UNE

Medical

Giraffe™ Incubator
Service Manual
Important ~ ou
The information contained in this service manual pertains only to those models of products which are mar-
keted by Ohmeda Medical as of the effective date of this manual or the latest revision thereof. This service
manual was prepared for exclusive use by Ohmeda Medical service personnel in light of their training and
experience as well as the availability to them of parts, proper tools and test equipment. Consequently,
Ohmeda Medical provides this service manual to its customers purely as a business convenience and for the
customer's general information only without warranty of the results with respect to any application of such
information. Furthermore, because of the wide variety of circumstances under which maintenance and repair
activities may be performed and the unique nature of each individuals own experience, capacity, and qualifi-
cations, the fact that a customer has received such information from Ohmeda Medical does not imply in
anyway that Ohmeda Medical deems said individual to be qualified to perform any such maintenance or
repair service. Moreover, it should not be assumed thai every acceptable test and safety procedure or
method, precaution, tool, equipment or device is referred to within, or that abnormal or unusual circumstances,
may not warrant or suggest different or additional procedures or requirements.

This manual is subject to periodic review, update and revision. Customers are cautioned to obtain and consult
the latest revision before undertaking any service of the equipment.

CAUTION A Servicing of this product in accordance with this service manual should never be undertaken
in the absence of proper tools, test equipment and the most recent revision to this service
manual which is clearly and thoroughly understood.

This static control precaution symbol appears throughout this manual. When this symbol appears
next to a procedure in this manual, static control precautions MUST be observed. Use the static
的 control work station (Stock No. 0175-231 1-000) to help ensure that static charges are safely
conducted to ground and not through static sensitive devices.

Technical Competence
The procedures described in this service manual should be performed by trained and authorized personnel
only. Maintenance should only be undertaken by competent individuals who have a general knowledge of and
experience with devices of this nature. No repairs should ever be undertaken or attempted by anyone not
having such qualifications. Genuine replacement parts manufactured or sold by Ohmeda must be used for all
repairs. Read completely through each step in every procedure before starting the procedure; any exceptions
may result in a failure to properly and safely complete the attempted procedure.

Definitions
Note: A note provides additional information to clarify a point in the text.
Important: An important statement is similar to a note, but is used for greater emphasis.
CAUTION: A CAUTION statement is used when the possibility of damage to the equipment exists.

WARNING: A WARNING statement is used when the possibility of injury to the patient or the operator exists.

A Type B Electrical equipment

UI Protective ground

L Functional Ground

Alternating Current (AC)

A Static Control Precaution

European Union Representative

Table of Contents

Chapter 1 — Functional Description

1.1 Control Board
1.2 Relay Board
1.3 Display Driver Board/EL Display .
1.4 LED Board
1.5 Power Supply
1.6 Peripheral Components...

Chapter 2- Service Checkout

2.1 Mechanical CHECKS iii 2-1
2.2 Controller checks
2.3 Accessory checks
2.4 Cable Connections and Mechanical Controls ....

Chapter 3- Calibration and Maintenance

3,1 Maintenance Schedule ii 3-1
3.2 Special Tools
3.3 System Calibration .. .
3.4 Line Voltage Calibration..... „3-3
8.5 Humidifier calibration... ei 8-4
8.6 Scale Calibration ..
3.7 Leakage Current ...
3.8 Ground Resistance

Chapter 4- Troubleshooting
4.1 Service Screen
4.2 Alarm Messages..
4.3 Error Codes....
4.4 Troubieshooting Table
4.5 Additional Troubieshooting Tips

Chapter 5- Repair Procedures

5.1 Hood removal for replacement ...
5.2 Uprights and End caps...
5.3 Compartment Probe repairs
5.4 Lower Unit Repairs ..............
5.41 Removing the chassis cover with the storage door in place...
5.42 Incubator fan/motor/optical sensor.
5.43 Cartridge heater replacement ..
5.44 Elevating base ...
5.45 Chassis repiacement ..
5.46 Elevating footswitch .......
5.47 Humidifier heater Replacement
5.5 Bed Tilt Brake Shoe Replacement
5.6 Castor Replacement ....................
5.7 Controller and Display Module repairs.
5.71 Display module .
5.72 Probe panel ......
5.73 Controller components
Control Board ........
Relay Board ....
Solid State Relay
Power Supply ..

Toroidal Transformer ...

Circuit breakers, power switch and outlets ..

6600-0356-000 08/15/01
Table of Contents
Chapter 6- Illustrated Parts
6.1 Exploded VieWS eee esere aseareeremaaresesern
6.11 Probe housing, display module and electrical enclosure ...
6.12 Bed and side doors
6.13 Hood and Compartment Probe ..
6.14 Chassis...
6.15 Humidifier.
6.16 Elevating base
6.17 Hood latch, wire covers and uprighis
6.18 Accessoryhangers....................
6.19 Storage drawer and shelves ...
6.2 Accessories...
6.3 Labels ........
6.4 PCB layouts ..
6.5 Wiring diagrams

Appendix
Compartment and Skin Probe Characteristics ..
Specifications

Lisi of Figures
1-1 Block Diagram ....

2-1 Cable connections and mechanical controls

8-1 Control board test points... issu 3-2

4-1 First service screen .

4-2 Second service screen
4-3 Status menu................
4-4 Switch diagnostic diagram ...
4-5 First service screen- diagnostics

5-1 Hood.. RS . 5-1

5-2 Uprights and endcaps .
5-3 Compartment probe .
5-4 Bed disassembly
5-5 Fan motor ..........
5-6 Heat sink and fan ..
5-7 Elevating base ...
5-8 Chassis bottom cover .
5-9 Humidifier parts ...........
5-10 Replacing the tilt brake.
5-11 Display module...
5-12 Probe panel........
5-13 Electronics enclosure ...

6-1 Prope Panel AssemDly erer eremaremenaasanaasansnzn 6-1

6-2 Display Module
6-3 Electrical enclosure .
6-4 Bed
6-5 Side door (E/W)
6-6 Flip door, corner brackets and grommets ..
6-7 Compartment Probe
6-8 Upper chassis and heat sink ..
6-9 Lower chassis ..
6-10 Humidifier

08/15/01 6600-0356-000
Table of Contents
6-11 Base and elevating column
6-12 Hood latch and wire covers...
6-13 Uprights and End caps.........
6-14 Drainage hangers and DIN rail
6-15StrorageDrawer......................
6-16 Instrument Shelf ..
6-17 Monitor Shelf........
6-18 E-Cylinder holder ...
6-19 Tubing management arm .
6-20 Dovetail mount DIN rail .
6-21 Control board ............
6-22 Display driver board
6-23 Relay board
6-24A Wiring Diagram Control Board . ..
6-24B Wiring Diagram Elevating Base ss. nn 6-35
6-24C Wiring Diagram Electrical Enclosure низине ил и зути вил ин ит ни я 6-36
6-24D Wiring Diagram Graphics Display ..
6-24E Wiring Diagram Incubator

6600-0356-000 08/15/01
Precautions

AWarnings
Before using the Giraffe Incubator, read through the entire operator's manual. As with all medical equipment,
attempting to use this device without a thorough understanding of its operation may result in patient or user
injury. This device should only be operated by personnel trained in its operation under the direction of qualified
medical personnel familiar with the risks and benefits of this type of device. Additional precautions specific
to certain procedures are found in the text of this manual.

Complete the “Pre-operative Checkout Procedures” section of the Operator’s manual before putting the unit
into operation. If the incubator fails any portion of the checkout procedure it must be removed from use and
repaired.

Do not use the incubator in the presence of flammable anesthetics; an explosion hazard exists under these
conditions.

Always disconnect the power before performing service or maintenance procedures detailed in this manual.
Apply power only if you are specifically instructed to do so as part of the procedure.

Thoroughly air dry the incubator after cleaning it with flammable agents. Small amounts of flammable agents,
such as ether, alcohol or similar cleaning solvenis left in the incubator can cause a fire.

A Gautions
Only competent individuals trained in the repair of this equipment should attempt to service it as detailed in this
manual.

Detailed information for more extensive repairs is included in the service manual solely for the convenience of
users having proper knowledge, tools and test equipment, and for service representatives trained by Ohmeda
Medical.

iv 08/15/01 6600-0356-000
 Chapter1- Functional Description
This functional description is divided into four sections representing each of the four boards. The reader
should also reference the block diagram and wiring diagram when studying this section.

1.1 Control Board

The Intel 80C188EC microcontroller is an enhanced X86 processor with many on-board peripheral features,
such as a interrupt controller, DMA controller, peripheral chip select driver, programmable timers, etc. A
programmable timer is used fo control the heaters. The input fo this timer is line frequency. This allows the
control signal to be synchronized with the line frequency to better control the zero-crossing solid state relays.
The on-board interrupt controller has several interrupts: analog-to-digital converter (ADC) conversion ready
signal, overtemperature comparator output, watchdog output, power fail signal, and module interrupt signal
from the system data bus. The microcontroller external bus is a multiplexed address and data bus.

The system memory consists of a programmable read-only memory (PROM) and static random access
memory (SRAM). The EEPROM is used for calibration values and infrequently changing variables. This
memory holds the data even after power is turned off.

The RS-485 integrated circuit converts the RS-232 TTL signals from the microcontroller to RS-485 signals for
the bus. This bus is the main communications bus from the control board to all other boards with processors.

There are two isolation transceivers used to isolate the circuits powered by +5V and the circuits powered by
+5VSTBY (battery backup). r

The board contains a 16 channel multiplexer. There are seven temperature measurement channels. These
channels measure the two patient probes with two thermistors each, the two air temperature thermistors used
for display and control, and an additional thermistor used to measure the heat sink temperature.
Additional channels include the humidity sensor (RHIN), LINE COMP, 5 Volts, Motor current, Vihref, VDAC,
and 1.2Vind.

Attached to the environmental probe connection is the relative humidity signal conditioning circuitry. The 1V
reference that is used for the analog circuitry is also the maximum input voltage and the offset voltage for the
ADC. This yields a purely ratiometric system.

The overtemperature circuit compares the air temperature to a reference level, generates an interrupt, and
turns off the heat if the air temperature is higher than the reference level. Since the thermistor measurements
are digitally calibrated, the circuit must allow for various voltage levels for overtemperature thresholds.

The watchdog function is housed in a RISC processor. The watchdog circuitry is independent of the 800188
controller. The audio function is also programmed into the RISC processor. The audio circuit includes a 8752
microcontroller that reads a wavetable located ina PROM and sends the table to a digital audio circuit and
amplifier. The high priority (HP) and other alarm signal lines select an output at the correct frequencies.
Three OR gates are combined to generate the error signal. The inputs to the circuit are overtemperature,
power failure, and system failure. This circuit generates an error signal that turns off the heater and sounds the
HP alarm. This circuit is independent of the microcontroller.

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Chapter 1- Functional Description

Microprocessor Time Membrane Switches

LED Board
PROM

SRAM Knob
EL Displa
pay Display Driver Board

Tem
Microprocessor Channels

Overtemp
PROM |

Watch
SRAM HH Dog
Audio
Control Board

Relay Board

RS485

Future Options
and
Modules
Power Supply

Figure 1-1
Block Diagram

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 Chapter1- Functional Description
1.2 Relay Board
The relay board contains the circuitry to drive the two solid state relays and the safety relay circuits. The
control signal for these functions is generated on the Control Board.

There is a current sense circuit for the bed heater and an additional one for the humidifier heater. These
circuits consist of a smail signal transformer that produces a current proportional to the current through the
heater circuits. The current is rectified and measured. The subsequent comparator then generates a digital
level based on a specified current level. This results in a signal representing the state of the heater (on or off).

The line compensation circuit consists of a signal transformer connected to the mains voltage. The secondary
of this transformer feeds a full wave rectifier and a capacitor. The resulting DC voltage is proportional to mains
voltage, and is measured on the control board.

The line frequency circuit consists of a half wave rectifier and a comparator. This circuit generates a digital
pulse synchronized with the line frequency (50 or 60 Hz).

The battery backup circuitry is connected to the +12V line. The 5V regulator generates the +5V standby from
either the +12V or the battery voltage, whichever is larger. If there is no mains power, 12 volts is not present,
and the battery will generate the +5V standby. When 12V is present, the battery is biased out of the circuit
with the diode and is merely being trickle charged.

The motor driver circuit turns the DC motor coils in the incubator fan motorron and off based on feedback from
the hall effect position sensors. This integrated circuit can also vary the speed and brake the motor based on
input signals from the control board.

The elevating base circuit consists of a series of relays that apply voltage to the elevating base motor. The e-
base motor is always driven at 24-32 volts.

The airflow sensor consists of an opto-coupler that outputs a clocking pulse proportional to the fan movement.
The signal is AC coupled to eliminate offset voltages and drifts. The resulting pulse is half wave rectified and
stored in a capacitor to yield a DC voltage proportional to the fan speed. If the fan stops or there is no fan, this
DC voltage becomes zero.

1.3 Display Driver Board / EL Display

The Display Driver board contains the same Intel microcontroller as the Control board. The processor on the
display board is used to control the EL display contents and monitor user inputs received from the membrane
switch panel and rotary encoder knob.
There are two groups of digital inputs: membrane switch panel and rotary encoder knob. The membrane
switches are pulled high; pressing the switch grounds the input. The encoder also has a switch, and two
optically isolated lines that pulse out of phase with each other. The number of pulses represents the number of
steps the knob rotates. The phase of the pulses represents the direction of the knob rotation.

The display board system memory consists of a programmable read-only memory (PROM) and static random
access memory (SRAM).

The RS-485 integrated circuit converts the RS-232 TTL signals from the microcontroller to RS-485 signals for
the bus.

The timekeeping RAM has a battery integrated into the chip so that the time and date are kept current even
with the power off. The battery has a minimum life of 10 years.

The graphics controller is an S-MOS VGA controller. The graphics controller interfaces the data from the video
RAM to the EL display. The controller also synchronizes the display using a horizontal pulse (LP) anda
vertical pulse for the whole display frame (YD). The controller handshakes with the 80C188 using the READY
line to eliminate any lost data during display refreshes.

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Chapter 1- Functional Description
1.4 LED Board
The LED Board contains five display banks and two display drivers. One of the display drivers controls the
patient temperature and air temperature display banks. The other driver controls the patient set temperature,
air set temperature, and the mode and override indicators.

This allows the two large displays (patient and air temperature) to be multiplexed at a slower rate than the
other LEDs. This results in brighter large displays. Each driver has a brightness potentiometer that is preset
at the factory and should not be adjusted in the field.

1.5 Power Supply

The universal input switching power supply converts the line voltage to +5V DC and +12V DC. This supply can
source up to 75 watts. The 5 volts powers the electronics and the 12 volts is used by the EL display and for
future boards.

1.6 Peripheral Components

There are several peripheral components.

The toroidal transformer bucks the line voltage to the range of the elevating base system.

The solid state relay mounted inside the electronics enclosure is used to control the bed heaters.

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 Chapter 2- Service Checkout
WARNINGS 4, Do not perform the preoperative checkout procedure while the-patient occupies the
unit.

A, Complete the preoperative checkout procedure section of this manual before

putting the unit into operation. If the equipment fails any portion of the checkout
procedure it must be removed from use and repaired.

2.1 Mechanical checks

Disconnect the power cord for the mechanical portion of the preoperative checkout procedure.

Examine the power cord for any signs of damage. Replace the cord if damage is evident.

Check that both plug retaining brackets are in place.

Examine the unit overall for any damaged or missing parts.

Check that all the casters are in firm contact with the floor and that the unit is stable. Lock the caster
brakes and check that they hold the unit in place. Release the brakes and check that the unit moves
smoothly.

Check the operation of the side doors. Open the doors and check thatthey swing all the way down and
hang perpendicular to the bed. Check that the doors are securely attached to the unit and that the hinge
pins are properly seated. Check that the inner walls are securely fastened to the doors. Close the doors
and check that the latches hold the doors securely shut. The orange latch open indicators should not be
visible when the latches are engaged. Check that the hood is in the iocked position.

Check the tubing acces door at the top of the ventilator slot in the back wall. it should flip up easily and
smoothly, and stay in position anywhere on its travel path.

Check the portholes. Open the portholes by pressing on the latch. The cover should swing open. Close the
porthole and check that the latch holds the cover securely shut and that the cover seals tightly against the
porthole gasket. Check that all the porthole seals are in place and are in good condition.

If the unit is equipped with an iris porthole, check the iris is installed and in good condition. Check that the
iris tightens when it is rotated.

10. Check that the tubing access covers in the four bed corners and the large siot grommet at the head of the
bed are in place and are in good condition.

11. Check the operation of the bed. The bed should rotate easily without binding. If the bed is properly seated
and locked in place, the mattress should be level. With the bed rotated back into the straight position,
check to see that the bed platform extends and stops when it is pulled out on either side. Check the
operation of the bed tilt mechanism. Squeeze the tilt control and push down on the foot of the bed. The
head of the bed should raise easily, and should stay in position at any angle along its tilt path when the tilt
control is released. Push down on the head of the bed. The foot of the bed shouid raise easily, and should
stay in position at any angle along Its tilt path when you the tilt control is released.

12. Check the operation of the hood lock. Release the lock and raise the hood. Make sure it locks in the open
position. Release the lock and lower the hood. Make sure it locks in the closed position.

6600-0356-000 08/15/01 2-1

Chapter 2- Service Checkout

2.2 Controller checks

WARNING А Do not use the Incubator in the presence of flammable anesthetics: an explosion
hazard exists under these conditions.

Connect the incubator power cord to a properly rated outlet .*

Connect the patient probe to jack 1 on the probe panel.

Switch on the power at the mains switch on the back of the unit, and at the standby switch on the jack
panel, while holding in the override button (>37) on the dispiay during power up until the software revision
screen appears. Release the button and the first service screen will appear.

Scroll to “Down? and select it to bring up the second service screen. Select Status to see Status screen.
Check status of the software self tests. These include: heater on (INCHTRON), ) heater off (IHTROFF),
humidifier heater on (RHHTR), remote monitoring data stream (RS232LOOP), incubator fan on (FANON),
and incubator fan off (FANOFF). All test should say PASS except RS232 LOOP. If the RS232 option is not
installed RS232LOOP will display N/A. To test the circuit if the option is installed, short pins 2 & 3 on the 9
pin connector on the back of the electrical enclosure.

Using the standby switch turn off the unit, then turn it back on.

Verify the following:

- All the displays and indicators light
- The software revision appears
- The prompt tone begins

Note: If the unit has been used in the last 2 hours, the patient history query appears.

Adjust the set temperature to silence the prompt tone.

Check the patient probe. If the probe is below 30 G, the display will show -L-. Warm it by placing it be-
tween your fingers, and verify that the baby temperature reading increases.

Unplug the patient probe and check that both visual and audio alarms trigger in the Baby control mode.

If so equipped, check the operation of the bed elevating system. Raise and lower the bed along its entire
travel range, checking that the mechanism operates smoothly. Check that the pedals on both sides of the
unit raise and lower the bed.

10. Check the power failure alarm and the battery backed up memory. Make note of the current control mode
and temperature settings and wait one minute, then unplug the Incubator from the wall outlet. An alarm
should sound and the power failure indicator should light. Wait one to two minutes and plug the Incubator
back in. Verify that the alarm cancels and that the Incubator returns to the same control mode and tem-
perature settings it displayed before the power interruption.

Note: A fully charged battery should supply the power failure alarm for approximately 10 minutes. If the
alarm is tested for the full 10 minutes the Incubator must be run at least two hours to recharge the battery
before it is used with a patient. Total recharge time is 8 to 10 hours.

12. Perform the Leakage Current and Ground Resistance checks in Chapter 3 of this manual.

2-2 08/15/01 6600-0356-000

 Chapter 2- Service Checkout
2.3 Accessory checks

1. Check that all accessories are securely mounted and out of the path of the hood in the open position.

2. Check the operation of any accessories with reference to their appropriate operation manuals.

Setup any required suction or gas supply systems. Check them for leaks as described in their respective
operation manuals.

6600-0356-000 08/15/01 2-3

 Chapter 2- Service Checkout

a 2.5 Cable Connections and Mechanical Controls

Numeric Temperature Displays

Graphics Screen

Ee Tubing access door

Temperature
CE Control Knob
Regulation Ventilator
Controls Hood > Slot
Compartment Probe e Side Door
a Latch
Tubing Grommets =

= "SE
\ Door Latch E

> トー RS 232
— see Connector
À в = тв
ーー ーー 1
Standby Probe Jacks ュー a
Power ーー —
Switch = =
(10) Humidifier Reservoir 一 一
(air intake filter located [qe -M Controlier
behind reservoir) ° Cover
Drainage =
Hanger Accessory 一 Mains Power
Caster Power Outlets Switch
Brake

FRONT BACK

Figure 2-1
Connections and controls

2-4 08/15/01 6600-0356-000

 Chapter 2- Service Checkout

Control Panel

Portholes

Hood 八
[一 一Upright

Side Door Latch |

E Dovetail rail

Ps Hood latch

ο ο G

7 “OF
Drainage
Hanger NS | OA
圖 へ Pieural Drainage Hanger
Storage Drawer
|교가
Eievating Column

SIDE \
Bed Height Pedal

6600-0356-000 08/15/01 2-5

Chapter 2- Service Checkout

2-6 08/15/01 6600-0356-000

 Chapter 3- Calibration and Maintenance
Use Static Control Work Station to help ensure static charges are safely conducted to ground.
© The velostat material is conductive; do not place electrically powered boards on it. Whenever
this symbol appears beside a procedure, take static control precautions.

WARNING A After performing any repair or calibration, always perform the Service Checkout Proce-
dure before putting the unit back into service.

3.1 Maintenance schedule

The unit should be maintained in accordance with the procedures detailed in this manual. Service mainte-
nance must be performed by a technically competent individual.

Service maintenance

This schedule lists the minimum frequencies. Always follow hospital and local regulations for required
frequencies.

Annually

Perform the electrical safety and calibration procedure as described in the service manual.

Calibrate the scale.

Every Two Years

Replace the battery.

Note: The battery is used to sound the power failure alarm and to power memory circuits during a
power failure.

Every Three Years

Calibrate the humidifier.

3.2 Special Tools

The foliowing tools (or their functional equivalents) are required to complete the recommended
service procedures:

Digital Multimeter, 4-1/2 digit

Leakage Current Tester
Static Control Work Station (recommended)
Light gray touch-up paint (Munsell .16GY8.56-0.44 chroma)-18m1 ........ 6600-07 14-200
Servo Humidity Calibration Kit... 6600-0048-850
Scale calibration weight- 5kg ............ eai 6600-0209-800

6600-0356-000 08/15/01 3-1

Chapter 3- Calibration and Maintenance

Г ーー、

if
b

T
σον |

TT
는
ター |
— y
Calibration jumper~——__ iP.

C
W

Néd BRAS
AZB|
Test Point 1
or
E

μα

Softuare PAR 1812

BiP

Figure 3-1
Control board test points

3-2 08/15/01 6600-0356-000

 Chapter 3- Calibration and Maintenance

3.3 System Calibration

Note: If Only performing line voltage calibration, follow instuctions in next section, 3.4.

Important: Be sure to perform System Calibration after replacing a control board.

1. Turn power off.

2. Remove electrical enclosure back panel.

Unplug the temperature sensors from J1, J4 and J2 on the control board.

Move jumper JP1 to the CAL MODE position on the control board (see Figure 3-1 on next page). Be sure
io orient the jumper correctly so pins 5-6 and 7-8 are shorted.

Turn power on. After running the power-up testing INITIALIZING will be displayed and dots will move
across the top of the screen.

After about 90 seconds CALIBRATION MODE, Enter “VREF”, and Enter “Mains” will be displayed.

Using a 4 % digit DVM (capable of measuring to 0.1 millivolt) measure VREF at TP1, pins 1 and 6 (pin 6 is
ground) on the control board. Measure to the nearest 0.1 millivolt.

Dial in VREF using the control knob. Press the knob to enter the value.

Measure the Mains Voltage at the AC connectors at the bottom of the electronics enclosure cover.

10. Dial in the Mains voltage using the control knob. Press the knob to enter the value.

11. After a few seconds the dots will stop moving across the screen and DONE will appear on the top right of
the display. Do not shut off the unit until the DONE message is displayed or the new calibration values will
not be stored.

If the message “Mains voltage calibration failed. Please enter the mains voltage again” appears this
indicates the dialed in line voltage is 20% different than the measured value (not the nominal value).

12. Power down the unit and move the calibrate jumper to the NORMAL MODE position. Be sure to orient the
jumper correctly so pins 1-2 and 3-4 are shorted. -

3.4 Line Voltage Calibration

Important: Be sure to perform line voltage calibration after replacing a relay board.

1. Hold the overide button (>37) while powering up the unit to enter the service screen.

2. On the second service screen select CAL LV.

Measure the line voltage at the AC connectors located at the bottom of the electrical enclosure.

On the CAL LV screen, dial in the mains voltage value that you measured and push the knob to enter it.

When calibration is completed screen will say Mains Voltage Calibration Complete.

If the message “Mains voltage calibration failed. Please enter the mains voltage again” appears this
indicates the dialed in line voltage is 20% different than the measured value (not the nominal value).

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Chapter 3- Calibration and Maintenance
3.5 Humidifier Calibration
Important: Be sure to re-calibrate the humidifier whenever either the sensor or the control board is
replaced.

Important: |n order for the water in the calibration bottle to be completely saturated, most of the salt
should not be dissolved. There should be as little standing water above the salt line as possible to mini-
mize the response time. The salt in the calibration bottle may only be used for a period of one year after it's
initial mix with water then the kit should be discarded.

Take the cap off the humidity calibration bottle and add one half cap full of distilled water to the bottle,
Shake the bottle to thoroughly mix the salt and water solution. Place the elbow on the bottle. The smaller
end goes over the bottle.

Slide the elbow over the humidity sensor (mounted on the back wall) until it stops.

Hold the override key while powering up to enter the service screen.

On the second service screen, select Cal RH. The screen will prompt “Push knob when RH reading is
stable.” Wait for 20 minutes or until the RH display stabilizes (does not change by more than 1% in 5
minutes).

You have the option to select STABLE, SET TO DEFAULT or EXIT. STABLE initiates calibration. SET TO
DEFAULT resets calibration values back to factory default settings. If you started calibration by mistake
(without the calibration bottle in place, for example) you would select SET TO DEFAULT and then calibrate
the unit. lf you have entered the calibration routine by mistake, select EXIT to leave without initiating
calibration

If “RH Sensor Calibration Completed.” is displayed the calibration is complete. Depress the knob to exit
the Cal RH routine.

If "RH Sensor Calibration Failed. Try Again.” is displayed verify your setup and press the knob to try the
calibration again.

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 Chapter 3- Calibration and Maintenance

3.6 Scale Calibration

NOTE: The scale is calibrated using a Class F calibration weight between 1 kilogram and’8 kilograms
(accuracy of 0.01%).

1. Place the test weight on the center of the bed.

2. Hold the override key (>37) while powering up to enter the service screen.

3. On the second service screen, select Cal Scale.

4. Remove the weight and push the knob at the screen prompt “REMOVE THE WEIGHT AND PUSH
KNOB”. The screen will prompt “INITIALIZING......” for a few seconds.

5. Replace the weight and push the knob at the screen prompt “PLACE TEST WEIGHT AND PUSH KNOB’.
The screen wiil prompt “MEASURING ....” for a few seconds

6. When the screen prompis “ENTER TEST WEIGHT” Dial in the test weight to the nearest gram. Press the
knob to enter. The screen will prompt “CALCULATING.” for a few seconds.

7. When the screen prompts:

SAVE AND EXIT
EXIT ONLY <
RESTORE DEFAULT

Select and enter “SAVE AND EXIT”

8. Turn off the power to exit the service mode.

3.7 Leakage Current

Use approved equipment and techniques to test the units leakage current and ground continuity. Follow the
directions supplied by the test equipment manufacturer to verify the following:

1. Less than 300 microamperes measured at any exposed metal surface for equipment rated at 120 Vac, 50/
60 Hz.

2. Less than 500 microamperes measured at any exposed metal surface for equipment rated at 220 Vac, 50/
60 Hz or 240 Vac, 50/60 Hz.

3.8 Ground Resistance Check

Use a electrical safety analyzer to measure the resistance between the ground pin on the line cord plug and
exposed metal of the electronic enclosure. The ground resistance must be less than 0.2 ohms.

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Chapter 3- Calibration and Maintenance

3-6 08/15/01 6600-0356-000

 Chapter 4-Troubleshooting

4.1 Service Screen

To access the service screen, hold in the override button (>37) during power up until the software revision
screen appears. Release the button and the first service screen will appear.

BDAC Volt 0.000

: Language English
Temp σ
Volume Maximum
Pat Alarm 1.06
Elevate Enable
Pat Ctrl Both
Pat Algo
Reserved
Reserved
Scale U gms
Scale R 10g
Comfort Enable
Set Time
: View Mods
ay

Last Ca: 4-12-00 Fri

Figure 4-1
First service screen <

Default options that may be selected from this screen appear along the left side of the screen

DAC Volt Digital/Analog Converter voltage. This is the over temperature voltage that is used by the
system to verify the computer independent circuitry is working. To manually test this circuit
enter voltages from 0 to .5 V. The DV value at the bottom right corner of the screen should
match this value within 10mV.

Language English is the default language that appears on the EL screen, but you can select French,
Spanish, etc., depending on what software is installed.

Temp U Changes temperature displays to show “Fahrenheit”, "Celsius” or "Celsius Only” so the
Fahrenheit option is not present on the user Set-up screen (Celsius is factory set default).

Volume Select one of four volume settings: 1 is minimum, 4 is maximum.

Pat Alarm Set the default Hot Baby/Cold Baby alarm to activate when either 0.5°C or 1.0°C differ-
ence is read between a set temperature and the baby probe temperature.

Elevate Disable or enable the elevating column foot pedal switches.

Pat Ctrl Allows you to disable patient control.

Pat Algo To be used for future software options.

Scale U Select from “Grams”, “Pounds” or “Grams Only” so that the pounds option is not present
on the user Scale screen (grams is the factory default).

Scale R Select from 2 scale resolution settings; 10 grams or 5 grams (10 grams is the factory
default).

Comfort Allows you to remove the Comfort Screen feature.

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Chapter 4- Troubleshooting

Set Time Set real time clock for time, day and date. Choose how date is displayed (North American
or European). Choose a 12 hour (AM/PM) or 24 hour time display.

View Mods Display the current software revision of the options installed on this specific unit (Humidi-
fier, Scale, SPO2, etc.)

Down Go to second service screen.

Up Return to previous screen.

Enable

HFS 1500
LFS 1000

Figure 4-2
Second service screen

INCHTRON
Hours Run INCHTROFF
Cal LV RHHTR
Cal RH RS232L00P
Cal Scale FANON
Man temp al. FANOFF
HFS 1500
LFS 1000

Figure 4-3 : 4-12-00 2 414-4-01 954am

Status menu

4-2 07/27/01 6600-0356-000

 Chapter 4-Troubleshooting
Status Check status of all self test the software runs continuously. These include: incubator
heater on (INCHTRON), incubator heater off (/ HTROFF), humidifier heater on (RHHTR),
remote monitoring data stream (RS232LOOP), incubator fan on (FANON), and incubator
fan off (FANOFF).

If the RS232 option is not installed RS232LOOP will display fail. To test the circuit if the
option is installed, short pins 2 & 3 on the 9 pin connector on the back of the electrical
enclosure.
Overide
control

Up Baby mode
Status control

Εποις Increase
E trol
Hours Run sem
Cal LV

‘Decrease
* control

| "Boost air
| curtain control

Elevating base pedal Humidifier

Figure 4-4
Switch diagnostic diagram

Switches Select to bring up a diagnostic diagram of the unit that displays the status of all the
switches. If the circle next to the switch is lit, the switch is closed; if it’s not lit, the switch is
open. Also, while the switch status screen is active, you can hold down the alarm silence
button to light the alarm light, system failure light and all LED segments to test them.

Errors Lists a chronological log of the last 8 system errors that occurred. Shows error number
and date. It is possible to clear the list.

Hours Run Brings up a screen with 2 hour meters; one that is resetable and one that is not. To reset
the resetable hour meter, highlight CLEAR and push the control knob.
+

Cal LV Use to calibrate line voltage at the factory. To calibrate line voltage follow the procedure in
calibration section (chapter 3) of this manual

Man temp al. Use to enable or disable the patient temperature alarms in the air mode.

Cai RH Brings up humidifier calibration screen. See calibration section for information on how this
screen is used.

Cal Scale Brings up scale calibration screen. See calibration section for information on how this
screen is used.

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Chapter 4- Troubleshooting

A number of diagnostic readings appear on the right side of the service screens.

DAC Vott 0.000

Language English
Temp U
Volume Maximum
Pat Alarm 1.0C
Elevate Enable
Pat Ctrl Bath
Pat Algo
Reserved
Reserved
Scale U gms
Scale R 10g
Comfort Enable
Set Time
View Mods
Down

Figure 4-6
First service screen
Diagnostics

HFS High fan speed. Should be 1500 + 100 (measured at power up only)

LFS Low fan speed. Should be 1000 + 100 (measured at power up only)

RH Relative Humidity. % humidity read in the patient chamber

ADT Air display temperature. Temperature read by the first thermistor in the compartment probe.
Should be + 0.3°C of ACT temperature.

ACT Temperature read by second thermistor in the compartment probe, Should be + 0.3°C of ADT
temperature.

P11 Reading from the first thermistor in patient jack 1. Should be + 0.3°C of P12 temperature.

P12 Reading from the second thermistor in patient jack 1. Should be + 0.3°C of P11 temperature.

P21 Reading from the first thermistor in patient jack 2. Should be + 0.3°C of P22 temperature.

P22 Reading from the second thermistor in patient jack 2. Should be + 0.3°C of P21 temperature.

HSP Heat sink probe resistance. Should be approximately 20000 ohms @ 25°C. See section 4.5
for resistannce verses temperature values.

LV1 Line voltage in first mains cirouit.

LF 60Hz or 50Hz

MC Motor current. Shows current drawn by the e-base motor

TV Thermistor valtage. Voltage of thermistor circuits located on the mother board.

5V Power supply voltage. Should be + 0.25V of 5V

VR Voltage reference. Independent voltage reference. Should be 1.235V + 1%

DV DAC output voltage. lt should match the DAC volt value within 10 mV.

Across the bottom of the screen the date of last time the temperature and line voltage calibration was performed
appears plus the current time settings of the unit.

44 07/27/01 6600-0356-000
 Chapter 4-Troubleshooting
4.2 Alarm Messages
CAUSE ACTION
FAN FAILURE Fan is missing or not turning. Verify the fan is installed and turning. During powerup it
should spin at low speed for a few seconds, stop fora
second, then start again at high speed. If the fan is not
turning replace the fan motor.

Defective optical sensor. If the fan is turning replace the optical sensor.

Defective relay board. If the problem persists replace the relay board.

FAN ALWAYS The heat sink temperature Check heat sink temperature sensor thermistor. See tips.
IN HIGH SPEED sensor thermistor is defective

Defective control board. If the thermistor is OK replace the contro! board.

AIR PROBE The air sensor is defective. Check the air sensor. See tips.
FAILURE
Defective control board. \f the sensor is OK replace the control board.

BAD MEMBRANE Alarm Silence has been on Verify switches. See tips.
SWITCH for more than 20 seconds or If these switches are OK replace the graphics driver
one of the temp control board.
switches has been on for
more than 50 seconds.

POWER FAILURE The 5 volt signal is not Check that power is coming into the unit. Check the
present. power supplies. See tips.

BED HEATER The t-stat is open if the unit was shut off when the heater was hot, allow the
FAILURE (possibly because the unit fan to run for several minutes to cool below 40 then
was shut down when the power down and back up. If the failure still persists
heater was hot) or the heater check the t-stst and heater resistance. See tips.
or t-stat is defective.

Defective cable between Check cable pins 37, 38, 39, and 40 for continuity.
the relay and control board.

Defective incubator solid Replace the incubator solid state relay.

state relay.

Defective relay board. Replace relay board.

HUMIDIFIER Humidifier heater will not Wait for the heater to cool. Check safety T-stat and
FAILURE turn on, because safety T-stat heater resistance. See tips.
is open or heater is defective.

BED UP/DOWN One of the elevating base up/ Check the switches. See tips.
PEDAL FAILURE down switches is shorted.

One of the pedals were Shut off unit and power up again to clear alarm.
touched during power up.

MOTOR DRIVE The elevating base motor Replace the relay board.
FAILURE was running when not
turned on.

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Chapter 4- Troubleshooting

4.3 Error Codes

ERROR # MEANING CAUSE(S) ACTIONS)
0 Display driver board} Defective control board, If the error occurs occasionally, may be random
notresponding. | cable, or display driver causes; e.g., static discharge. If failure persists,
Communication | board check or replace the cable between display driver
error between the and control boards. If failure persists, replace the
display driver display driver board. If failure persists, replace the
board and the control board.
control board

1 No Timer2 The Timer2 circuit of the Replace the control board.

Microprocessor on control
board is defective.

2 Timer2 Too Fast | There is no line frequency | Power cycle the unit. Ifit shows “system failure 8”
signal to feed timer0 & see the instruction below for “system failure 8”. If it
timer1 of the micro on still shows “system failure 2”, replace the control
control board, or the timer2 | board. ・
of the micro on control
board is defective.

3 During ADC All of the thermistors were | Before calibrating make sure J1, J2 and J4 on the
calibration the not unplugged during control board are disconnected. Verify JP1 is
software detected | calibration. correctly positioned. Try calibrating again. If the
a channel out of error persists, replace the control board.
range. Defective circuit on control
board.

5 The 1.235 volt ADC out of calibration. Recalibrate the ADC.

reference
is out of Defective control board. Repiace controi board.
the 1.171V -
1.259V range.

6 Bad overtemp ADC out of calibration. If the error occurs occasionally, may be random
DAC circuit on Defective control board. causes; e.g., static discharge. If failure persists,
the control recalibrate the ADC. If failure still persists, replace
board. the control board.

7 1.0 V Thermistor | ADC out of calibration. Recalibrate the ADC. If the failure still persists
reference voltage | Defective control board. replace control board.
is out of 0.95V -
1.049V range.

8 No Line Defective cable between | Measure the signal on the control board between
Frequency the control board and the |J9 pin 43, and TP1-6 (Ground). It should be a 120
relay board. hertz square wave. If the signal is OK replace the
Defective relay board. control board. If no signal check the 50 pin cable,
Defective control board. pin 43. If bad replace the cable. If cable is OK,
replace relay board.

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 Chapter 4-Troubleshooting
ERROR # MEANING CAUSE(S) ACTION(S)
11 The ADC on the | The humidifier sensor or Disconnect J1 on the control board. If the error
control board is | cable is shorted. persists replace the control board. If it powers up
not operating to | Bad control board. OK either the cable or the humidity sensor is bad.
spec. (too slow) Reconnect J1 and disconnect the humidity sensor
at the compartment probe. If the unit now powers
up OK the humidity sensor is bad, or the cable
is bad.

12 Bad Checksum | Defective control board Change socketed IC U42 on the control board. If
PROM failure persists, replace control board.

13 Bad SRAM Defective SRAM circuit If the error occurs occasionally, may be random
on control board causes; e.g., static discharge. If failure persists,
replace control board.

14 Bad WDOG Defective control board Replace socketed IC U21 on control board. If
Watch Dog failure persists, replace control board.

15 Heater Safety Air temperature sensor is | If the unit was shut off when the heater was hot,
Relay test failure.| above 40C at powerup. allow the fan to run for several minutes to cool to
Unable to turn below 40 then power down and back up.
incubator heater | Air display sensor is Check the air sensor. See tips.
on. shorted.

Defective relay board if failure persists, replace relay board.

Defective DAC circuit on If failure persists, replace control board.

control board.

If the error occurs during Make sure J1, J2 and J4 on the control board
ADC calibration it could are disconnected. Verify JP1 is correctly
be caused by failure to positioned then recalibrate.
unplug the probes
during calibration.

16 Bad Incubator The bed Tstat is open If the unit was shut off when the heater was hot,
Solid State (possibly because the allow the fan to run for several minutes to cool to
Relay. Unable unit was shut down below 40 then power down and back up. Ifthe
to turn the when the heater was hot) | failure still persists check the t-stat and heater
incubator heater | or the heater or t-stat is resistance. See tips.
on. defective.

Defective cable between Check cable pins 37, 38, 39, and 40 for continuity.
the relay and control board :
Defective incubator solid | Replace the incubator solid state relay.
state relay.
Defective relay board. Replace relay board.

17 Not Used

18 Bad Variables Defective SRAM circuit Replace the control board.

on control board.

19 No Audio Defective audio circuiton | Replace socketed !C U22 on control board.

Frequency contro] board. If failure persists, replace the control board.

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Chapter 4- Troubleshooting
ERROR # MEANING CAUSE(S) ACTION(S)
20 Display WDOG | Display board software If the error occurs occasionaliy, may be random
Time Out upset. causes; e.g., static discharge. If failure persists,
replace display board.

22 During operation | See other errors. Power down the unit. During the system tests after
the system was power-up the unit should detect systern failure 15,
unable to turn bed heater failure.
ON the incubator Follow the tips for those failures.
heater.

23 During operation | Defective solid state relay. | Replace the SSR.

the system was
unable to turn
OFF the
incubator
heater

24 Bad Air Bad air sensor. This failure is normally caused by a faulty air
Temperature Bad control board. temperature sensor. When the error occurs,
Sensor. The observe the difference between the air control and
system detected air display thermistor readings on the service
a difference in screen. If the difference exceeds 0.3°C, replace
the two air the air temperature sensor and repeat the test. If
thermistors of the error persists, replace the control board.
>0.3 degrees C.

25 Bad Air Flow Fan is missing or not Verify the fan is installed and turning. During
turning. powerup it should spin at low speed for a few
seconds, stop for a second, then start again at
high speed. If the fan is not turning replace the fan
motor.
Defective optical sensor. If the fan is turning replace the optical sensor.
Defective relay board. If the problem persists replace the relay board.

26 During the Defective relay board. Replace the relay board.

power up tests
the sysiem was
unable to turn off
the RH safety
relay.

27 Bad non-volatile | Defective circuit on Replace the control board.

memory control board.

28 The display driver | Defective cable Verify the cable between control board J8 and
board lost display driver board is installed properly and is pin
communication . to pin connected.
with control board | Defective control board. Replace control board.

29 Bad 5VAN signal | Defective cable, control Check the system power supplies.
on control board. | board, power supply, or See tips.
relay board.

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 Chapter 4-Troubleshooting
ERROR # MEANING CAUSE(S) ACTION(S}
30 Line Circuit Line voltage is out of Measure the line voltage at the power socket, it
Failure range. should be 99-132V or 198-264V. If it is out of this
range, the line voltage is out of spec.

Line Voltage Comp Circuit Calibrate the unit.

is not calibrated correctly.

Defective relay board. If the failure persists, measure the voltage at the
relay board, J37 pin 48 to J37 pin 45. If the line
voltage is 115V, the measured voltages should be
3-5V. If the line voltage is 230V, the measured
voltage be 7-10V. if not, replace the relay board.

Defective cable. If the failure persists measure the same voltage at

the control board, J9 pin 48 to J9 pin 45. If the
voltage is bad the cable is bad.

Defective control board. If the voltage is OK replace the control board.

33 Bad RH Solid Defective RH Solid State Replace relay board

State Relay Relay

34 Software revision The software revision of This error may occur after replacing the control
level does not the control board and the or display driver board. Check Software revision on
match display driver board does power up. Replace the software EPROM
not match

35 Wrong dipswitch Check the 8 position dipswitch on the contra! board.

set up Verify that Switch 1 is on and Switch 2 is off.

50 Display Bad Defective PROM on the Replace socketed IC US on display driver board.
Checksum display driver board If failure persists, replace display board.

51 Display Bad Defective SRAM circuit If the error occurs occasionally, may be random
SRAM on the display driver board causes; e.g., static discharge. If failure persists,
replace display driver board.

52 Display No Defective display driver lfthe error occurs occasionaliy, may be random
Timer2 board micro circuit. causes; e.g., static discharge. If failure persists,
replace display driver board.

53 Display Timer2 Defective display driver Replace the display driver board.
Too Fast board micro circuit.

55 Display board Defective display driver If the error occurs occasionally, may be random
On Line Self board SRAM circuit. causes; é.g., static discharge. If failure persists,
Test Failure replace display driver board.

98 Overflow Software upset. If the error occurs occasionally, may be random

causes; e.g., static discharge. If failure persists
replace the control board.

99 Logic problem on Software upset Replace the control board.

the control board.

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Chapter 4- Troubleshooting

4.4 Troubleshooting Table

SYMPTOM POSSIBLE CAUSE ACTION
No audio alarm. Defective speaker. Use an ohmmeter to verify the speaker resistance is
about 8 ohms. (J40, pins 5-6)
Audio driver circuitry Replace the control board.
is defective.

Unit equipped with Unit is functioning as a If the sensor is not installed the unit is operating
servo-humidity but manual humidifier. Look correctly. No action required.
unable to set RH at the air sensor and
setpoint above 10 verify the humidity sensor
and % indicator is is installed.
not displayed. Defective humidity sensor. Replace the humidity sensor.
Defective control board. If problem persists, replace control board

ADD WATER Humidifier reservoir switch Remove reservoir, but take care because surface may
message stays on is jammed. be hot! Check that the white button on the reservoir
even after water has switch moves freely. Listen for switch to click when the
been added button is depressed.

Elevating base will Defective switch. Check switches. See tips.

not go up or down Defective e-base motor. Check voltage to the e-base. See tips. If OK replace
the e-base motor. <
Defective relay board. If bad check the input signals on the relay board. See
tips. If OK replace the relay board.
Defective cable. If bad check the output signals from the control board.
if OK then the cable is bad.
Defective control board. lf signals are incorrect replace the control board.

Pedals disabled on Setup Check Setup screen (wrench symbol) to see if pedals
screen are disabled.

Unit will not switch A patient probe is plugged Disconnect probe from Jack 2 (unit will only allow Baby
to Baby Control into Jack 2 on the probe Control operation with a single probe in Jack 1)
Mode panel
Baby Control is disabled Select BOTH for Baby Control on service screen.
on Service screen

Unit will not Defective scale Disconnect scale. If unit powers up, scale is defective.
power up
Defective battery Remove the electrical enclosure cover and disconnect
the battery. Power down and power up again. If the unit
powers up, replace the 9V battery (8600-1024-600).

Baby Hot or Baby MANUAL TEMP alarm is Select OFF for MANUAL TEMP alarm on Setup screen.
Cold alarms selected on the Setup
activated while unit screen
is in Air Mode

Air Temp >38C Alarm is not designed to Shutoff unit and power up again to clear alarm.
or Air Temp >40C automatically reset after
alarm activated alarm condition is resolved.
and heater is
operating
even though
compartment
temp is < alarm

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 Chapter 4-Troubleshooting

4.5 Additional Troubleshooting Tips

Following are tips on taking many of the measurements and diagnosing the failures that are réferred to in the
troubleshooting charts.

INCUBATOR AIR HEATER AND THERMOSTAT

There are two separate incubator heaters. They are connected in parallel for 115 volt operation and in series
for 230 volt operation. Measure between the black wire on the incubator SSR and J49 pin 2 on the relay board.

The resistance of each heater is about 48 ohms so it should measure about 24 ohms for 115 units, 96 ohms
for 230 units. The heater and t'stat are in series so if the reading is open circuit you must determine which is
defective.

POWER SUPPLIES

The 5V and 12V supplies are generated on the power supply. Measure the power supply output at the input to
the relay board.
Signal Location Value
+5V J41 pins 1-4 4.75 10 5.25
+12V J41 pins 4-7 10.8 to 13.2

+5STBY is generated on the relay board. The output of the relay board can be measured on the power supply
bus cable coming off J42 on the relay board.
Signal Location Value
+5V 442 ртз 1-2 4.75 to 5.25
+5VSTBY 442 pins 1-4 4.75 to 5.25
+12V J42 pins 1-3 10.8 To 13.2

+5VAN and -5VAN are generated on the control board and can be measured on the test points on the control
board.
Signal Location Value
+5V TP2 pins 1-4 4.75 to 5.25
+5VSTBY TP2 pins 3-4 4.76 to 5.25
+5AN TP1 pins 5-6 4.75 To 5.25
-5AN TP1 pins 4-6 | -4.5 To -5.5

SWITCHESITSTAT
Use switch status diagram on the second service screen to assist in troubleshooting the switches.
Humidity reservoir Relay bd J32 pins 2-3 Closed when reservoir is closed
Add water t-stat Relay bd J32 pins 1-3 Opens when reservoir needs water

The following switches are membrane switches. When closed the resistance should be less than 200 ohms.
DISPLAY TOUCH PANEL SWITCHES
Alarm Silence Graphics Driver bd J21 pins1-2 Closed when switch is pressed
>37 degrees Graphics Driver bd J21 pins1-3 Closed when switch is pressed
Servo Control Graphics Driver bd J21 pins1-4 Closed when switch is pressed
Up Graphics Driver bd J21 pins1-5 Closed when switch is pressed
Down Graphics Driver bd J21 pins1-6 Closed when switch is pressed
Intervention Graphics Driver bd J21 pins1-8 Closed when switch is pressed
Manual Mode Inc. Graphics Driver bd J21 pins1-9 Closed when switch is pressed

E'base
Left or right up Relay bd J40 pins 2-4 Closed when either switch is pressed
Left or right down Relay bd J40 pins 1-4 Closed when either switch is pressed

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Chapter 4- Troubleshooting
HUMIDIFIER HEATER/SAFETY T-STAT

The humidifier has two separate heaters that are connected in parallel for 115 volt operation and in series for
230 volt operation. The safety t-stat is in series with the heater. Measure at J53.1 to J53.3

The resistance of each heater is about 144 ohms so it should measure about 72 ohms for 115 units, 288
ohms for 230 units.

AIR PROBE and PATIENT PROBE

There are two thermistors in each air probe or patient probe. During stable temperature conditions the ther-
mistors should read the same resistance within a few ohms.

Patient probe #1 Control bd J4 pins 1-3, 2-3

Patient probe #2 Control bd J2 pins 1-3, 2-3
Air probe Control bd J1 pins 1-2, 3-4

Temperature (C) Resistance (Ohms)

20 12527
25 10000
30 8037
35 6500

INCUBATOR HEAT SINK TEMPERATURE SENSOR THERMISTOR

Thermistor Control bd J3 pins 1-2

Temperature (C) Resistance (Ohms)

20 25000
25 20000
30 16102
35 13048
40 10636

E-BASE MOTOR
The e-base is driven at 24 volts DC (acceptable range 24-32). The following chart shows the control signal
values and the output voltages for each of the motor conditions.

Switch Control Signals, Relay Board E-base

J37 pin 23 437 pin 26 437 pin 24 J37 pin 27
24V SELECT E/H ACTIVATE _NVERTPOLARITY _E/H SELECT | J45-1 J45-2
Raise E-base 0 0 1 0 +24V Gnd
Lower E-base 0 0 0 0 Gnd +24V
None NA 1 NA NA NA NA

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 Chapter 5- Repair Procedures
Use Static Control Work Station to help ensure static charges are safely conducted to
ground. The velostat material is conductive; do not place electrically powered boards on it.
Whenever this symbol appears beside a procedure, take static control precautions.

WARNING A After performing any repair or calibration, always perform the Service Checkout
Procedure before putting the unit back into service.

5.1 Hood Removal for Replacement (Figure 5-1 and 5-3)

1. Open both the side doors.

2. Using a small straight blade screwdriver, remove the 2 snap fasteners from the inside of the hood that
secure the hood to each of its hinges. Each fastener has two halves that snap together and can be
pryed apart.

3. Remove the compartment probe and cable clip on the hood backwall as descibed in section 5.3.

4. Push the trigger on the hood latch post to disengage the latch and carefully lift the hood off the chassis.

Compartment probe

Snap fastener

Figure 5-1
Hood

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Chapter 5- Repair Procedures

5.2 Uprights and End Caps (Figure 5-2)

1. Slide the decorative strip up about 12” in the groove on the outside of the upright to access hardware that
secures the lower end cap. You may wish to use a piece of tape to grip the strip. Use a 2.5mm hex key to
remove the screw, then remove the bottom cap. Slide the decorative strip down to access the two screws
that secure the upper end cap, then remove the top end cap.

2. Using a 2mm hex key, remove the 4 button head socket screws and split ring washers that secure the
back cover to the display module and remove the cover.

3. Remove the 2 screws that secure the hood latch receptacle to the upright and remove the receptacle.

4, Using a 2mm hex key, remove the screw that secures the wire cover to the side of the upright.

5. To remove the wire cover, slide the wire cover up about %”, and then pull it straight back by grasping its
back edge.

6. Using a 3mm hex key, remove the 2 screws that secure the display module to the nut bar and pull the nut
bar up and out of the upright. Using a 3mm hex key, remove the screw that attaches the ground wire. Be
careful not to drop the star washers down into the upright.

7. Hold on to the upright, and using a 4mm hex key, remove the 2 screws in the holes in the lower side of the
upright . Remove the entire upright.

Upright Top so D
a

> -

Mounting studs A
. IT
Ground wire —|

q «y
..
©

k
y a Decorative strip—7|_ J
e M

Lg

Figure 5-2 <> 一 Bottom endcap

Uprights and endcaps º

5-2 08/15/01 6600-0356-000

 Chapter 5- Repair Procedures
Re-installing the upright

1. To assist in reattaching the upright to the unit, there are four mounting studs on the bracket casting that
mate with four holes in the upright. Place the upright on the studs. Be careful not to pinch any wires
between the unit and the upright.

2. Secure the upright to the unit by reinstalling the 2 screws in the holes inside the upright. Apply LOCTITE™
242 to the screws. Be careful not to drop the screws into the upright.

3. Attach ground wire to rail. Fasten the dispaly module to the upright with the two screws and nut bar
removed earlier.

4, Reinstall the wire cover. Take care to route the wires in the upright channels and not to pinch them with the
cover when securing with the screw.

5. Reistall the hood latch receptacle with the two screws removed earlier.

6. Attach ground wire to rail. Fasten the display module to the upright with the two screws and nut bar
removed earlier.

7. Fasten the back pane! to the display module with its 4 mounting screws.

8. Slide the decorative strip up and install the end caps.

5.3 Compartment Probe Repairs (Figure 5-3)

1. Using a 2.5mm hex key, remove the screw that secures the jack cable clip to the hood back wall.

2, Remove the 2 screws (2mm hex key) that secure the probe housing cover and remove it. The top screw
secures the probe shield, so that it can now be removed from the inside front of the probe housing.

3. -Disconnect the electrical connectors for the temperature and humidity sensor (if installed) wires and
remove the front of the probe housing.

Hood latch post

Probe shield

Probe housing cover

Probe "D ©

O-ring

Humidity sensor

Cylindrical spacer

Break plate

7 ack cable cli

Figure 5-3 ao cable clip
Compartment probe

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Chapter 5- Repair Procedures
Note: Some early units have temperature probes with jack connectors at the probe panel and should be
disconnected there.

4. Remove the 4 screws in the break plate and remove the plate.

5. To replace humidity sensor, pull it back out of the probe housing. Slide the wires out of the cylindrical
spacer. Place the O-ring over the tip of the new sensor, and genily push it back into the housing using the
cylindrical spacer until the O-ring seats. The sensor tip should be visible, but not up against its guard.
Check to ensure that the O-ring did not roll over the sensor flange during insertion.

Note: Always perform Humidifier Calibration after replacing the humidifier sensor.

6. To replace the temperature sensor, you must replace the entire probe housing.

7. When reassembling the probe housing make sure the groove in the break plate faces the probe housing
cover. Also check that the temperature sensor is oriented so that it is on top.

5.4 Lower Unit Repairs

5.41 Removing the chassis cover with the storage drawer in place (Fig. 5-3)

1. Slide the drawer all the way over in one direction, and use a 2.5 mm hex key to remove the 3 chassis
cover screws on one side, て

2. Slide the drawer to the other side.and remove the 3 remaining screws from the cover.

3. Remove the humidifier reservoir.

4. Remove the bottom 2 screws (2mm hex key) that secure the right end of the wire raceway cover.

5. Flex the raceway cover and carefully slide the cover panel forward until it drops off the back drawer slide.

6. Rotate the cover slightly and push it out the right side of the unit.

7. Remove the ground wire.

Figure 5-4
Bed disassembly

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 Chapter 5- Repair Procedures
5.42 Incubator fan/motor/optical sensor (Figure 5-5 and 5-6)

1. Remove the rotating bed, translation deck, tilt platform and pan.

2. Remove the fan, rubber adapter and fan seal from the top of the fan motor shaft.

3. Remove the chassis cover (see section 5.41).

4. Disconnect the motor leads.

5. Remove the 4 screws in the motor bracket and remove the motor assembly.

6. The motor isolators pop out of the holes in the bracket.

7. To replace the optical sensor, disconnect its connector, remove the screw from the boss in the chassis that
holds it in piace, and remove the assembly.

Motor shaft

Motor isolators

Motor bracket

Figure 5-5
Fan motor

5.43 Cartridge heater replacement (Figures 5-6 and 6-9)

To remove the heater closest to the foot of the bed:

1. Remove the chassis cover (see section 5.41).

2. Remove the screw (4mm hex key) in the heatsink directly in front of the heater cartridge.

3. Disconnect the heater's electrical connector.

4. Remove the retaining clip and slide the cartridge out of the heat sink.

To remove the heater closest to the head of the bed:

1. Remove the rotating bed, translation deck, tilt platform and pan.

2. Remove the fan, rubber adapter and fan seal from the top of the fan motor shaft.

3. Remove the chassis cover (see section 5.61).

4. Disconnect the heater’s electrical connector, the thermostat connections and the heat sink probe connector.

5. Remove the upper shroud.

6. Remove the 14 mounting screws that secure the heat sink. Remove the heatsink.

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Chapter 5- Repair Procedures

Heat sink

Figure 5-6
Heat sink and fan

7. Remove the retaining clip and slide the cartridge out of the heat sink.

8. To reassemble, seat the fan seal in the center bore of the heatsink and use it to align the fan shaft before
fully securing the heat sink with its mounting screws.

5.44 Elevating Base (Figures 5-4 and 5-7)

1. Run the elevating base to its top travel limit then switch off and unplug the unit.

2. Remove the mattress, bed and translation deck.

3. Remove the chassis cover (see section 5.61).

4. Disconnect the elevating base electrical connector at J-45 on the relay board, and tie a wire io it so you
can fish it back through during reassembly.

Connect the replacement elevating column to the relay board, switch the unit back on and using the foot
pedais fully extend the new column. Switch off and unplug the unit.

Using a 4mm hex key remove the 4 screws (at the bottom of the base- 2 in back and 2 in front) that secure
the lower shroud and slide it up past the speaker.

6. Using 3mm hex key remove the 8 screws that secure the upper shroud and remove it.

7. Pull the base wire harness out from the bracket casting.

Lock the back castors and tay the unit down on its back (controller on the floor). Place blocks under the
uprights so the back castors are off the floor.

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 Chapter 5- Repair Procedures

Lower shroud
Upper shroud |

Column power cable

Elevating column

Outer column

Lower mounting plate

Castor

Elevating base 6mm serew

footswitch

Figure 5-7
Elevating base

9. Using a 4mm hex key, remove the four socket head screws in the bottom of the elevating column that
secure the lower mounting plate to the column, and remove the mounting piate/leg assembly.

10. Using a 13mm socket, remove the 4 nuts that secure the elevating column to the casting and remove the
column.

Note: Should the elevating column fail in the completely retracted position, the outer column will prevent
access to the 4 column mounting nuts. To remove the outer column, you must first remove the lower
mounting plate and slide the outer column out. This requires a T-30 Torx key (service tool number 6600-
1204-400)

11. To replace the column, reverse the assembly steps above. Check that the castors are still locked before
lifting the unit back into its upright position. If you are returning the oid elevating column in it’s original

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Chapter 5- Repair Procedures

Wire raceway cover

:
Le

Chassis cover

AAVANAA
Chassis

Figure 5-8
Chassis bottom cover
packaging, attach it to the relay board and run it down to it’s fully retracted position. Release the shipping
locks.

Note: With the unit on its back, be sure the column power cabie is pointing up before you attach the
column.

5.45 Chassis Replacement (Figure 5-4, 5-5, 5-6, 5-8, and 6-11)

1. Remove the side doors, hood,(see section 5.1) rotating bed, translation deck, tilt platform and pan.

2. Remove the bottom chassis cover, (see Section 5.41) and remove the two side chassis covers (3 mm hex
key)

3. Disconnect the wiring harnesses.

4, Remove the two screws at the bottom corners that secure the probe panel to the enclosure (see 5.72)

WARNING A. Be sure the front of the chassis is supported before removing the screws from the
bracket to prevent the chassis from falling.

While supporting the chassis, remove the 5 bolts on either side of the bracket casting that secure the
chassis to the bracket and remove the chassis.

Remove all the components from the old chassis (bed tilt; fan and motor; heatsink; humidifier; front hinge
covers, side panels, etc.) and install them on the new chassis.

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 Chapter 5- Repair Procedures
5.46 Elevating Footswitch (Figure 5-7)

1. Run the bed up to the elevating base’s top travel limit. Unplug the unit.

2. Using a 4mm hex key remove the 4 screws (at the bottom of the base- 2 in back and 2 in front) that
secure the lower shroud and slide fi up past the speaker.

3. Make note of the switches’ electrical wire routing; the cable from the replacement switch must feed up
through the same slot.

4. Using a 4 mm hex key, remove the button head socket screws on either side of the foot pedal, located
between the column base plate and the leg wire cover.

5. Pull the pedal out and disconnect the switch electrical connector. Discard old footswitch/pedal assembly.

6. Install new footswitch/pedal assembly. Make sure that you do not pinch the electrical wires.

f Humidifier top bracket

Spacer. i
a
Silicone gasket
Add water T-stat sw

Heater cartridge sheath

Reservoir

Figure 5-9 Insulating cylinder

Humidifier parts

5.47 Humidifier Heater Replacement (Figures 5-8 and 5-9)

1. Remove the humidifier reservoir.

2. Remove the 6 screws (2mm hex key) that secure the wire raceway cover and remove the cover.

3. Remove the chassis cover (see section 5.41).

4. Disconnect the 3 electrical connectors.

5. Remove the 2 screws on either side of the humidifier heater assembly.

6. Remove the humidifier heater assembly.

7. Use a 2mm hex key to remove the 2 screws from the micro-switch and remove the switch.

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Chapter 5- Repair Procedures
8. Remove the 5 screws that secure the humidifier top bracket. Back the bracket off feeding the wire har-
nesses through as you remove it.

Remove the silicone gasket, feeding the wire harnesses through as you remove it. The thermostat wire
harness can slide through the slots in the gasket.

10. Remove the 4 screws in the heater mount. Loosen the screw next to the safety thermostat, but do not
remove it. Remove the ramp biock.

11. Remove ihe 3 screws in the heater cartridge sheath.

12. To remove the heater cartridge, unscrew it from it’s threaded hole. To remove either of the thermostats,
remove the nuts that secure them.

When reassembling, tighten the heater cartridge into it's threaded hole, then back it off until the wires exit
between the 2 thermostats. If either thermostat or the heater cartridge is being replaced, check all compo-
nents (especially the plastic ones) for signs of heat damage or corrosion. We recommend repiacing the
sheath when replacing the heater cartridge.

8
è
®

Tilt assembly cover ῇ

<
Brake lever
Brake pad Brake pad
Finger pocket latch

Positioning nl

Ball insert

Figure 5-10 Tilt platform

Replacing the tilt brake Brake lever

5.5 Bed tilt brake shoe replacement (Figures 5-4 and 5-10)

1. Remove the mattress, clear plate, rotating bed and translation deck.

2. To release the tilt screw ball, squeeze the tilt release and slide open the finger pocket latch until you hear
the ball drop.

Release the tilt platform from the chassis by pushing the pivot pin tabs in on both sides, then lifting the tilt
platform out of the chassis.

4. Turn the tilt platform over and remove the 4 screws (2.5mm hex key) that secure the tilt assembly cover.

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 Chapter 5- Repair Procedures
Remove the two plastic inserts. The long insert holds a positioning spring and the smaller ball insert holds
the screw ball in position.

Press back the brake lever to provide access to the brake pad, then use pliers or a thin 14mm open end
wrench to remove the nut to which the brake pad is fastened. Replace the brake pad assembly.

5.6 Castor Replacement (Figure 5-7)

The castors may be replaced with the unit upright or carefully placed on its back.
1. Lock all the other castors.

2. Lift the castor off the floor and use blocks to support the leg near the castor you are replacing.

3. Remove the screw on the side of the leg that holds the castor in its mounting hole. Remove the castor.

Line up the hole in the castor stem with the set screw hole in the leg and insert the castor. As you tighten
the screw the castor should be drawn into the leg.

Membrane touch panel

LED display board

Module housing

Figure 5-11
Display module

5.7 Controller and Display Module Procedures

© 5.71 Display module (Figure 5-11)

1. Using a 2mm hex key, remove the 4 button head socket screws and lock washers that secure the back
cover to the display module and remove the panel.

To remove the display driver board, first remove the 4 screws the hold the board to the standoffs, then
disconnect the electrical connectors.

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Chapter 5- Repair Procedures
3. To replace the digital encoder for the EL display, pull the control knob off the shaft, disconnect the electrical
connector, remove the nut that secures the encoder, and remove the encoder.

To remove the LED display board, disconnect the electrical connectors, then remove the 2 standoffs (6mm
wrench) that hold the board in place, and then the 2 nuts with hardware.

5. To remove the EL display, disconnect the electrical connectors, then remove the 2 nuts that hold the
display in place. Be careful not to get finger prints on the display and be sure it is clean before replacing it.

Power switch

Figure 5-12
Probe panel

6. The standoffs that hold the back cover also secure the bezel to the front of the module housing. Remove
the standoffs (6mm wrench) and remove the bezel. To replace the membrane switch panel, first discon-
пес! Из electrical connector and then peel it off the display module housing. Be careful to remove all
residue adhesive from the module before installing a new membrane panel. The membrane panel can not
be repositioned once it has been applied without damaging it.

5.72 Probe panel (Figure 5-12 and 6-28)

1. Using a 2.5 mm hex key, loosen the 2 screws in the keyhole slots and remove the 6 remaining screws that
secure the controller cover, then remove the cover. Disconnect the wire harnesses coming from the probe
panel.

2. Remove the 2 screws at the bottom corners that hold the probe panel to the enclosure.

3. © Remove the probe panel assembly.

While tilting the panel enclosure forward, use a 3mm hex key to remove the 4 screws that hold the panel
frame in place. Add new jacks through the panel frame as appropriate.

Note: The power switch panel must be on the far left. The position of the remaining panels is not critical.

5.73 Controller Components (Figure 5-13)

Using a 2.5 mm hex key, loosen the 2 screws in the keyhole slots and remove the 6 remaining screws that
secure the controller cover, then remove the cover. Now you can access the electrical components listed
below.

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 Chapter 5- Repair Procedures

Battery

era cage

Control board 一一 |

| “toroidal transformer

Power supply ——____|

|— Relay board

- Relay board retainer bracket

[OX Solid state relay

Power outlets
Line filter

Power switch
Circuit breakers L - 8>
1 pu E
Figure 5-13 = TE Cla Connection panel
Electronics enclosure

Control Board
Slide the control board out about an inch and disconnect all the electrical connectors along its outside
edge, then remove the board.

Dipswitch configeration on replacement control boards:

Switch 1 must be ON
Switch 2 must be OFF
Switch 3 must be ON if servo humidifier is installed
Switches 4,5, 6 and 7 are unused and should be OFF
Switch 8 must be OFF

Note: Always perform System Calibration and Humidifier calibration after replacing the control board.

Relay Board
Remove the two M3 hex nuts that secure the relay board retainer bracket with a 5.5 mm socket, then pull
the board out a little and disconnect the electrical connectors on the outer edge. Then pull it out a little
more and disconnect the connectors at the bottom end of the board. Now the board can be pulled out the
rest of the way so the back connectors can be disconnected. You can now access the 2 fuses on the
board.

Note: Always perform Line Voltage Calibration after replacing the relay board.
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Chapter 5- Repair Procedures

Solid State Relay

To replace the solid state relay, disconnect the electrical connections, and using a 7mm wrench remove
the 2 nuts that secure it to the enclosure.

Power Supply
To access the power supply, disconnect the 50 pin ribbon cable that crosses in front of it. To remove the
power supply, use a 5.5mm wrench to remove the nuts that secure it.
After installing the replacement power supply perform the following tests:

To verify the power supply outputs are correct measure the following voltages on one of the unused
connectors that feed power to the option boards. The voltages are not adjustable. If they are out of
specification the power supply must be repiaced.

Signal Measure. at Acceptable Range

5 Volts Pins 2 to 1 4.75 volts to 5.25 volts
12 volts Pins 3 to 1 10.80 volts to 13.20 voit

Battery
The battery snaps into a holder on the side of the card cage. It has two snap connectors at its top. When
replacing the battery, its easier to first connect the terminals then push the battery into its holder.

Toroidal transformer ィ
To replace the elevating base toroidal transformer, it may easier to first remove the entire card cage. To
remove the card cage first remove probe panel so you can access the 4 screws on the top wall of the
cage. Then remove the relay board to access the 2 screws on the right edge of the cage that secure it to
the back wall of the electrical enclosure. Take out the last 3 screws in the middle that secure the cage to
the back wall of the electrical enclosure and remove the cage. Now you can access the toroidal trans-
former.

Circuit breakers, Power switches and Power outlets

The circuit breakers, power switches and power outlets can all be more easily accessed by removing the
connection panel at the bottom of the enclosure by removing the 3 screws that secure it with a 2.5 mm hex
key.

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