specified range Safety shutdown 2 is not operating properly shutdown The Battery Voltage was measured to be above the specified range The battery s capacity was measured to be below the specified range Safety shutdown 1 is not operating properly charge enable The Constant Voltage deviated from
46. als see Manual Battery Testing Procedure in order to confirm adequate battery capacity Note Actual battery run time will vary from model to model depending upon the amount of current that is drawn by each device Refer to the Operator s Manual of your model to determine the actual battery run time For example a battery contains at least 1 5 ampere hours while a ZOLL Defibrillator may draw approximately 8 ampere of current The run time of the battery is calculated by dividing the battery capacity by the current drawn In this example there is a minimum of 1 875 hours of battery run time for this device IV 2 CN CC Main PCB Embedded Processor LED Micro processor mS PCB PD1400 HS 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 Refers to the electronics assembly which controls the voltage and current being supplied to the Battery Pack PD4410 A software programmable device used to sense and process a series of input signals to produce control status output signals Light Emitting Diode A software programmable device used to sense and process a series of input signals to produce control status output signals Mil
47. bypassing R 107 is a balance resistor for U102A A second current feedback amplifier with inputs at U103 13 and U103 14 limits supply current to 2A in the event of a failure of amplifier 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 resistor R127 through R116 C126 stabilizes the amplifier ensuring proper control loop operation R130 is a series gate protection resistor for Q104 A final level of component failure protection is provided by the 2A pico fuse F101 Each Compartment output voltage is protected by a transorb from positive to negative terminal TV101 JP101 and a transformer rather than an inductor allows the switches to be converted from a Buck regulator to a flyback style Battery Test Control Circuitry The microprocessor initiates a battery test sequence when it has detected the presence of a battery in the charging compartment and the test switch has been pressed A fail safe charge enable circuit is provided which requires that the microprocessor is functioning properly before the test load can be applied to the battery Refer to the Charge Control Circuitry Section Page IV 8 for a description of the Charge Enable Control circuitry Once the Charge Enable control is established the microprocessor may either charge or discharge the battery to prepare a battery for use or determine its
48. calibration 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 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 e Department where equipment is in use A Purchase Order to allow tracking of loan equipment A Purchase Order for systems out of warranty GENERAL INFORMATION International Customers 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 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 D
49. dicators LED1 LED4 for charging compartment 1 LED5 LED8 for charging compartment 2 LED9 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 Drive Circuitry section and the Test Switch Interface Circuitry Power Up Operation At power on the POWER indicator will turn on The controller for each channel will perform a series of power on diagnostics including a test of the four LED s and then advance to the appropriate mode based on whether a fault is detected a battery is present and the status of the test switch See Diagnostics Section for a detailed description of the power on diagnostics If a fault is detected the controller will revert to the FAULT Mode Any power brown out 90VAC or interruption will cause a charging sequence to be restarted when proper power is re established If a test is in progress during a power brown out or interruption the controller will revert to normal operation when proper power is re established Press the TEST button to start the testing cycle again Turn on Delay The system will delay no more that 10 seconds after power on to allow the battery power electronics to stabilize and go through a self test The CHARGER ON indicator will be turned on after the delay if a battery is present IV 12 FUNCTIONAL DESCRIPTION Charge Mode In thi
50. ec o vee INTO P 1 5 BTALRM NZ MAX 1232 m 18 INT AEST e e FT 102 Oo REF TO P1 T B1BDET U106A CLOCK TEST 8 FT101 O4 PO O AS A P 1 0E l 2 BTCHRG TEST SWITCH BTTSW PROD SEL 7 i PO 2 VP U106B R134 Cl22 PO 3 47 EN 4 PO A PWM uL P 5 F ar C103 RZ 5 B IRDY Z 0106 a 33pF 53 94 U106C TiNa734A UE 4 4 e 3 74HC 14 NZ H 2 5 6 5 6V Ll R114 P3 3 L BITST cree I rs m wem L ZOLL MEDICAL CORPORATION 10 R6 SSEL 10 74HC14 ll wg di 235 28 SSEL11 9 8 BIELTz vcco U104 vige BEER U197 ZOLL 32 SECOND AVENUE 33PF 5 144Mnz 870752 LAMP DISPLAY 28 14 8 14 BURLINGTON MA 01803 SELECT LINES 74HC 14 FRONT PANE Sie s ete SE TITLE DISPLAY PATTERN 12 7 4 7 SCHEMATIC PCB SYSTEM SE PO C GER y BASE POWERCHARGER CHARGE SELECTION TABLE CHARGE BATT FAULT READY L SSEL IQ SSEL LI CHARGE MODE DWG NO TEST ai SC o o CV CHARGE PWRCHGR 4X4 9301 0147 o 1 ENABLE TEST LOAD I o CC CHARGE I 1 ENABLE TEST LOAD OF T SCALE NONE V 7 SERVICE MANUAL W C t T V GE EEN L 0205 II OPTIONAL INDUCTOR BUCK CONVERTER WITH JP201 SHORTED cos OR XFMR FLYBACK WITH JP201 OPEN
51. epartment l 10 GENERAL INFORMATION CHECKOUT PROCEDURES SECTION II CHECKOUT PROCEDURES ZOLL recommends that you check your Base PowerCharger for proper operation at least once everv six months This section contains information vou need in order to verifv that the Base PowerCharger is functioning properly Daily operational checks are described in Section 3 Maintenance and TroubleShooting in the Operator s Guide TABLE OF CONTENTS 1 Leakage Current Test 2 Functional Test 9650 0072 Il 1 Rev D CHECKOUT PROCEDURES 9650 0072 Il 2 Rev D CHECKOUT PROCEDURES LEAKAGE CURRENT 9650 0072 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 Il 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 Il 4 TEST 90 265 VAC LIMITS Gnd Wire Resistance Line Voltage Hot to Neutra Hot to Gnd Neutral to Gnd Current Consumption Chassisleakage Ground Wire Leakage 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 Re
52. he current limits for each of the two charge select states see table on page IV 6 Diodes D 107 provides static discharge protection for the gates of the current and voltage selection FETs Q104 and Q102 Display Drive Circuitry The four status LEDs CHARGER ON BATT READY TESTING and FAULT on the LED PCB assembly are controlled by PORT 3 control lines of the microprocessor U104 pins 2 5 Each control signal is buffered by both a logic inverter U106A U106B U106C and U106D and a darlington driver U7 or U2 A 270 ohm resistor network RN1 amp RN2 limits the LED on current to 15mA J2 connects all of the LED and test switch control signals to the LED PCB assembly over a ribbon cable Resistor R17 turns on the POWER LED on the LED PCB when the 45V VCC logic supply powers up See the Operator s manual for further clarification of the LEDs and their use IV 8 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 R134 limits the current into the microprocessor from a possible short circuit and D106 is used as a guard against static discharge Battery Voltage Sense Circuitry The microprocessor monitors the switchmode power supply output and the batte
53. he Watchdog device U101 as described above has the ability to both disable the microprocessor and shut down power supply operation The microprocessor also has the ability to shut down power supply operation in the event that a fault condition is detected This control function is provided via inverter U106 and diode D102 via R117 As described in the previous section current sourced through the diode causes the safety current limiting comparator U103 13 and U103 14 to turn on producing a shut down of the power supply output Power supply shut down also occurs when the battery test load is enabled IV 7 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 This is accomplished via the circuit built around the NOR gate U107C During normal operation the microprocessor produces a pulse train signal CHRG ENB with a frequency of approximately 500 HZ and a pulse width of approximately 10 uS This signal passes through the DC blocking capacitor C132 where it is buffered and inverted by U107 The output of U107 U107 8 is rectified by the network com
54. ies such as disposable electrodes patient cables and batteries ZOLL cannot make representations as to safety and clinical effectiveness when a device is used with non ZOLL 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 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 GENERAL INFORMATION HOW TO USE THIS MANUAL Who it is for The Base PowerCharger 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 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
55. in Diodes D6 through D9 protect each amplifier from static discharge and C9 C11 C15 and C17 are used as filter capacitors C10 C12 C14 and C16 are RF filtering capacitors Each charging compartment s microprocessor observes its battery detection signal at port P1 7 U104 22 with a positive voltage signifying the presence of a battery 3 COMPARTMENT CIRCUITRY DESCRIPTION The following section describes the electronics that are common to all four charger compartments A block diagram overview of compartment circuitry is attached For simplicity all part designators will be referenced to the first compartment only All of the reference designators for the other three compartments are exact increments of 100 in relation to charging compartment 1 s values The reference designators for the microprocessor for example is U104 U204 U304 and U404 for charging compartment 1 2 3 and 4 respectively All reference designators below 100 are associated with common circuitry Microprocessor Each charging compartment contains a microprocessor that controls charging discharging and capacity testing of the compartment s battery The microprocessor also monitors battery voltage battery current system ambient temperature and the system power supply to determine if any fault condition has occurred Four status LED s and a test switch are also controlled by the microprocessor IV 5 FUNCTIONAL DESCRIPTION The microprocessor U104 is a 87C752
56. 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 l 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 Section II Checkout Procedures This section contains information you need in order to verify that the Base PowerCharger is functioning properly and procedures for checking the Base PowerCharger For daily inspection and operational checks see the Operator s Manual Section Ill Troubleshooting Guides This section contains an operational troubleshooting section for use by non technical personnel to respond to common problems detected during Base PowerCharger operational use Section IV Functional Descriptions This section provides a basic technical description of the Base PowerCharger main subassembly modules The information should be thoroughly reviewed before servicing Section V Schematic Drawings Major circuit board schematics are included for troubleshooting purposes GENERAL INFORMATION Section VI Component Layout Drawings Major component
57. it may be because either the VCC power is out of specification or the reference device has failed In either event the microprocessor will revert to a fault condition to prevent improper operation A series resistor R136 is provided in line with the 3 3V reference to insure that if a microprocessor fails within one of the charging compartments that it does not prevent the others from operating Watchdog Circuit The Watchdog device U101 provides two functions First it acts as a power on reset circuit to insure that the microprocessor is held RESET until the 45 volt VCC power supply is stable The watchdog timer continues to monitor the power supply and drives RESET high if the VCC supply falls below tolerance 4 62 volts nominal anytime during normal operation Secondly the device will reset the microprocessor if it does not receive a refresh strobe at its input pin U101 7 at least once every 250 milliseconds If a reset condition occurs the microprocessor will be held reset for a minimum of 250 mS Whenever the microprocessor is held reset by the watchdog the switchmode power supply circuitry is also disabled via diode D103 and R117 As current is sourced through this device the safety current limiting comparator U103 13 and U103 14 turns on causing a shut down of the power supply output Refer to Switchmode Power Supply Section for a detailed description of the switchmode power supply control circuitry Shut Down Control T
58. kCharge on the charger label directly beneath the product name If the device is not labeled the QuickCharge instructions should be followed for proper device operation For questions concerning the chargers configuration please consult a ZOLL technical service representative AutoTest The ZOLL Base PowerCharger with AutoTest automatically tests battery capacity with each battery recharge In addition the ZOLL Base PowerCharger with AutoTest illuminates the Batt Ready indicator when the battery is fully charged and capable 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 cause the FAULT light to illuminate With AutoTest the full charging cycle is complete in eight 8 hours or less The AutoTest feature virtually eliminates the need to periodically test battery capacity since this test is performed each time a battery is recharged QuickCharge The ZOLL Base PowerCharger with QuickCharge illuminates the Batt Ready indicator when the battery is fully charged The full charging cycle is complete in four 4 hours or less The QuickCharge version provides no information regarding battery capacity because it does not test the battery capacity with each recharge The ZOLL Base PowerCharger with QuickCharge relies on the user to manually initiate the battery test cycle at recommended interv
59. l Power Supply Accuracy Verify that the logic power supply is within tolerance Charger voltage control test Verify CC and CV voltage levels Run Time Tests The controller will perform a series of internal tests to insure safe operation Some of these tests will be performed continuously Other tests will be performed at the appropriate moment of run time operation A summary follows Power Supply accuracy Verify that the power 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 Performed during the CC charge sequence Verify that the battery is within acceptable voltage limits Charge Current validity Performed during the CC charge sequence Verify that the charge current is within acceptable limits Temperature validity Performed continuously Verify that the temperature is within acceptable limits If temperature is too high or too low the controller will disable constant current charging and will turn the FAULT indicator on Embedded Processor Operation Performed continuously Verify that the processor is properly executing its program If any of these tests fail the controller will either be disabled or will revert to the Fault mode For those faults in which the microprocessor is still functional CV charge operation will be maintained Except for a battery voltage
60. l case gt 4 R435 1 92K CURRENT zk SZ R441 THERM gt xX X an R442 1 O2K MONITOR 55 68 1K SSEL40 1 O2K U407C D4 10 WATCHDOG CHARGING SHTDWN 4 l 1N4 148 U406E 8 Nou vec U40 D403 R436 D402 10 Vi o 1N4 148 vec 11 10 SSEL4 1 3 o 3 3REF T4HC 132 ITOL _ 5 1 02K rie 1N4 148 r BSTR U404 YO 0411 RI RET as 6 MR 9 RST ADO P 1 0 13 v BAT4 1N4734A tiic RST PK 10 2 AD1 P1 1 HS R443 U406A 5 6v x44 ro _ AD2 P 2 H 1 02K Spe E WDO c423 i AD3 P1 3 HS 2 SZ 4 a REF AD4 P 1 4 bad BACHRG L INTO P1 5 2T BAALRM U406B 6432 18 ING Ae a 74HC 14 01 NA REF TO P1 7 B4BDET 3 4 ARDY 8 po 0 AS U4OBC l PO 1 05 74HC 14 PO 2 VP 227 PO S 2 BATST PO A PWM U406D VCC c403 SZ pep bs 74HC 14 33pF P3 1 L4 2 B BAFLT R431 14 x4 P3 2 L3 OK pss Le LAMP DISPLAY R423 vcco_U404 U496 U4O U4Q7 E R414 P3 4 1 74HC 14 SELECT LINES 100k c402 Lt 475 E5 2 JET CHGENB 28 14 14 J401 R413 5 10 26 SSELAO c412 c428 C401 C430 jm i ki 1 Re BTCHSE ES Silzs SSEL41 1 1 1 1 oi 5 aspe Y491 P3 T CLOCK TEST d 12 T 4 7 100 si 6 144Mhz it lt TM re ZOLL MEDICAL CORPORATION x SES c427 Raga caze sE ZOLI 32 SECOND AVENUE l 475 Ts BURLINGTON MA 01803 _ ea2 1 RZ FRONT PANEL bios XN TITLE Taror ISPLAY PATTERN inarsqA Vv SCHEMATIC PCB SYSTEM 5 6V gt 7 SE PO C GERA BASE POWERCHARGER CHARGE BATT FAULT CHARGE SELECTION TABLE READY DWG NO SSEL40 SSEL41 CHARGE MODE TEST e PWRCHGR 4x4 9301 0147 CV CHARGE ENABLE TEST LOAD CC C
61. liseconds Printed circuit board This term refers to the any of the PD1400 1600 2000 Pacemaker Defibrillator family of products that are compatible with the Base PowerCharger Microseconds 2 COMMON CIRCUITRY DESCRIPTION As shown in the attached Block Diagram each charger compartment operates independently from the others except that all four compartments share a common DC power bus VCC power supply voltage references and temperature measurement circuitry The occurrence of a fault condition in one of the common circuit areas may cause all four charging compartments to suspend operation In the following sections there will be periodic reference to a device s reference designation and pin number For example U3 5 will refer to pin number 5 of device U3 This information is to be associated with the attached system diagram and schematic set In a similar fashion there will be reference to the microprocessor s port designation For example P3 1 will refer to the microprocessor s bit 1 of I O port 3 Refer to the 8051 Data Handbook for a detailed description of the 87C752 I O port capabilities and other features IV 3 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 transforme
62. mplifier that demands minimum ON time dominates control of the loop Power to the regulator IC is filtered via R115 and C117 IV 10 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 The positive input of the amplifier senses the power supply output voltage via voltage divider R128 and R119 through R108 The divider is filtered by C127 and C118 R C network R102 and C106 compensate the amplifier ensuring stable operation R120 is placed in parallel with R119 via Q102 to change the maximum charging voltage during CV or CC charging R121 is the gate protection resistor in Q102 During battery charging the current feedback amplifier U102A dominates control of the loop The output current of the power supply is measured through sense resistor R127 The sense voltage developed across this resistor is then compared to a fraction of the on board 1 2V reference determined by the voltage divider resistors R104 and R105 The result of this compare function is to limit the output current of the power supply to 1A during CV charging and by placing R129 across R104 to 500mA during CC charging Capacitor C125 provides stabilization for this control loop C105 and C113 provide RF filtering and C104 provides power supply
63. ng the Heat Sink Mounting Brackets should be torqued to 9 10 inch pounds VII 8 DISASSEMBLY PROCEDURES 3 TRANSFORMER SCREWS 4 PLACES 1 WIRING DIAGRAM e BLACK ERIT BLACK DEN 1 13 z 9 amp T WHITE J3 sr 8 6 BLUE 7 gt ps RED 2 1 a 3 PY 1 9 VU BROWN GROUND WIRE U F PCB POWER TRANSFORMER WI SER HARNESS FASTONS POWER SUPPLY HARNESS FASTONS VII 9 DISASSEMBLY PROCEDURES 4 REMOVING THE TRANSFORMER TOOLS REQUIRED e No 1 Phillips head screwdriver e Needle Nose Pliers 1 Remove the Base Pan as described in VII 3 2 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 Remove the upper mounting bracket and screws Remove the Transformer INSTALLING THE TRANSFORMER TOOLS REQUIRED No 1 Phillips head screwdriver 1 Reverse steps 2 thru 5 above 2 Install the Base Pan as described on Page VII 3 NOTE e Screws above to be torqued 7 9 inch pounds e The PCB Power Harness is routed under the ground wire attached to the rear plate If mis routed the Base PowerCharger may exhibit HI POT failures or fuses blowing VII 10 DISASSEMBLY PROCEDURES
64. of time T required to arrive at this CC charge point e 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 remains constant or begins to drop during a three minute period e The controller will then maintain a top off CC charge for a period of time equal to the value T obtained above divided by 6 i e Timex T 6 e Upon completion of the top off phase the controller will return to an appropriate mode to maintain a float charge on the battery The controller will remain in this state until the AC power or the battery is removed IV 14 FUNCTIONAL DESCRIPTION I O Signal Summary Pinno UO SignalName Definition Comments s Qvo g BateyChagePin i BISENS Battery Sense Battery 1 detection signal 9 Qvo 81 BateyRum oo le Qvo Bae Batterychargerin 7 2 s2sens Battery Sense Battery 2 detection signal AAA 1o wo e BateyReum 7 vo 83 Batterychargerin la BOSENS Battery Sense Battery 3 detection signal m vo o BateyRum 0 la Quo Bas BateryChagePin 7 4 i BASENS Battery Sense L atenn detection signal om juo o _ BateyRum Diagnostics The following sections describe several types of diagnostics that will be performed by the system to insure product safety and simplify assembly and test requirements
65. prised of D110 C131 and R140 which charges up to 5V at each pulse After the voltage across C131 exceeds 2 4 volts both Schmitt triggered gates U107B and U107D are enabled Since the R C time constant of C131 and R140 is much slower than 500 Hz the rectified voltage does not have time to drop below the logic high threshold limits of U107 4 and U107 12 before the next pulse occurs If a failure causes the microprocessor to halt leaving the CHRG ENB signal at either a stable logic high or logic low R141 will pull both U107C 9 and U107C 10 inputs high This action causes the mode select gates U107B and U107D to be disabled 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 possible voltage and current limiting values are selected via control gate U107A and U107B The microprocessor asserts SSELO low at U104 26 to select a one amp charge rate FET Q104 turned off via control gate U107A and a nominal CV voltage setting of 11 75 volts FET Q102 turned off via control gate U107A If the SSELO signal is driven high FETs Q104 and Q102 are turned on to establish a current control setting of 500 mA and a voltage limit of 16 5V by placing shunt resistor R129 across R104 via Q104 and R120 across R119 via Q102 the gate of Q102 is protected by R121 and the gate of Q104 is protected by R130 For a summary of t
66. r and enters the board via 2 pin connector J3 This AC input is rectified by bridge BR1 and filtered by capacitors C133 C233 C333 and C433 Any transients from the line which are not eliminated by the filter capacitors are absorbed by the metal oxide varistor TV1 JP8 R42 R43 R44 and D11 dissipate energy stored on the caps when AC is turned off JP8 allows this dissipation circuit to be disabled 12Vdc Supply U3 with R7 and R8 provide a regulated 12 volts used to operate the alarm C1 provides RF bypassing C2 is a voltage filter capacitor D1 is a reverse current protection diode JP7 provides the user with the ability to select where the raw voltage comes from for the alarm Logic Power Supply A 5V 25V power supply is produced from the 24 Vac input originating from connector J3 to power the analog and digital circuitry on the board D4 and D5 along with C8 R9 and C3 rectify and filter this AC input voltage providing an unregulated 30Vdc input voltage for the fixed 5V output switching regulator U4 U4 along with D3 L1 C5 C6 C7 and R11 are implemented in a buck configuration D2 provides a 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 used to create all of the reference voltages that are routed to the charging compartments U9 is biased by R27 and buffered by
67. ry voltage over a range of 8 5 to 16 5 volts to determine the battery s charge status and if it or the internal control electronics or the power supply has failed The microprocessor resolves the voltage reading to within 50 millivolts 33mV 8 bit in order to support the battery charging algorithm requirements Op amp U105A forms a basic amplifier circuit with a gain of approximately 0 574 and an offset of 8 01V established by the resistor combination R111 R112 and R110 Resistors R133 and R132 form a voltage divider to drop the battery voltage by a factor of 6 to keep the 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 Capacitors C111 and C108 provide noise filtering while and capacitors C109 and C110 provide RF interference and static discharge protection C119 is a power supply bypass capacitor AND voltage 5 Battery voltage 8 01 0 574 Current Sense Circuitry The microprocessor monitors the supply current over a range of approximately 0 to 2 amps to determine the battery s charge status or if a control circuit has failed The microprocessor resolves a current reading to within 8 3 milliamps in order to support the battery charging control requirements OP amp U102B forms a basic amplifier circuit with a gain of approximately 24 to amplify the current sense signal through the 10
68. s VI 14 VIII Replacement Parts e Field Replaceable Units eee aaa aaa aaa aaa ee VIII 2 APPENDIX A OPERATOR S MANUAL 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 Operator s Guide Service Technicians should be aware of all safety considerations prior to servicing the equipment THE BASE POWERCHARGER DEVICE SHOULD BE SERVICED BY QUALIFIED PERSONNEL ONLY Unauthorized persons should not attempt to service this device The Base PowerCharger is protected against interference from radio frequency emissions typical of two way radios used in emergency service public safety activities Users of the Base PowerCharger should assess the devices performance in their environment of use for the possibility of radio frequency interference 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 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 Do not use the Base PowerCharger until the unit has been inspected by the appropriate personnel
69. s 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 For more information see the Battery Charging Algorithm section Battery Test Mode This mode will occur only if the test button is activated and a battery is detected by the controller The TESTING indicator will be activated whenever the channel is in this test mode The battery test sequence will be as follows First the battery will be fully charged e Battery charging will then be disabled e A test load will be presented to the battery The load is to simulate the load presented by the 1400 Series Devices This load will be maintained until the battery is depleted e The capacity will then be calculated see discussion below e Finally the battery will be recharged If the capacity is determined to be adequate a BATT READY indicator will be activated after the battery is recharged and the TESTING indicator will remain on If the 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 the battery or interrupt the AC power Refer to the Battery Charging Algorithm section Unit Test Mode This mode occurs only if
70. st 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 C22 and C21 provide RF filtering Since thermistor RT1 has a nominal value of 10K at 25 C the output voltage at room temperature will be 2 5V midrange on the microprocessor A D With an 8 bit converter on each microprocessor the system s internal ambient temperature can be determined within the range 0 70 C with 596 accuracy and 1 C resolution Temperature compensation is based on ambient not battery temperature Alarm Circuitry U1A and R1 R2 and Q1 provide the control mechanism for turning the alarm LS1 on from the alarm ports located on each compartment microprocessor Battery Detection Circuitry A set of battery detection circuits comprised of differential amplifiers USA USB USC and U5D and associated components signals each microprocessor if a battery is installed into its charging compartment The input signal for each circuit is the battery sense lead which enters the board along with the battery positive and negative terminals via connector J1 A resistor divider R13 R14 R15 R16 etc is used 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 the negative input p
71. sults on Test Data Sheet Page Il 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 Il 4 Subtract the two values and the difference should be less than 1 ohm Il 3 Rev D MANUAL TEST CHECKOUT PROCEDURES Record Results on Test Data Sheet Page Il 4 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 Press each of the four 4 TEST buttons corresponding to each of the four 4 battery compartments The unit will light all of 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 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 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 Ill 3 to identify the fault and take corrective 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 bat
72. tall the Base Pan as described on page VII 3 NOTE e Screws above to be torqued 7 9 inch pounds VII 5 DISASSEMBLY PROCEDURES VII 6 DISASSEMBLY PROCEDURES ES PLAC WS SCR SCREW SECURING GROUND WIR VII 7 DISASSEMBLY PROCEDURES 3 REMOVING THE HEAT SINK TOOLS REQUIRED e No 1 Phillips head screwdriver e Adjustable Wrench Remove the Base Pan as shown on page VIl 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 Remove one 1 screw securing the ground wire to the Heat Sink Remove the two 2 Heat Sink Mounting Brackets if necessary NO aA F WN gt Remove the Heat Sink INSTALLING THE HEAT SINK TOOLS REQUIRED e No 1 Phillips head screwdriver 1 Reverse steps 2 thru 7 above CAUTION When reconnecting the components to the Heat Sink check the following e That there are no burrs nicks or scratches on the surface of the Heat Sink especially where the components will mount e That there are no metal flakes chips or other debris that might have attached to the Heat Sink e That the thermal pad is installed and is properly seated 2 Install the Main PCB as described on Page VIl 5 3 Install the Base Pan as described on Page VII 3 NOTE e Screws above to be torqued 7 9 inch pounds e The two 2 screws securi
73. tery 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 Il 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 9650 0072 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 Il 4 Rev D CHECKOUT PROCEDURES BASE POWERCHARGER DEVICE CHECKOUT PROCEDURE DATA SHEET OPERATOR COPY THIS FORM BEFORE USING SECTION 1 LEAKAGE TEST 1 1 Chassis Leakage Normal Pol w Ground YES or NO Normal Pol No Ground YES or NO Reverse Pol No Ground YES or NO Reverse Pol w Ground YES or NO 1 2 Ground Wire Leakage Normal Pol No Ground YES or NO Reverse Pol No Ground YES or NO SECTION 2 FUNCTIONAL TEST 9650 0072 Il 5 Rev D CHECKOUT PROCEDURES 2 1
74. the specified range The charging voltage was measured to be below the specified range The amount of current during a charge was below specified range 111 4 R N 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 A EE 1 y APC A L s ne Ze A p koki Aaa i IV 2 Common Circuitry Description sms IV 3 Compartment Circuitry Description IV 5 LED BOB DENS IV 12 IV 1 FUNCTIONAL DESCRIPTION 1 SYSTEM NOTE Any reference to PD 1400 includes PD 1400 D 1400 PD 2000 D 2000 and ZOLL 1600 unless otherwise specified Product Overview The ZOLL Base PowerCharger ka i 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 id with QuickCharge or AutoTest provides four battery charging testing compartments Up to four battery packs may be charged or tested in any combination at one time The ZOLL Base PowerCharger can be configured in either the AutoTest or QuickCharge mode This configuration is performed by ZOLL Medical Corporation prior to device shipment The Base PowerCharger is clearly labeled AutoTest or Quic
75. the test button is activated for two seconds with no battery installed When a self test is performed all LED s illuminate for a brief period of time and if successful the TESTING and BATT READY indicator s are turned on for a few seconds or if there is a failure the FAULT LED is turned on and left on This test will be also run automatically at power up and after a battery is removed Fault Mode If a fault is identified by the controller the FAULT LED for that channel will light all other LED s for that channel will be turned off If the test button is activated for 2 seconds in this state then one of 15 patterns of the four LED s will be activated to indicate the type of fault This pattern will remain on only while the key is pressed This mode will be reset every time a battery is installed or removed and at power up See the Operator s manual for a description of the fault codes Idle Mode If the battery is not in place the channel will remain in a standby mode all LED s are off except for the AC Power LED IV 13 FUNCTIONAL DESCRIPTION Battery Charging Algorithm The algorithm used to charge the battery in both the charge and test modes is as follows e When a battery is installed the controller will begin charging operation in a CV charge mode Atthis time a charge timer will be started e The CV mode will continue until the charge current drops to the constant current charge rate The controller will then record the length
76. ti th rs 9320 0022 31 Power Entry Module boob e oe e RR ER 0500 0022 32 Screw 4 A0x3 B a nissan 0163 1316 VIII 2 33 34 35 36 37 38 39 40 REPLACEMENT PARTS Locknut Hex 4 40 with Nylon Insert ss 0163 0044 Heatsink sci E a et ob gi A poz aint ed 9165 0002 HeatSink Mounting Base us 9320 0047 Label Screw COVER ic OTW eni te ee a eria ED a A 9305 0101 Slow Blow Fuse 2A 250V nn ran nanna rna 0180 0003 Label Fuse Warning tet Rd hun tite c n ci tun 9305 0258 01 SHANK TUBING oM THEE 0500 0204 Label Specification a eter eT ee m tien een 9305 0268 01 VIII 3 REPLACEMENT PARTS VIII 4 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 Be sure to observe anti static precautions whenever the unit is open Assembly and disassembly should be performed on a soft protected work surface to guard against scratches 1 Remove the eight 8 screws located in the base pan of the Base PowerCharger Four 4 screws in the feet of the base pan do NOT need to be removed Lift base pan straight up and remove 2 Locate four 4 software proms U104 U204 U304 and U404 Refer to diagram for correct orientation of the software proms With

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