1-FC - Care Plus 3/98 - Diagramas Electrónicos Para Reparararchivos.diagramas.mx/otros/CarePlus Service Manual[1].pdf · Care Plus® Access Incubator Service Manual. ... 2.3 Mounting

Ohio® Care Plus®

Series 3000/4000 andCare Plus® AccessIncubatorService Manual

Table of Contents

i i6600-0017-000 03/12/98

ImportantThe information contained in this service manual pertains only to those models ofproducts which are marketed by Ohmeda as of the effective date of this manual or thelatest revision thereof. This service manual was prepared for exclusive use by Ohmedaservice personnel in light of their training and experience as well as the availability tothem of parts, proper tools and test equipment. Consequently, Ohmeda provides thisservice manual to its customers purely as a business convenience and for thecustomer’s general information only without warranty of the results with respect to anyapplication of such information. Furthermore, because of the wide variety of circum-stances under which maintenance and repair activities may be performed and theunique nature of each individual’s own experience, capacity, and qualifications, the factthat a customer has received such information from Ohmeda does not imply in anywaythat Ohmeda deems said individual to be qualified to perform any such maintenance orrepair service. Moreover, it should not be assumed that every acceptable test andsafety procedure or method, precaution, tool, equipment or device is referred to within,or that abnormal or unusual circumstances, may not warrant or suggest different oradditional procedures or requirements.

This manual is subject to periodic review, update and revision. Customers are cau-tioned to obtain and consult the latest revision before undertaking any service of theequipment.

CAUTION w Servicing of this product in accordance with this service manual should neverbe undertaken in the absence of proper tools, test equipment and the mostrecent revision to this service manual which is clearly and thoroughly under-stood.

s This static control precaution symbol appears throughout this manual. Whenthis symbol appears next to a procedure in this manual, static control precau-tions MUST be observed. Use the static control work station (Stock No. 0175-2311-000) to help ensure that static charges are safely conducted to groundand not through static sensitive devices.

Technical Competence

The procedures described in this service manual should be performed by trained andauthorized personnel only. Maintenance should only be undertaken by competentindividuals who have a general knowledge of and experience with devices of thisnature. No repairs should ever be undertaken or attempted by anyone not having suchqualifications.

Genuine replacement parts manufactured or sold by Ohmeda must be used for allrepairs.

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 attemptedprocedure.

Table of Contents

ii ii6600-0017-000 03/12/98

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 empha-sis.

CAUTION: A CAUTION statement is used when the possibility of damage to theequipment exists.

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

Accuracy: As stated in the performance specifications, the assigned accuracy of theequipment; including all the system components from the sensors to the display.

Air Control Mode: Manual mode of operation. The interior incubator temperature ismaintained at the air control temperature.

Desired Environmental Temperature (DET): The air temperature required to maintainthe infant’s temperature at the patient control temperature (patient control mode).

Incubator Temperature: The air temperature measured at a point 10 cm above themattress.

Patient Control Mode: Servo mode of operation. The incubator changes the DET tomaintain the desired patient skin temperature.

Patient Probe: The Ohio patient temperature probe, model LA003, or disposableprobe LA005.

Temperature Rise Time: The time required for the incubator temperature to rise 10°C.

Temperature Equilibrium: The condition where the average incubator temperaturedoes not vary by more than 0.2°C in a one hour period.

Temperature Variability: The maximum difference between the incubator temperatureand the average incubator temperature at equilibrium.

Temperature Overshoot: The number of degrees by which the maximum incubatortemperature exceeds the average incubator temperature at temperature equilibriumfollowing a change in the air control temperature (air control mode).

m Type B Electrical equipment

x Protective ground

y Functional Ground

~ Alternating Current (AC)

s Static Control Precaution

Definitions

Table of Contents

iii iii6600-0017-000 03/12/98

Important

Technical Competence .................................................................................................... i

Definitions

Definitions ....................................................................................................................... ii

Precautions

Warnings ........................................................................................................................ xi

Cautions ........................................................................................................................ xii

1/Functional Description

1.1.1 Control Board (Software Revision 04.00 and Higher) ........................................1-1A. Microprocessor .............................................................................................1-3B. SRAM & EPROM ..........................................................................................1-6C. Over temperature & Air_Display Sensor.......................................................1-6D. Power Supply Circuitry .................................................................................1-7E. Heater Control ..............................................................................................1-8F. Analog Inputs ..............................................................................................1-10G. Watchdog Timer .........................................................................................1-10H. Audible Alarm .............................................................................................1-11I. A/D Converter .............................................................................................1-11

1.1.2 Control Board (Software Revision 03.10 and Lower) .......................................1-13A. Power Supply Circuitry ...............................................................................1-15B. Analog to Digital Converter .........................................................................1-16C. Microcontroller ............................................................................................1-19D. Heater Control ............................................................................................1-20E. Watchdog Timer .........................................................................................1-22F. Alarm Tone Generator ................................................................................1-23G. Air Safety Circuit .........................................................................................1-23H. Relay Circuit ...............................................................................................1-24

1.2.1 Display Board (6600-0512-700) .......................................................................1-25A. Switch Decoding .........................................................................................1-25B. LED Displays ..............................................................................................1-25C. Multiplexing of Displays ..............................................................................1-25

1.2.2 Display Board (6600-0105-700 & 6600-0420-700) ..........................................1-26A. Switch Decoding .........................................................................................1-26B. LED Displays ..............................................................................................1-26C. Multiplexing of Displays ..............................................................................1-26

1.3 ThermaLink Option...........................................................................................1-26

Table of Contents

Table of Contents

iv iv6600-0017-000 03/12/98

2/Set Up and Checkout

2.1 Receiving ...........................................................................................................2-1

2.2 Mounting the Care Plus on the Elevating Base..................................................2-1

2.3 Mounting the Care Plus on the Cabinet .............................................................2-2

2.4 Mounting the Cabinet Rail System .....................................................................2-3A. Mounting the Basic Rails ..............................................................................2-4B. Mounting the Overhead Shelf .......................................................................2-5

2.5 Mounting the rail system on cabinets with pre-stamped knock outs ..................2-5

2.6 Checkout Procedure ..........................................................................................2-7A. Mechanical Checks.......................................................................................2-7B. Accessory Checks ......................................................................................2-11C. Controller Checks .......................................................................................2-12D. Operational Checks ....................................................................................2-15

3/Calibration and Adjustment

3.1 Maintenance schedule .......................................................................................3-1

3.2 Special Tools and Equipment ............................................................................3-2

3.3 Calibration Loop (background information) ........................................................3-3

3.4.1 Calibration Procedures(Software Revision 04.00 and Higher) ...............................................................3-3A. Preparation ...................................................................................................3-4B. Check Voltage Supplies................................................................................3-5C. Display Brightness ........................................................................................3-5D. Alarm Frequency ..........................................................................................3-6E. Line Voltage Compensation..........................................................................3-7F. Analog to Digital Converter (ADC) ................................................................3-7G. Alarm Volume ...............................................................................................3-9H. Air Safety Circuit Calibration (High Air Temperature Alarm).........................3-9I. Fan Sensor Adjustment ..............................................................................3-10J. Thermal Switch Operation ..........................................................................3-10K. Setting the Patient Temperature Alarm Threshold .....................................3-10L. Setting the Maximum Patient Control Temperature....................................3-11M. Closure .......................................................................................................3-11

3.4.2 Calibration Procedures(Software Revision 3.1 and Lower) ..................................................................3-12A. Preparation .................................................................................................3-12B. Check Voltage Supplies..............................................................................3-14C. Display Brightness ......................................................................................3-14D. Alarm Frequency ........................................................................................3-15E. Line Voltage Compensation........................................................................3-16F. Analog to Digital Converter (ADC) ..............................................................3-16G. Alarm Volume .............................................................................................3-18H. Air Safety Circuit Calibration (High Air Temperature Alarm).......................3-18I. Fan Sensor Adjustment ..............................................................................3-19J. Thermal Switch Operation ..........................................................................3-19K. Setting the Patient Temperature Alarm Threshold .....................................3-20L. Setting the Maximum Patient Control Temperature....................................3-20M. Closure .......................................................................................................3-20

Table of Contents

v v6600-0017-000 03/12/98

3.5 Electrical Safety Check ....................................................................................3-21A. Leakage Current .........................................................................................3-21B. Ground Resistance Check ..........................................................................3-21

4/Troubleshooting

4.11 Alarms and Error Codes (Software Revision 04.00 and Higher) ........................4-2A. Front Panel Alarms .......................................................................................4-2B. Error Codes ..................................................................................................4-5

4.12 Alarm and Error Codes (Software Revision 03.10 and Lower) ........................4-10A. Front Panel Alarms .....................................................................................4-10B. Error Codes ................................................................................................4-13

4.2 Power Up Tests................................................................................................4-18

4.3 On Line Testing ................................................................................................4-19

4.4 ThermaLink Option Self Test ...........................................................................4-19

4.5 On Demand Testing .........................................................................................4-20A. RAM Memory Display Loop ........................................................................4-20B. Switch Activated Displays ...........................................................................4-21

4.6 Test Points .......................................................................................................4-22

5/Repair Procedures

5.1 Hood Repair ...........................................................................................................5-1

5.2 Front Door Repair ..................................................................................................5-5

5.3 Air Temperature Sensor Replacement ..................................................................5-6

5.4 Base Platform Cover Replacement .......................................................................5-8

5.5 Controller Access ...................................................................................................5-8

5.6 Control Board Replacement ..................................................................................5-8

5.7 Display Board Replacement.............................................................................5-10A. Replacement on units with HBJ and HAG serial numbers. ........................5-10B. Replacment on units with HCE serial numbers only ...................................5-12

5.8 Solid State Relay Replacement .......................................................................5-14

5.9 Heater and/or Heater Gasket Replacement .....................................................5-15A. Replacement for controllers with HBJ and HCE serial numbers ................5-15B. Replacement for controllers with HAG serial numbers ...............................5-17

5.10 Thermal Switch Replacement ..........................................................................5-18

5.11 Fan Sensor Replacement ................................................................................5-18

5.12 Air Flow Sensor Replacement..........................................................................5-19

5.13 Fan Motor Replacement...................................................................................5-21A. Fan motor replacement for units with fan sensors ......................................5-21B. Fan motor replacement for controllers with air flow sensors. .....................5-22

5.14 Battery Replacement........................................................................................5-24

5.15 Continuous Tilt Knob Assembly Service ..........................................................5-24

5.16 Cabinet Caster Replacement ...........................................................................5-27

Table of Contents

vi vi6600-0017-000 03/12/98

6/Illustrated Parts

6.1 Hood Components .............................................................................................6-1

Compartment probe and related items...............................................................6-7

6.2 Base Platform Components ...............................................................................6-8Continuous Tilt Assembly.................................................................................6-12

6.3 Cabinet Components .......................................................................................6-14

Cabinet Rail System and Overhead Shelf ........................................................6-20

6.4 Accessories and Disposable Parts...................................................................6-22

6.5 Controller Components ....................................................................................6-27Controllers with air flow sensor ........................................................................6-27Controllers with HAG serial numbers ...............................................................6-28Controllers with HBJ or HCE serial numbers ...................................................6-34Controllers with HBJ serial numbers ................................................................6-42Controllers with HCE serial numbers ...............................................................6-44

6.6 Board Components ..........................................................................................6-46Display Boards .................................................................................................6-46Control Boards .................................................................................................6-52

6.7 Label Sets ........................................................................................................6-59

6.8 Replacement controllers ..................................................................................6-60Systems without the ThermaLink Option .........................................................6-60Systems with the ThermaLink Option ..............................................................6-61

6.9 Servo-controlled Humidifier Upgrade Kits ........................................................6-61

Appendix

Patient Temperature Probe and Air Temperature Sensor Characteristics ................. A-1

Temperature Conversion Chart .................................................................................. A-2

CarePlus Specifications ............................................................................................. A-2A. Electrical specifications................................................................................ A-2B. Performance specifications.......................................................................... A-3C. Safety specifications .................................................................................... A-5D. Environmental specifications ....................................................................... A-6E. Electromagnetic Compatibility (EMC) Specifications ................................... A-6F. Mechanical specifications ............................................................................ A-6G. ThermaLink Option Specifications ............................................................... A-6

Serial data ..................................................................................................... A-7Nurse Call ..................................................................................................... A-9

External Humidifier ................................................................................................... A-10

Internal humidifier ..................................................................................................... A-11

Table of Contents

vii vii6600-0017-000 03/12/98

1/Functional DescriptionFigure 1-1 Control Circuitry Block Diagram (Software Revision 04.00) ................1-2

Figure 1-2 Power Supply Circuitry (Software Revision 04.00) ..............................1-7

Figure 1-3 Heater Control and Monitoring Circuits (Software Revision 04.00) .....1-9

Figure 1-4 Control Circuitry Block Diagram (Software Revision 03.10) ..............1-14

Figure 1-5 Power Supply Circuitry (Software Revision 03.10) ............................1-15

Figure 1-6 Heater Control and Monitoring Circuits (Software Revision 03.10) ...1-23

2/Set Up and CheckoutFigure 2-1 Mounting the CarePlus Incubator on an elevating base ......................2-2

Figure 2-2 Mounting the CarePlus Incubator on a cabinet ....................................2-3

Figure 2-3 Mounting the basic rail system .............................................................2-4

Figure 2-4 Mounting the overhead shelf ................................................................2-5

Figure 2-5 Mounting the rails and the overhead shelf ...........................................2-6

Figure 2-6 Operating Controls, Indicators and Connectors .................................2-10

Figure 2-7 Control Panel .....................................................................................2-12

3/Calibration and AdjustmentsFigure 3-1 Cable for Variable Resistance Box ......................................................3-2

Figure 3-2 Control Board Test Points and Potentiometers(Software Revision 04.00 and higher) ..................................................3-4

Figure 3-3 Display Brightness Adjustment(Software Revision 04.00 and higher) ..................................................3-6

Figure 3-4 Control Board Test Points and Potentiometers(Software Revision 03.10 and lower) .................................................3-13

Figure 3-5 Display Brightness Adjustment(Software Revision 03.10 and lower) .................................................3-15

4/Troubleshooting

Figure 4-1 Air Temperature Sensor Connector (end view) ...................................4-7

5/Repair ProceduresFigure 5-1 Remove the Inner Wall ........................................................................5-2

Figure 5-2 Remove the Outer Hood ......................................................................5-3

Figure 5-3 Remove Hood Hardware .....................................................................5-4

Figure 5-4 Front Door Disassembly ......................................................................5-5

Figure 5-5 Base Platform Cover Removal .............................................................5-7

Figure 5-6 Controller Interior .................................................................................5-9

Figure 5-7 Replace the Display Board ................................................................5-10

Figure 5-8 Display Panel Grounds Controllers With HAG Serial Number ...........5-11

Figure 5-9 Display Panel Controllers With HCD Serial Number ..........................5-13

Figure 5-10 Heater, Thermal Switch and Fan Sensor Replacement .....................5-16

Figure 5-11 Air Flow Sensor Installation ...............................................................5-20

Figure 5-12 Fan Motor Replacement on HBJ and HCE Controllers ......................5-21

Figure 5-13 Fan Motor Replacement on Controllers With Air Flow Sensor ..........5-23

Figure 5-14 Right Hand Tilt Knob Assembly .........................................................5-25

List of IllustrationsList of Illustrations

Table of Contents

viii viii6600-0017-000 03/12/98

6/Illustrated Parts

Figure 6-1 Incubator Assembly, Front View ..........................................................6-1

Figure 6-2 Hood Seals and Related Hardware .....................................................6-3

Figure 6-3 Inner Wall Assembly, Hood ..................................................................6-4

Figure 6-4 Front Door and Related Hardware .......................................................6-5

Figure 6-5 Hinge Detail .........................................................................................6-6

Figure 6-6 Incubator Assembly, Rear View ...........................................................6-7

Figure 6-7 Base Platform, external humidifier and Cover Assembly .....................6-9

Figure 6-8 Base Platform Hardware (bottom view of platform) ...........................6-11

Figure 6-9 Continuous Tilt Assembly ..................................................................6-13

Figure 6-10 Cabinet Assembly (base and sides) ..................................................6-14

Figure 6-11 Cabinet Assembly ..............................................................................6-15

Figure 6-12 Refresher instruction tray assembly ...................................................6-17

Figure 6-13 Cabinet Doors and Shelf ....................................................................6-19

Figure 6-14 Cabinet Rails and Shelf .....................................................................6-21

Figure 6-15 Care Plus Incubator with Accessories ...............................................6-23

Figure 6-16 Adapter Plate Assembly .....................................................................6-24

Figure 6-17 Instrument Shelf .................................................................................6-24

Figure 6-18 22 Inch Utility Post .............................................................................6-24

Figure 6-19 Oxygen Flowmeter, w/Bracket ...........................................................6-24

Figure 6-20 Air Flowmeter, w/ Bracket ..................................................................6-24

Figure 6-21 Vacuum Manifold w/DISS Adapters ...................................................6-24

Figure 6-22 Manifold w/ 1/8 Inch Pipe Thread ......................................................6-25

Figure 6-23 Vacuum Bottle Slide Bracket .............................................................6-25

Figure 6-24 Manometer w/ Bracket .......................................................................6-25

Figure 6-25 I.V. Pole .............................................................................................6-25

Figure 6-26 Ventilator Mounting Post ....................................................................6-25

Figure 6-27 Retaining Clips ...................................................................................6-25

Figure 6-28 3.5 Inch Utility Post ............................................................................6-26

Figure 6-29 Duo-O-Vac .........................................................................................6-26

Figure 6-30 BiliBlanket Plus phototherapy system ................................................6-26

Figure 6-31 Controller Back Panel Controllers with HAG Serial Numbers ...........6-27

Figure 6-32 Controller Plate and Motor Mounting Hardware .................................6-29

Figure 6-33 Controller Latch and Fan Assemblies ................................................6-30

Figure 6-34 Transformer and Side Mounted Controller Components ...................6-31

Figure 6-35 Wire Harnesses and Additional Controller Components ....................6-32

Figure 6-36 Control Panel Assembly .....................................................................6-33

Figure 6-37 Motor, fan sensor, circuit breaker and transformer assembly ............6-35

Figure 6-38 Back panel .........................................................................................6-37

Figure 6-39 Controller chassis and fan assembly .................................................6-39

List of Illustrations

Table of Contents

ix ix6600-0017-000 03/12/98

Figure 6-40 Cover assembly .................................................................................6-40

Figure 6-41 ThermaLink assembly ........................................................................6-41

Figure 6-42 Control panel assembly .....................................................................6-43

Figure 6-43 Control panel assembly .....................................................................6-45

Figure 6-44 Display board .....................................................................................6-47



Figure 6-47 Control board .....................................................................................6-53



7/Schematics

Figure 7-1 Wiring Diagram (HAG controllers) .......................................................7-1

Figure 7-2 Controller Plate Wiring (HAG controllers) ............................................7-2

Figure 7-3 Detail, Air Temp. and Patient Temp. Wiring (HAG controllers) ............7-3

Figure 7-4a Control Board Schematic-Software Revision 02.00 (page 1 of 2) .................................................7-4

Figure 7-4b Control Board Schematic-Software Revision 02.00 (page 2 of 2) .................................................7-5

Figure 7-5 Display Board Schematic (HAG & HBJ controllers) .............................7-6

Figure 7-6 Display Board Schematic (HCE controllers) ........................................7-7

Figure 7-7 Wiring-Software Revision 03.10 (HBJ & HCE controllers) ...................7-8

Figure 7-8a Control Board Schematic-Software Revision 04.00 (page 1 of 7) .................................................7-9

Figure 7-8b Control Board Schematic-Software Revision 04.00 (page 2 of 7) ...............................................7-10

Figure 7-8c Control Board Schematic-Software Revision 04.00 (page 3 of 7) ...............................................7-11

Figure 7-8d Control Board Schematic-Software Revision 04.00 (page 4 of 7) ...............................................7-12

Figure 7-8e Control Board Schematic-Software Revision 04.00 (page 5 of 7) ...............................................7-13

Figure 7-8f Control Board Schematic-Software Revision 04.00 (page 6 of 7) ...............................................7-14

Figure 7-8g Control Board Schematic-Software Revision 04.00 (page 7 of 7) ...............................................7-15

Figure 7-9a Display Board Schematic-Surface Mount Board (page 1 of 2) ....................................................7-16

Figure 7-9b Display Board Schematic-Surface Mount Board (page 2 of 2) ....................................................7-17

Figure 7-10 Wiring Diagram (Software Revision 04.00) ........................................7-18

Figure 7-11 Controller Plate Diagram (HBJ & HCE controllers) ............................7-19

Figure 7-12a Control Board Schematic-Units with 3711 Chip (page 1 of 2) .....................................................7-20

Figure 7-12b Control Board Schematic-

List of Illustrations

Table of Contents

x x6600-0017-000 03/12/98

Units with 3711 Chip (page 2 of 2) .....................................................7-21

Figure 7-13a Control Board Schematic-Units with ADC Daughter Board (page 1 of 3) ...................................7-22

Figure 7-13b Control Board Schematic-Units with ADC Daughter Board (page 2 of 3) ...................................7-23

Figure 7-13c Control Board Schematic-Units with ADC Daughter Board (page 3 of 3) ...................................7-24

Figure 7-14 ThermaLink Board Schematic-Boards with Test Switch .....................................................................7-25

Figure 7-15 ThermaLink Board Schematic-Boards without Test Switch ................................................................7-26

Appendix

Figure A-1 Serial Data .......................................................................................... A-9

Figure A-2 Using the external humidifier ............................................................ A-10

Figure A-3 Using the internal humidifier ............................................................. A-11

Table of Contents

xi xi6600-0017-000 03/12/98

wWarnings

Two people are required to lift the Care Plus Incubator. Follow safe lifting techniques toavoid injury.

After completing a repair, the appropriate calibration procedure must be performed.After completing any portion of the calibration and adjustment procedures, perform theCheckout Procedure to make sure that the Care Plus Incubator is operating correctly.In addition, a final Electrical Safety Check , section 3.4, must be performed. Record theinformation for future reference.

Disconnect the power to the incubator for the mechanical portion of the CheckoutProcedure.

Use extreme care while performing calibration and adjustment procedures, or whileworking on the Care Plus Incubator with power connected. An electrical shock hazarddoes exist; be certain to observe all standard safety precautions.

Before any disassembly or repair, disconnect the electrical supply and any gas supplyconnections. Also remove any accessories. Do not perform any service or maintenancewith the power applied unless specifically told to do so in the procedure.

If a system failure alarm occurs, the unit must be removed from use until it has beenserviced.

Disconnect power to the incubator and allow the heater to cool adequately beforeservicing or cleaning to avoid the danger of a burn.

Never oil or grease oxygen equipment unless a lubricant that is made and approved forthis type of service is used. Oils and grease oxidize readily, and in the presence ofoxygen, will burn violently. Vac Kote® is the oxygen service lubricant recommended(Stock No. 6700-0092-200).

Two people are required to safely replace a caster. Remove the incubator and allaccessory equipment from the cabinet before replacing a caster.

The humidifier must be installed for proper incubator operation, even if you do not planto use the humidifier.

Safely mounting or dismounting the Care Plus Incubator requires two people. Removethe controller unit before mounting or dismounting the incubator.

If mounting hardware is not securely fastened, the incubator could tip off the ElevatingBase or the cabinet.

The patient probe is not isolated from the earth ground. Any additional equipment usedwith the Care Plus must comply with UL 2601-1, CSA 601-1, IEC 601-1 and VDE 750

If you use the normally open Nurse call connection, a disconnected Nurse Call cablewill not trigger an alarm.

® Vac Kote is a Registered trademark of Ball Brothers Corp.

PrecautionsPrecautions

Table of Contents

xii xii6600-0017-000 03/12/98

Precautions

wCautions

Servicing of this product in accordance with this service manual should never beundertaken in the absence of proper tools, test equipment and the most recent revisionof this service manual which is clearly and thoroughly understood.

sThis static control precaution symbol appears throughout this manual. When thissymbol appears next to a procedure in this manual, static control precautions MUST beobserved. Use the static control work station (Stock No. 0175-2311-000) to help ensurethat static charges are safely conducted to ground and not through static sensitivedevices.

Use the Static Control Work Station (Stock No. 0175-2311-000) to help ensure thatstatic charges are safely conducted to ground. The Velostat material is conductive. Donot place electrically powered circuit boards on it.

When handling the controller, avoid bumping the fan or the heater. If these items areknocked out of alignment, the fan can grate against either the heater or the base.

Insulation on the electrical wiring can deteriorate with age. When performing theCheckout Procedure, check for brittle or deteriorated insulation on the power cord.

Inner wall fasteners are permanently attached to the inner wall and cannot be removedwithout damaging them.

Make sure the control board connectors are properly aligned before applying power.

If early model heaters are not installed with the nuts on the inside of the controller andthe screws on the outside, water can leak in during cleaning and damage the electron-ics.

If gaskets are not installed properly, water can leak in during cleaning and damage theelectronics.

The tape on the stiffener plate used on the cabinet rail system will not support anyweight. The only reason for the tape is to help you line the parts up.

Make sure that the rail support bracket is securely attached to the rails. The bolts mustbe torqued to 22.6 ± 0.6 Nm (200 ± 5 in-lbs or 16 ± 0.5 ft-lbs).

The total weight of all items placed in a storage module cannot exceed 12 kg(25 lbs).

The maximum load on cabinet rail systems must not exceed 23 kg (50 lbs). Thisincludes the weight of items placed on rail mount or overhead shelves.


1-1 1-16600-0017-000 03/12/98

1/Functional DescriptionImportant: Section 1.11 is the functional description for control boards with softwarerevision 4.0 and higher. The unit's software revision level is displayed on power up, butthese new boards can be physically identified by their surface mounted componentsand 28 pin test point connector. Section 1.12 is the description for earlier control boardsprior to software revision 4.0, which can be identified by their components mountedthrough the board and two 8 pin test point connectors.

The incubator control circuitry is located inside the removable controller. The controllerinterfaces with the operator through the LEDs and switches on the display board,mounted behind the control panel.

The major portion of the control logic, switch interpretation, and power supply genera-tion occurs on the control board.

For controllers with serial numbers beginning with HBJ and HCE, two external ther-mistor assemblies supply a total of three temperature signals to the control board.

The patient temperature probe attaches to the patient and plugs into the jack locatedon the left side of the controller. It contains one thermistor and outputs the patienttemperature signal, which is used to generate the patient temperature display and toadjust heater output in the patient control mode.

The air temperature sensor mounts on the hood inside the infant compartment andattaches with the air temperature sensor connector, located on the left side of thecontroller. It contains two separate thermistor circuits: the air control thermistor signal isused by the control circuitry to adjust heater output and to trigger alarms; the air displaythermistor signal is used by the control circuitry to generate the front panel air tempera-ture display. The air display signal is also input to an independent air safety circuit,which shuts down the heater if the signal exceeds preset temperature safety limits.

For controllers with serial numbers that begin with HAG, an air flow sensor is mountedon the rear bulkhead of the controller and is used to verify that the heater fan is work-ing. The air flow sensor contains two thermistor circuits, one of which is heated by aresistor inside the sensor assembly. Normally, the fan cools the heated thermistor towithin several degrees of the unheated thermistor. If the fan fails to operate properly,the temperature difference between the unheated and the heated thermistors increasesand triggers the air circulation alarm ( Comparing the two thermistor readings cancelsout any changes in room temperature. This means that air flow sensor operation isindependent of ambient temperature within the operational range).

A separate thermal switch, mounted on the rear of the controller, shuts down the heaterif the heater temperature (monitored at the thermal switch) exceeds 76.7°C (170°F).

1.11 Control Board (Software Revision 04.00 and Higher)

The control board contains the incubator logic circuitry, diagrammed in Figure 1-1, aswell as the power supply and distribution circuitry, diagrammed in Figure 1-2. Pleaserefer to the schematics in section 7 of this manual.

This board is an 80C32 microprocessor based controller board. The processor ac-cesses the outside world via multiple digital I/O ports and a multichannel 12 bit analogto digital converter (ADC) circuit. The board also contains its own power supply circuit,making use of off board transformers and a nickel cadmium (NiCd) backup battery todrive the alarm in case of power outages.

Software Revision 04.00 and Higher


1-2 1-26600-0017-000 03/12/98

CI.2

3.06

7

* Circuit produces feedback signal to microcontroller.

Figure 1-1Control Circuitry Block Diagram (Software revision 04.00 and higher)

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


1-3 1-36600-0017-000 03/12/98

A. Microprocessor

Memory Allocation and Peripherals

The processor accesses the digital I/O ports via two different methods: Port 1 of themicrocontroller (pins 2-9) interface to the display board, while all of the other ports areexternal memory mapped. Memory mapping the ports simplifies both the hardware andsoftware, and allows for the use of common off the shelf parts to minimize the chanceof obsolescence. The external data space is 64K bytes, and is divided up as indicatedin the table below.

External Address Range

(hex) Function Port Type

0000h - 0FFFh Expansion bus chip select I/O

1000h - 1FFFh SRAM chip select (U7) I/O

2000h - 2FFFh DIP switch port (U3) Input

3000h - 3FFFh Input Port #1 (U4) Input

4000h - 4FFFh Output Port #1 (U20) Output

5000h - 5FFFh Output Port #2 (U19) Output

6000h - 6FFFh ADC Latch Low (U6) Input

7000h - 7FFFh ADC Latch High (U5) Input

8000h - FFFFh Expansion Bus I/O

Table 1-1 — External Data Space Decoding

Some of these peripherals, such as the input or output latches, have only one register.When these locations are accessed, all addresses within that range will contain thesame value. For an output port, any address in this range can be written to. As anexample, to write to Output Port #1, writing to address 4000h is the same as writing toaddress 4FFFh - only one write is needed to latch the data.



1-4 1-46600-0017-000 03/12/98

Address decoding is accomplished by decoding the upper address lines with a74HC138 3-to-8 decoder. The top address line, A15, enables the device when it is low;this creates the 32K of address space for the expansion bus, as shown in Table 1-1.When enabled, one output of the decoder goes low, depending upon the state of the 3address lines A12 through A14. The outputs are further qualified by /RD and /WR usingOR gates U1 and U2. This prevents programming errors from writing to a read onlyport. It also prevents activating a port when accessing program memory, since only oneof the signals /PSEN, /RD or /WR will be active for any given bus cycle. The tablebelow defines the bits of the Input #1 port (U4).

Bit Signal Name Function

0 HEATER_STATUS High when AC is appliedto heater.

1 /OT (OverTemp) From Air Overtemp circuit

2 S/O (Short/Open) Detects shorts or opens inAIR_DISPLAY sensor

3 Frequency From U23, square wave withfrequency the same as AC line

4 2KHz 556 timer - audible alarmfrequency

5 DATA_OUT Read data from theEEPROM (U28)

6 “0” Not used, grounded

7 “0” Not used, grounded

Table 1-2 — Input #1 bit definitions

The table below defines the bits of the Output #1 port (U20).


0 HIGH_PRIORTY_ALARM See Table 1-4

1 LOW_PRIORTY_ALARM See Table 1-4

2 WATCHDOG_TIMER Pulsed on a regular basisby firmware to keep thewatch dog timer reset

3 -MUX_CAL Used by the Air Overtempcircuit mux (U26)

4 MUX_A

5 MUX_B Selects the analog channelto convert at the ADC

6 MUX_C

7 RUN/HOLD Enables/disables the ADCconversions.

Table 1-3 — Output #1 bit definitions

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


1-5 1-56600-0017-000 03/12/98

The lowest 2 bits of the Output #1 port are used to control the audio alarm. This alarmhas four modes of operation: off, low priority (a constant 2 kHz tone) and two highpriority (2 kHz alternated with a 1.75 kHz tone, at a 1 Hz rate). Table 1-4 identifies thealarm modes with the bit states. The table below identifies the alarm modes with bitstates.

Bit 1 Bit 0 Mode

0 0 Low Priority

0 1 High Priority

1 0 Off

1 1 High Priority

Table 1-4 — Alarm Bit Modes

The next table defines the bits of the output #2 port (U19)


0 HEAT Controls external heatersolid state relay

1 CALL Signals the external NurseCall board

2 SBR1

3 SBR2 Bank select for SRAM.Allows 64K of storagespace to be used.

4 SBR3

5 SBR4

6 SERIAL_CLOCK Clock for the EEPROM(U28) & EEPot (U30)

7 DATA_IN Write data for EEPROM &UP/DN signal for EEPot

Table 1-5 — Output #2 bit definitions



1-6 1-66600-0017-000 03/12/98

B. SRAM & EPROM

The SRAM (U7) on the board is 128K x 8 in size. Only 4K of the device is available tothe processor (via the /CS1 chip select). A bank select scheme was implemented usingthe spare outputs on U19. This allows access of up to 64K of the SRAM, 4K at a time.The top address line, A16, is hardwired to ground due to lack of an additional outputport pin. This chip is currently not used and is available for future expansion.

The program for the processor is contained in a 512K x 8 EPROM (U21). TheEPROM is located within the Program space, and is controlled by the processor via the/PSEN line. The processor can access up to the full 64K of program memory, allowingfor firmware expansion.

An electrically erasable PROM (EEPROM) is located at U28. This is the common93C46 serial EEPROM. Data is shifted in and out via a serial clock(SERIAL_CLOCK).The chip select for the device is generated by pin 9 of the proces-sor. This chip is currently not used and is available for future expansion.

C. Over temperature & Air_Display Sensor

In the case of the Air Overtemp circuitry, software will perform the temperature regula-tion in the system, but this redundant circuitry provides additional protection against anover temperature condition.

A set of voltage dividers generates voltages corresponding to temperature readings.The analog multiplexer at U26 selects the voltage divider (via 2 bits (1 & 2) of dipswitch SWI and the -MUX_CAL signal from the processor) and presents it to U10. If theinput voltage from the AIR_DISPLAY thermistor input is over the limit set by the se-lected voltage divider, the OT and /OT signals go active. The remaining 2 gates of U10act as a window comparator: When the input voltage is between the voltages set atpins 4 and 7 of the comparators, the open collector outputs stay high. When the inputgoes outside this range (for example, the AIR_DISPLAY sensor is missing or shorted toground), the S/O and /S/O outputs are asserted.

If any of the comparators are active, the RELAY signal is de-asserted (dropped to “0”),and the onboard relay K1 is turned off, disabling the heater.

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


1-7 1-76600-0017-000 03/12/98

Line FrequencyPulsed DC Signal(Power FailureDetection)

+8 V Unregulated(To Heater ControlCircuit)

8 Vac

+5VRegulator

+5 V Display(To DisplayBoard)

11 Vac

11 Vac

Rectifier

Line VoltageSignal(Adjustable)

Regulator(AdjustableBias)

+9.8 V (ToBattery andAir FlowSensor)

+9 V Standby(Approx. 7 Volts;from Batteryduring PowerFailure

+5 V Standby(ControlBoard Logic)

Regulator

8 Vac

Rectifier

CI.0

2.13

6

D. Power Supply Circuitry

Power is supplied by two off board AC transformers as shown in Figure 1-2: 8VAC forthe LED displays and 11VAC for logic power. Both circuits use a full wave bridgerectifier composed of 4 discrete diodes. A single package bridge rectifier was avoideddue to future availability of parts. Fuses F1 and F2 are included in case of catastrophicfailure of the rectifier circuit.

Logic power is supplied by a dual linear regulator design. Voltage regulator VR3 is a7805 5 volt regulator, with the GND pin raised up from ground to generate the 10Vsignal (+9V_STDBY) from the input rectified voltage (+11_UNREG). This is used totrickle charge an off board NiCd backup battery through R34. Schottky diode D1presents a low impedance path for powering the board during loss of AC power. DiodeD4 isolates VR3 from the battery backup power.

VR1 drops the 10 volts down to the 5V supply needed by the logic. VR1 is an LM2937low dropout (LDO) regulator. C64 is the output capacitor for the regulator, and must bepresent to guarantee that the LDO regulator remains stable. The regulator was chosento be footprint compatible with the 7805, but allows for longer battery life by presentinga lower voltage drop between input and output pins.

Figure 1-2Power Supply Circuitry (Software revision 04.00 and higher)



1-8 1-86600-0017-000 03/12/98

The LINE_COMP signal is used by the software to adjust heater duty cycle to compen-sate for variations in AC line voltage. Resistor R99 and capacitor C40 create a lowpass filter that eliminates the AC line ripple on the unregulated bus. Diode D2 preventsmomentary sags in line voltage from affecting the readings. Resistor R33 and potenti-ometer RP2 act as a voltage divider to present a fraction of the input voltage to theADC for conversion.

The design of the power supply to the display is similar, but uses only one voltageregulator (VR2; a 7805). This circuit is not battery backed.

The FREQUENCY circuit generates a square wave with a frequency proportional to theAC input frequency. Diode D5 half wave rectifies the incoming AC power, and thisvoltage is dropped by a voltage divider composed of R36 and R28. The resultingvoltage drives the Schmitt trigger gate at U23, which converts the half wave rectifiedsignal to a clean square wave.

E. Heater Control

The heater control algorithm ensures that line voltage variations will not affect theheater output as long as the voltage remains between 90 and 110% of the nominalvoltage (115 volts for 120 volt units). For voltages outside this range, the line voltage isassumed to be either 90 or 110% depending on the violated limit.

Heater output is controlled by varying the number of ac cycles delivered to the heater.Depending on the line voltage and the percentage of the maximum heater outputnecessary to maintain the required temperature, between 0 and 60 cycles will bedelivered to the heater every second. When the line voltage is within 10% (90% to110%) of the nominal voltage, the number of heater power cycles is calculated propor-tionately:

Number of cycles = 50 x (rated voltage)2 x (required % max. heater output)(line voltage)2

If the line voltage is less than or equal to 90% of the nominal voltage, the number ofcycles is calculated by multiplying the percentage of the maximum heater outputrequired by 60. For example, at 90% of the nominal voltage, the heater would be on for60 cycles out of 60 when 100% of the maximum heater output was required. Above110% of the rated voltage, the number of cycles is calculated by multiplying the per-centage of maximum heater output by 40. Heat output is independent of line frequency.

1. Heater Control Circuit

As shown in Figure 1-3, the heater control circuit consists of a safety relay, a solid staterelay, and a thermal switch wired in series. The heater is normally switched ON andOFF by closing or opening the solid state relay.

The heater is switched by two relays, and its voltage status is sensed by an electricallyisolated circuit. Darlington transistor Q2 and resistors R41 and R45 control an off boardsolid state relay (SSR). This is controlled by the HEAT signal, from output port of chipU19. The onboard relay, K1, is controlled by Darlington transistor Q1 and associatedcomponents by the RELAY signal, from the Air Overtemp circuitry.

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


1-9 1-96600-0017-000 03/12/98

CI.0

2.13

3

Figure 1-3

Heater Control and Monitoring Circuits

2. Heater Status

Diodes D7, D8, D17 and D18 form a full wave bridge rectifier, with the AC inputsattached across the heater terminals. Resistors R29, R35, R37 and R38 limit themaximum current through the bridge circuit, and provide a level of redundancy. Theoutput of this bridge is attached to the diode section of U11, a CNY17-3Z optoisolator.When the heater is turned on, the optoisolator transistor turns on. This discharges C44,and presents a low to pin 10 of U23. U23, a Schmitt trigger NAND gate, is wired as aninverter, so HEATER_STATUS is high when heater power is applied. Inverter gate U8lights the LED D6 when HEATER_STATUS is active.

Maximum temperatures and the corresponding voltages are shown below.

Control Alarm Approx.Mode Temperature Temperature Voltage Resistance

Air Control < 37°C 38°C 540 mV 5,740 Ohm

Air Control > 37°C 40°C 520 mV 5,289 Ohm

Patient All 40°C 520 mV 5,289 Ohm

Table 1-6 — Heater temperature/voltage relationship

Important Control board dip switches 1 and 2 must both be set to OFF for the high air tem-perature circuit to function.

Note: The alarm has about 1°C hysteresis before resetting.



1-10 1-106600-0017-000 03/12/98

Safety Relay

The safety relay, K1, is controlled by the Relay signal, which is produced by gating theoutputs of the air safety circuit and the watchdog timer circuit. The safety relay shutsdown the heater if the watchdog timer fails to receive clock pulses, if the air probeshorts or opens, or if the air temperature exceeds the preset limit.

Under normal conditions, the Relay signal is high ( +2.4 Vdc minimum). This switcheson transistor Q1, causing the relay coil to energize and close the contacts.

Note: This requires a minimum 7.32 Vdc from the unregulated +8 volt supply (TP1-21).

If the air safety circuit or the watchdog timer triggers an alarm, the Relay signal goeslow (0.5 Vdc Maximum), switching OFF the transistor and opening the safety relaycontacts.

Solid State Relay

When the safety relay is closed, the solid state relay switches the heater ON and OFFunder microcontroller control.

The microcontroller switches ON the heater by setting the Heat signal high. Thisswitches ON Q2, turning on the solid state relay and activating the zero crossingdetection circuit inside the relay. Because this circuit switches ON or OFF only at zerovoltage there may, in practice, be up to a half cycle switching delay.

Thermal Switch

The thermal switch is mounted on the rear of the controller, near the heating element,and is set to open if its temperature exceeds 76.7°C (170°F). The thermal switch selfresets (closes) when it has cooled.

F. Analog Inputs

The analog input to the system is through U27, a 74HC4051 analog multiplexer. All thethermistor inputs are from the input to ground, with a 5.76K, 0.1% pull-up resistorcompleting the sensor circuit. External patient inputs are filtered with pi filters consist-ing of two caps and an inductor.

G. Watchdog Timer

U12 and related circuitry is the watchdog timer. The processor firmware generatesregular pulses to the WATCHDOG_TIMER signal (via output port U20). This keeps thedevice constantly triggered. If the software should stop re-triggering the timer (due tohardware or software failure, for example), the device times out. This causes a numberof things to occur:

• An interrupt is generated to the processor -INT1 pin. If the fault is in software, thismay bring the software back on track and correct the problem.

• The high priority alarm is enabled. For a software error, this signal will be assertedso briefly that no alarm may be heard. For true faults, the alarm will sound.

• The RELAY signal is de-asserted, disabling the heater relay K1 and the heater.

The OPTO input (from connector J5) circuit is used to check fan speed. The heater fanspeed is constantly monitored via a reflective optocoupler built into the fan housing.Resistor R56 supplies current to the LED. The photo transistor is pulled up via RP3 andsupplied to comparator U10. Resistors R52 and R53 set a threshold for the compara-tor, which converts the variable input voltage to a clean square wave. RP3 adjusts thethreshold of the circuit.

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


1-11 1-116600-0017-000 03/12/98

H. Audible Alarm

The alarm tones are generated by a 556 dual timer. The leftmost timer generates a 1Hz 50% duty cycle square wave, which is used to generate the two tone high priorityalarm. The second timer generates the signal that goes to the transducers. (newerversions of the control board have only one transducer)

The output of the second slot of the LM556C timer is used to generate both a 2 kHzand a 1.75 kHz signal. If the output from the first slot is a logic “0”, the transistor, Q3,will not be conducting. If the output from the first slot is a logic “1”, the transistor, Q3,will be conducting.

When the high priority alarm is sounding, the tone emitted will be 2049 Hertz (+34 / -49Hertz) for a period of 0.50 seconds (+/- 0.05 seconds) and then 1745 Hertz (+36 / -34Hertz) for a period of 0.51 seconds (+0.06 / - 0.07 seconds). When the low priorityalarm is sounding, the tone emitted will be 2049 Hertz (+34 / -49 Hertz) for a period oftime which is determined by software.

Q3, an MMBT3904 NPN transistor, is used to switch the capacitor C26 in and out of thecircuit, altering the frequency of the tone generated. This pin is connected to a resistorladder inside the device. By applying a voltage to this pin, the thresholds of the internalcomparators are changed, changing the output frequency.

As the voltage is varied, the volume varies accordingly. VR4 is an LM317L adjustablevoltage regulator. Its output voltage is controlled by RP4, a multiturn potentiometer, orU30, a Xicor nonvolatile EEPot under software control. Resistors R100 and R102 areadded to control the range of the pots. Note that only one of the two variable resistors(RP4 or U30) will be installed.

By shorting pins 1 and 2 of TP1, the audio circuit will be muted. This ties the thresholdand trigger pins on the second timer of the LM556C timer to +5V_STDBY, which stopsthe multivibrator from toggling. This also allows the processor to detect the disabledtimer, preventing field service or manufacturing from releasing a board into service withthe alarm disabled.

I. A/D Converter

The analog to digital converter section is totally ratiometric. This means that all of theanalog measurement circuitry, from the sensor voltage to the A/D converter referencevoltage, is a function of Vref, the analog reference voltage. This means that Vref’saccuracy can be less critical.

Vref is generated by U15, an LM385 1.2V band gap reference. This voltage is sentthrough a low pass filter consisting of R73 and C49, and is then buffered by U24,another voltage follower op-amp.

The selected sensor input from U27 is applied to voltage follower op-amp U25. Thissignal is then sent into an RC low pass filter consisting of R69 and C27, and is thensent into the non inverting input of U14, an ICL7109 analog to digital converter.

U13 is a switched capacitor DC/DC inverter, which generates -5V from the 5V supplyrail. This voltage is needed by the ADC and the op-amps. L6, C32 and C53 create aseparate analog Vcc plane and electrically isolate the plane from any noise on thedigital Vcc plane of U14.



1-12 1-126600-0017-000 03/12/98

The ICL7109 generates an output based upon the difference in voltage between theIN_HI and IN_LO inputs. By raising the IN_LO pin above ground, this voltage iseffectively subtracted from the input voltage, achieving the input scaling without exter-nal components. This DC offset voltage is controlled by RP5 (DC_OFFSET). The fullscale value of the ADC is set by RP6, the SPAN_ADJUST potentiometer. This adjuststhe voltage applied to the REF_IN+ pin, the ADC reference voltage.

Connector Function

TP1 Test Point connector, used during debug and field service

J1 AC interface connector for heater and heater control

J2 AC power input for the board (8VAC, 11VAC & battery)

J3 Display/front panel switch connector

J4 Patient & Air probes

J5 Heater fan optoisolator

J6 Nurse call interface

J9 Patient 2 and Patient 3 probe inputs (Future)

J10 Expansion bus interface (Future)

J12 Power tap for AC transformer (8VAC, 11VAC)

Table 1-7 — Connector and Test Point Identification

Pin Function Pin Function

1 +5V_STDRY 17 /HEAT

2 /ALARM OFF 20 9.8V

4 2 kHz 21 +8V Unreg.

5 AIR DISPLAY 24 GND

6 /S/O 25 +9 STDBY

7 OT 28 +5V_DSPLY

8 AFS

Table 1-8 — TP1 Connector Pin Identification

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


1-13 1-136600-0017-000 03/12/98

1.12 Control Board (Software Revision 03.10 and Lower)

The control board contains the incubator logic circuitry, diagramed in Figure 1-4, aswell as the power supply and distribution circuitry, diagramed in Figure 1-5.

The board centers around U19, the 8032 microcontroller. The microcontroller interfaceswith its peripherals through three I/O expanders on the data bus. Analog signals aremultiplexed to the Analog to Digital Converter (ADC), and the results of the conversionare read in through I/O expander U15. The microcontroller communicates with the airsafety circuit, the watchdog timer, and the alarm tone generator through a second I/Oexpander, U17. A third I/O expander, U2, located on the display board, interfaces withthe control panel touch switches and displays. As indicated in Figure 1-4, the heatercontrol, the air safety, the watchdog timer, and the alarm circuits generate feedbacksignals to the microcontroller.

Software Revision 03.10 and Low

er


1-14 1-146600-0017-000 03/12/98

CI.0

2.25

2

ThermistorSignals

Air Display Temp.

HeaterControlCircuit*Solid StateRelay

Control

Lines

Data

U14ADC

U15I/OExpander#2

U5, U8, U7AirSafetyCircuit*

U9WatchdogTimer*

Data

(U6, U8, U7,U11, U12)AlarmCircuit*

U18OctalLatch

Address

ControlBoard

A0 A7

Address

A8 A13

U16EPROM Data

D0 D7

FanSensor‡

DisplaysU1DisplayMultiplexer

U2I/OExpander #1

Switches

DisplayBoard

U19Micro-Controller

U17I/OExpander#3

U1Multi-Plexer

A/DModule †

† on units with A/D daughter board

* Circuit produces feedback signal to microcontroller.

‡ Fan sensor applies to controllers with serial numbers beginning with HBJ and HCE.

Figure 1-4Control Circuitry Block Diagram (Software revision 03.10 and lower)

Softw

are

Revi

sion

03.

10 a

nd L

ower


1-15 1-156600-0017-000 03/12/98

Line FrequencyPulsed DC Signal(Power FailureDetection)

+8 V Unregulated(To Heater ControlCircuit)

8 Vac

+5VRegulator

+5 V Display(To DisplayBoard)

11 Vac

11 Vac

Rectifier

Line VoltageSignal(Adjustable)

Regulator(AdjustableBias)

+9.8 V (ToBattery andAir FlowSensor)

+9 V Standby(Approx. 7 Volts;from Batteryduring PowerFailure

+5 V Standby(ControlBoard Logic)

Regulator

8 Vac

Rectifier

The program memory is stored in the EPROM U16. A transparent octal latch connectedto the EPROM address lines (A0 through A7) allows the microcontroller’s bi-directionaldata bus port to both address the EPROM and then read out programmed data.

The power supply circuitry produces regulated low voltage dc supplies for the controlcircuitry and the display board. It also generates two monitoring signals used to com-pensate heater output for fluctuations in line voltage and to detect a power failure. Inthe event of a power failure, a NI-CAD battery inside the controller supplies the powerfailure alarm and maintains the standby control memory for up to 10 minutes (with thebattery fully charged).

A. Power Supply Circuitry

The power supplies and power monitoring signals are generated as shown inFigure 1-5. The line frequency signal pulse that detects power failures, the +8 Vunregulated supply to the heater control circuit safety relay, and the +5 V displaysupply to the display board are derived from the 8 Vac transformer secondaries.

The 11 Vac transformer secondaries supply:

1. The line voltage signal, which adjusts the number of heater power cycles to com-pensate for voltage fluctuations.

2. The 9.8 Vdc supply, which is used to:

a. Charge the battery.

b. Supply the fan sensor LED (on controllers with serial numbers beginning withHBJ and HCE)

c. Heat the air flow sensor thermistor (on all other controllers)

d. Provide the +5 V standby supply, used to power control board circuitry.

Signals that can be adjusted as part of the calibration procedure are indicated in Figure 1-5.

During a power failure a NI-CAD battery supplies two voltage levels (+5 V STBY and+9 V STBY). The +9 V STBY supply (actual voltage approximately 7 Vdc) activates thealarms, and the 5 volt supply powers the microcontroller and the associated integratedcircuits.

CI.0

2.13

6

‡ On controllers with serial numbers beginning with HBJ and HCE, Battery and Fan Sensor LED

Figure 1-5Power Supply Circuitry (Software revision 03.10 and lower)


er


1-16 1-166600-0017-000 03/12/98

1. Line Frequency, +8 Volt Unregulated and +5 Volt Display Supplies

A nominal 8 Vac from the line voltage transformer secondary is input to the controlboard at J2 pins 2 and 3.

This signal is conditioned by CR1 and R14, and fed through a 1K resistor to a Schmitttrigger NAND gate, U7B. The other gate input is tied high, so the gate acts as aninverter. The gate will not respond until the input exceeds 1.9 Vdc minimally. Theresulting signal pulse is input to the I/O expander U15 (on controllers with serial num-bers beginning with HBJ) or is input to the microcontroller on P3.2 (on all other control-lers). Absence of this signal is interpreted as a power failure.

Bridge rectifier CR2 and capacitor C3 provide a filtered, unregulated +8 Vdc, whichsupplies the coil controlling the heater control circuit’s safety relay, and the +5 voltregulator (VR2). The unregulated +8 volt supply can be measured at TP1-5.

Regulator VR2 outputs a nominal +5 Vdc to power the display board LEDs. This outputcan be measured at J3 pin 12, 13 or TP1-3. When the line voltage is within 10% of thenominal voltage, the regulator output should range between 4.8 and 5.2 Vdc with a loadof 500 mA. The maximum allowable ripple voltage is 150 mV.

2. Line Voltage Signal, +9.8 Volt, +9 Volt and +5 Volt Standby Supplies

A nominal 11 Vac from the transformer secondary is input to the control board at J2pins 4 and 5. Bridge rectifier CR3 and capacitor C4 provide a full wave, unregulatedvoltage of approximately +12 Vdc.

This voltage is applied to resistor R19 to produce the line voltage monitoring signal. Theline voltage signal is input to the ADC through the multiplexer (U1). The digital output issent to the microcontroller where it adjusts heater power cycling to compensate for linevoltage changes. When the incubator is operating at the rated voltage and R19 is properlyadjusted, a reading of approximately 700 mV can be measured at U1 pin 15.

The nominal +12 volt supply is also applied to regulator VR1 to produce the 9.8 voltsupply. Regulator output can be calibrated using R20. When R20 is properly adjusted,a reading of 9.8 ± 0.1 Vdc can be measured at TP1-1. This voltage is used for chargingthe NI-CAD battery through R18, and for supplying the fan sensor LED (on controllerswith serial numbers beginning with HBJ) or for supplying the resistor used to heat theheated air flow sensor thermistor (on all other controllers). It also supplies +5 voltstandby regulator, VR3.

When line voltage is available, current flows from the output of VR1 through CR10 tosupply 9.0 volts at the input of VR3, (TP1-6). In turn, regulator VR3 outputs a voltage of5.0 ± 0.2 Vdc to the control circuitry (TP1-4). The maximum allowable ripple voltage is150 mV.

When power loss occurs, the 7.2 volt NI-CAD battery maintains power to control boardregulator VR3 through CR11. The output of VR3 powers the incubator logic circuits andwill remain at +5.0 ± 0.2 Vdc until the input to the regulator drops below +7.0 Vdc.When the input voltage falls below +7.0 Vdc, the regulator output (+5 Vdc supply) maynot be within the allowed tolerance (±0.2 Vdc). The battery’s + 9 Vdc standby outputalso supplies approximately +7 Vdc to the alarm speaker.

B. Analog to Digital Converter

On older units with the U14 ADC, the analog to digital conversion circuit shown in theFigure 1-1 block diagram, page 1-2, has three separate sections: the Analog to DigitalConverter (ADC); a multiplexer used to select converter input; and a reference voltagegenerator. On units with the ADC daughter board, the ADC circuit shown has threeseparate sections: the A/D module; an analog multiplexer ; and a reference voltagegenerator.

Softw

are

Revi

sion

03.

10 a

nd L

ower


1-17 1-176600-0017-000 03/12/98

1. Analog to Digital Converter (ADC), units with 3711 chip at U14

The ADC, U14, operates asynchronously, continuously converting analog voltageinputs into a number of counts between 0 and 3999 (BCD format). The conversion rateis set by an internal oscillator whose frequency is determined by the external compo-nents R67 and C37. The exact oscillator frequency is not critical and may vary by ±15% from the nominal 400 kHz. The oscillator frequency can be measured on pin 18 ofU14. With a nominal 400 kHz clock frequency, conversions within the ADC 3711 willtake place at an approximate rate of three per second.

The ADC communicates with the microcontroller through I/O expander U15. The ADCdata latch is permanently enabled by tying pin 19 (DLE) low. The start conversion andthe conversion complete signals synchronize the data conversion, which proceeds asfollows:

1. The microcontroller’s start conversion pulse triggers a new conversion, prematurelyending any conversion in progress.

2. The conversion complete output goes low on the falling edge of the start conver-sion pulse. It returns to a high level when the ADC completes the conversion. Thelow to high transition prompts the microcontroller to read the ADC output.

3. The first set of data, from the prematurely terminated cycle, is discarded sincethere is no way to determine if it represents an entire conversion.

4. The microcontroller waits until the new conversion cycle has been completed.

5. The data is read by the microcontroller, converted to temperatures or voltagepercentages, and stored in RAM.

The BCD data is output on binary data lines, (bit 1 to bit 8, pins 23, 24, 3, and 4 respec-tively) in accordance with the coded digit select signals applied to the ADC digit selectinputs (D0 and D1, pins 20 and 21 respectively). The digit select codes are summa-rized below:

D0 D1 Selected Digit

L L Digit 0 (LSD)

L H Digit 1

H L Digit 2

H H Digit 3 (MSD)

1a. A/D Module

The A/D module contains three separate sections required to convert analog signalsand to communicate with the microcontroller. They are the ADC, a 4 to 1 digital multi-plexer, and a -5 volt supply.

Analog to Digital Converter (ADC)The ADC is a dual slope, integrating ADC with auto-zero function. The ADC operatesin an “on demand” mode. When instructed to by the microcontroller the ADC convertsthe analog voltage at its input into a number of counts between 0 and 4095. Theconversion rate is set by crystal Y1 on the A/D module board. A single conversiontakes 132 ms. Components C3, C4, C5, and R1 are used by the ADC to integrate thevoltage signals and perform internal zeroing.

Units with 3711 chip

Units with daughter board


1-18 1-186600-0017-000 03/12/98

The ADC communicates with the microcontroller through I/O expander U2. The ADCdata latches are permanently enabled by tying the high byte enable and low byteenable Low. The Run/Hold and Status signals synchronize the data conversions, whichproceeds as follows:

1. The ADC begins conversion when a high signal is present on its RUN/HOLD pin.

2. When the conversion is complete and the digital data has been latched onto theoutputs of the ADC pulls the status line low.

3. To ensure that the analog input signal has stabilized, the first three data conver-sions are discarded and another conversion is initiated.

4. The fourth data conversion is read by the microcontroller, converted to temperatureor voltage percentages, and stored in RAM.

4 to 1 MultiplexerThe 4 to 1 multiplexer circuit consists of two 4 to 1 multiplexers (U2 and U3 on A/Dmodule). U2 and U3 act as 4 bits (nibble) data selectors for the microprocessor. Themicroprocessor selects a nibble of data at a time. The select lines of each of the 4 to 1multiplexers, pin 2 of U2 and U3 and pin 14 of U2 and U3 are configured so that theyprovide the microprocessor with two select lines. The truth table below shows theoutput.

D0 pins 14 D1 pins 2 Data line selected Data Description0 0 1C0 and 2C0 B1-B40 1 1C1 and 2C1 B5-B81 0 1C2 and 2C2 B9-B121 1 1C3 and 2C3 A/D Signature

The 12 bits of data are present in the first three data nibbles. The fourth nibble ispermanently wired so that the output will always be 1000B. This allows the micropro-cessor to identify the type of ADC converter being used.

-5 Volts SupplyThe -5 volt supply is required by the ADC converter to properly bias the chip, operatethe internal switches, and as a supply for the internal integrator. The -5 volts is createdby U4 which is a DC to DC converter. U4 contains an internal 10 KHz. clock thatcontrols the internal switches. During the first half cycle of the clock C1 is connected to+5 volts and ground. During the second half cycle C1 is disconnected from the + 5volts and ground and connected across C2 so that the polarity is inverted. This createsa negative voltage that is proportional to the +5 volt in. V out (pin 5) should be -4.8 volts+/-0.4 volts with no more than 0.2 volts ripple.

2. Analog Inputs

Analog voltage signals are directed to the ADC inputs through an eight channel analogmultiplexer, U1. Multiplexer switch selection is software controlled by themicrocontroller, which toggles the A, B, and C input lines of the multiplexer through I/Oexpander U15.

Softw

are

Revi

sion

03.

10 a

nd L

ower


1-19 1-196600-0017-000 03/12/98

Control Input

A B C Switch Pin No. Signal

0 0 0 X0 13 CAL LOW

1 0 0 X1 14 CAL HIGH

0 1 0 X2 15 LINE COMP

1 1 0 X3 12 AIR FLOW UNHEATED*

0 0 1 X4 01 PATIENT

1 0 1 X5 05 AIR DISPLAY

0 1 1 X6 02 AIR CONTROL

1 1 1 X7 04 AIR FLOW HEATED*

* These channels are not used on controllers with serial numbers beginning with HBJ and HCE.

3. Reference Voltage

On units with the 3711 chip at U14, the LM-10 combination op-amp and voltage referencecircuit (U13A and B) uses its 200 mV internal reference source to supply two referencevoltages. The buffer portion of the LM-10, U13B, supplies a fixed, nominal 1 volt referenceto the ADC input circuits. This is amplified by the op-amp portion of the LM-10 to providean adjustable, nominal 2 volt reference to the ADC. During ADC calibration, the level ofthe 2 volt reference is adjusted using R25. On units with the A/D module on the daughterboard, the 2 volt reference is applied to a voltage divider network on the A/D module madeup of R2 and R3. The voltage developed across R3 is used as a voltage reference for theADC. The nominal voltage reference to the ADC is 287 mV.

The nominal 1 volt supply should give a reading of about 1.1 Vdc at TP2-3. The nomi-nal 2 volt ADC reference should give a reading of about 2.06 Vdc (on controllers withserial numbers beginning with HBJ or HCE) or 2.2 Vdc (on all other controllers) at TP2-4. The exact readings may vary between units.

C. Microcontroller

The heart of the control system is the 8032 microcontroller U19. It has been configuredto operate from external memory by grounding the EA line, pin 31. The clock speed is 6MHz and can be verified by measuring a frequency of 1 MHz at the Address LatchEnable (ALE), pin 30, (ON = 0.33 usec and OFF = 0.67 usec).

1. EPROM Read

Port 0 and port 2 are used to read instructions from EPROM U16 (27128A). Port 2outputs the high level address bits (8 bits) directly to U16, while port 0 serves as amultiplexed lower level address (8 bits) and data bus.

At the start of the read, all address bits are output simultaneously. On the falling edgeof the ALE signal, the lower eight address bits are latched into a transparent octal datalatch, U18, and port 0 is set to input mode. Then, the program store enable signal(PSEN) goes low to enable data transfer from the EPROM.

2. Peripheral Interface

Port 1 goes directly to three 8243 I/O expanders. Bits 5-7 are connected to the chipselect lines of display board expander U2 (bit 5), and control board expanders U15 (bit6) and U17 (bit 7). Only one of the I/O expanders can be enabled at a time. Bits 0-3hold the instructions to be carried out by the enabled integrated circuit when bit 4 goesfrom a high to a low logic level.


er


1-20 1-206600-0017-000 03/12/98

3. Miscellaneous Functions

Port 3 performs several miscellaneous tasks required by the control system: it providesa serial interface; monitors the fan speed (on controller with serial numbers beginningwith HBJ) ; monitors the presence or absence of line power (on controllers with serialnumbers beginning with HAG); checks the status of the watchdog timer; and sendsdata and clock signals to the display board driver.

On controllers with serial numbers beginning with HBJ and HCE, the serial interfaceconsists of the microcontroller transmit line (TXD/P3.1) and the receive line (RXD/P3.0). These lines are all connected to J6, along with a +5 Volt Standby connection, aconnection to logic ground, and a nurse call signal . These signals can be connected tothe ThermaLink board, whose functions are described in the ThermaLink Optionsection 1.3.

On all other controllers, the serial interface consists of the microcontroller transmit line(TXD/P3.1), the receive line (RXD/P3.0), a +5 Volt Standby connection and a connec-tion to logic ground. These lines are all connected to J6 to allow factory testing.

On controllers with serial numbers beginning with HBJ or HCE, INT0/P3.2 monitors thefan speed. Absence of fan speed signal pulse is used to detect an air circulation failure.

On all other controllers, INT0/P3.2 is the line frequency signal pulse, which is derivedfrom the +8 Vac nominal supply (discussed in Section A, Power Supply Circuitry).Absence of the line frequency signal pulse is used to detect a power failure.

INT1/P3.3 monitors the status of the watchdog timer and the two unused address bits.

T0/P3.4 sends serial data to the display driver, U1 (display board), while T1/P3.5 clocksthe driver.

D. Heater Control

The heater control algorithm ensures that line voltage variations will not affect theheater output as long as the voltage remains between 90 and 110% of the nominalvoltage (115 volts for 120 volt units). For voltages outside this range, the line voltage isassumed to be either 90 or 110% depending on the violated limit.

Heater output is controlled by varying the number of ac cycles delivered to the heater.Depending on the line voltage and the percentage of the maximum heater outputnecessary to maintain the required temperature, between 0 and 60 cycles will bedelivered to the heater every second. When the line voltage is within 10% (90% to110%) of the nominal voltage, the number of heater power cycles is calculated propor-tionately:

Number of cycles = 50 x (rated voltage)2 x (required % max. heater output)

(line voltage)2

If the line voltage is less than or equal to 90% of the nominal voltage, the number ofcycles is calculated by multiplying the percentage of the maximum heater outputrequired by 60. For example, at 90% of the nominal voltage, the heater would be on for60 cycles out of 60 when 100% of the maximum heater output was required. Above110% of the rated voltage, the number of cycles is calculated by multiplying the per-centage of maximum heater output by 40.

Heat output is independent of line frequency.

Softw

are

Revi

sion

03.

10 a

nd L

ower


1-21 1-216600-0017-000 03/12/98

1. Heater Control Circuit

As shown in Figure 1-6 the heater control circuit consists of a safety relay, a solid staterelay, and a thermal switch wired in series. The heater is normally switched ON andOFF by closing or opening the solid state relay.

Safety Relay

The safety relay, K1, is controlled by the Relay signal, which is produced by gating theoutputs of the air safety circuit and the watchdog timer circuit. The safety relay shutsdown the heater if the watchdog timer fails to receive clock pulses, if the air probeshorts or opens, or if the air temperature exceeds the preset limit. On controllers withserial numbers that begin with HAG an opto-isolator triac driver, U4, isolates the lowvoltage and line voltage circuits.

Under normal conditions, the Relay signal is high ( +2.4 Vdc minimum). This switcheson transistor U12C (FET U12 B on controllers with serial numbers that do not beginwith HAF), causing the relay coil to energize and close the contacts.

Note: This requires a minimum 7.0 Vdc ( 7.32 Vdc on controllers with serial numbersthat do not begin with HAF) from the unregulated +8 volt supply (TP1-5).

If the air safety circuit or the watchdog timer triggers an alarm, the Relay signal goeslow (0.5 Vdc Maximum), switching OFF the transistor (FET on controllers with serialnumbers that begin with HAF) and opening the safety relay contacts.

Solid State Relay

When the safety relay is closed, the solid state relay switches the heater ON and OFFunder microcontroller control.

The microcontroller switches ON the heater by setting the Heat signal (U15 pin 21;P5.3) high. This switches ON U12D (U12 A on controllers with serial numbers thatbegin with HAF), turning on the solid state relay and activating the zero crossingdetection circuit inside the relay. Because this circuit switches ON or OFF only at zerovoltage there may, in practice, be up to a half cycle switching delay.

Figure 1-6Heater Control and Monitoring Circuits

CI.0

2.13

3, 1

34

Controllers withHBJ and HCE Serial Numbers

Controllers withHAG Serial Numbers

Safety

Relay

Heater

Thermostat

Solid State Relay

Neutral

HeaterMonitoringCircuit

Heat Signal

HeaterStatusLED

+ 5 V

Relay Signal

Phase


er


1-22 1-226600-0017-000 03/12/98

Thermal Switch

The thermal switch is mounted on the rear of the controller, near the heating element,and is set to open if its temperature exceeds 76.7°C (170°F). The thermal switch selfresets (closes) when it has cooled.

2. Heater Monitoring Circuit

Note: On controllers with serial numbers beginning with HBJ and HCE, heater status ismonitored across the thermal switch and heater. Due to the leakage current of the solidstate relay, when the thermal switch is open, the feedback from the monitoring circuitmay indicate that the heater is ON.

On controllers with serial numbers beginning with HAG, heater status is monitoredbefore the thermal switch. Hence when the thermal switch is open, the feedback fromthe monitoring circuit still indicates that the heater is ON.

The heater monitoring circuit outputs the heater status signal to the microcontrollerthrough I/O expander U17. When the heater is ON, the heater status signal is high(signal is low on controllers that have serial numbers that do not begin with HBJ orHCE). As a diagnostic aid, a heater status LED on the control board illuminates when-ever the heater is ON.

The heater status signal is derived from a portion of the heater ac signal input to CR13.On controllers with serial numbers beginning with HBJ, when the heater is OFF, thereis insufficient voltage across CR13 to power the opto-isolator U13. This sets the U7ANAND gate input high. The NAND gate output goes low, is inverted by U11A, therebyturning off the heater status LED.

When the heater is ON, there is sufficient voltage potential across CR13 to power opto-isolator U13. The second NAND gate input is tied high, so the gate output goes high, isinverted by U11A, and turns on the heater status LED.

On all other controllers, when the heater is OFF, the dc output from CR13 powers opto-isolator U3 and sets the U7A NAND gate input low. The NAND gate output goes high,and the heater status LED goes out.

When the heater is ON, there is no voltage potential across CR13, and the opto-isolatoris not powered. The second NAND gate input is tied high, so the gate output goes low,and the heater status LED illuminates.

Note: On all controllers, every half cycle the output U3 pin 4 will show small glitchescaused by the charge/discharge of capacitor C20. These glitches do not affect circuitperformance unless they exceed U7’s (74LS132) trigger voltage of 1.4 Vdc.

E. Watchdog Timer

A watchdog timer circuit checks that the microcontroller is working properly. After everycycle through the system software, the microcontroller sends a low pulse to the A inputof U9A, a retriggerable monostable timer (74LS123). This causes the output (Q) to gohigh and the inverted output (Q) to go low for a period of time determined by the timeconstant of the RC network on the RxCx and Cx pins (Tau = 0.45 x R x C = 0.23 Sec).If another pulse from the microcontroller is not received at the A input before the timeconstant expires, both outputs change logic levels. The output, (Q), goes low and isgated by NAND gate U7D and NOR gate U8A to produce a logic low Relay signal. Thisde-energizes the safety relay and shuts down the heater. The inverted output, (Q),serves 3 functions (on controllers with serial numbers that begin with HAF, (Q) servesthe first two functions only). It sets the Reset pin on timer U6A high, triggering the highpriority audio alarm. Secondly, it is gated through NOR gate U8C to produce the logiclow interrupt signal that begins the microcontroller software recovery routine (INT1).

Softw

are

Revi

sion

03.

10 a

nd L

ower


1-23 1-236600-0017-000 03/12/98

Thirdly, it is gated with the call signal from the microcontroller to produce the nurse callsignal which controls the nurse call relay on the optional ThermaLink Call board.

F. Alarm Tone Generator

The alarm circuit consists of an alarm tone generator and control circuitry for high orlow priority alarm conditions. Frequencies for the tone generator are produced by twotimer circuits, U6A and U6B. If no alarm is present, the reset pins on both timers areheld low and no signal is produced.

1. High Priority Alarms

Two timers are cascaded to generate the high priority audio alarm. They can betriggered either by the microcontroller through I/O expander U17 or by the watchdogtimer. NOR gate U8B checks the output of both circuits. If either signal goes high, thereset pins for both timers go high. This causes U6B to generate a 2 kHz signal. A 1 Hzsignal from the second timer (U6A) pulses the control line of the first timer through R35.This alters the frequency of the first timer (U6B) to produce a warbling effect (two tonealternating alarm).

U7C gates the output of NOR gate U8B with the low priority alarm line. This ensuresthat the high priority alarm will override the low priority alarm when both are active.

2. Low Priority Alarms

The low priority alarm is triggered by a 1 Hz pulse from the microcontroller through I/Oexpander U17. Before the command is executed, NAND gate U7C checks the lowpriority alarm signal against the output of NOR gate U8B to make sure that a highpriority alarm is not already in effect. If no high priority alarm is active, (U7C pin 5 high),the reset line on timer U6B is pulsed once a second, producing a pulsed, 2 kHz signal(TP2-1). This results in a one second on, one second off (i.e. 2 kHz) audio alarm. The 2kHz signal is adjusted to ±100 Hz by R36. The volume of the audio alarm is adjustedby R37. The volume is set at the factory and should not normally require adjustment.

G. Air Safety Circuit

The air safety circuit opens the safety relay to shut down the heater if the air tempera-ture exceeds the preset safety limit, or if a short or open circuit is detected in the airtemperature sensor. The air safety circuit is completely independent of themicrocontroller and has two subcircuits: the air probe test circuit, which monitors the airdisplay signal to detect a short or open circuit; and the high air temperature circuit,which monitors the air display signal to detect high temperatures.

1. Air Probe Test Circuit

Important The information on voltage input levels given in this section and in the appendicesis approximate. It is based on an offset voltage of 1.99 Vdc measured at TP2-4 andwill vary with the actual offset voltage.

The SO signal output by this circuit goes low when the air display thermistor circuit isopen or shorted. Air display signals that exceed 880 mV (approximately equivalent to25.69 kOhm, or 5°C) are interpreted as open circuits. Signals that fall below 410 mV(approximately equivalent to 3.563 kOhm, or 50°C) are interpreted as short circuits.

The air display signal is input in parallel to two open collector comparators U5B andU5C, which feature high outputs under normal conditions. If the air display thermistoropens, comparator U5C’s output pulls SO low. If the air display thermistor shorts,comparator U5B’s output pulls SO low.


er


1-24 1-246600-0017-000 03/12/98

The SO signal is gated by the relay circuit to produce the Relay signal. A logic low SOsignal causes the Relay signal to go low, opening the safety relay to shut down theheater. The SO signal (TP2-5) is also fed back to the microcontroller through I/Oexpander U17, pin 1 (P5.0) for alarm generation.

2. High Air Temperature Circuit

Important The information on voltage input levels given in this section and in the appendicesis approximate. It is based on an offset voltage of 1.99 Vdc measured at TP2-4 andwill vary with the actual offset voltage.

Comparator U5A compares the air display signal to a reference voltage supplied byone of five resistor networks. Each network corresponds to a different temperature limit.They are connected to the comparator through multiplexer U10. Microcontroller signalsapplied through I/O expander U17 select the appropriate network based on the mode ofoperation and the control temperature. If the air display thermistor voltage signal is lessthan the reference voltage, comparator output, OT (TP2-6), floats high and is gatedthrough U8A to produce a logic low Relay signal, which opens the safety relay to shutdown the heater.

The OT signal (TP2-6) is also fed back to the microcontroller through I/O expanderU17, pin 23 (P5.1).

Maximum temperatures and the corresponding voltages are shown below.

Control Alarm Approx.Mode Temperature Temperature Voltage Resistance

Air Control < 37°C 38°C 540 mV 5,740 Ohm

Air Control > 37°C 40°C 520 mV 5,289 Ohm

Patient All 40°C 520 mV 5,289 Ohm

Important Control board dip switches 1 and 2 must both be set to OFF for the high air tem-perature circuit to function.

Note: The alarm has about 1°C hysteresis before resetting.

H. Relay Circuit

The relay circuit produces the Relay signal, which directly controls the heater safetyrelay. The relay circuit and all the signals used by the circuit are independent of themicrocontroller.

The relay circuit consists of two gates: NAND gate U7D gates the output of the watch-dog timer and the air probe test circuit signal (SO); NOR gate U8A gates the NANDoutput with the OT signal to produce the Relay signal. The Relay signal goes low,opening the safety relay to shut down the heater if: the SO signal goes low; the OTsignal goes high; or the watchdog timer output goes low.

Softw

are

Revi

sion

03.

10 a

nd L

ower


1-25 1-256600-0017-000 03/12/98

1.2.1 Display Board (6600-0512-700)

The display board is the interface between the operator and the control system. Itinforms the operator about the incubator and patient status. The operator controls thesystem by depressing the various switches on the front display. The control board usesP2 bank as bi-directional data lines, plus several timer and control lines for the displayunit.

A. Switch Decoding

Signals pass between the micro controller and the display board, at a rate of approxi-mately 1 MHz. Command words are latched in U6 and decoded in U4 on the high tolow transition of the PROG line and decoded to set a high impedance on the selectedport lines. Buffer U2 is connected to the front panel switches. When a switch is de-pressed, the corresponding line is pulled low and loaded into U2 and is transferred tothe micro controller depending on which address is selected by the decoder, U4 andthe low to high transition of the PROG line.

B. LED Displays

The LED display driver, U3, controls the LED displays. Data is input to pin 25 synchro-nously with the clock signal (pin 24). The first bit activates the driver, and 35 data bitsfollow. After the 35th bit is loaded, data is latched to provide direct output. Because theoutput is inverted, a logical 1 input switches ON the appropriate LED at the output.

Display brightness is factory preset, but can be adjusted using RP1.

C. Multiplexing of Displays

To minimize the number of driver lines required, displays are multiplexed through U3.Displays are divided into four groups: control temperature LEDs, air temperature LEDs,patient temperature LEDs and miscellaneous LEDs (mode, alarm and heater power).U5 bank select latch turns on a Darlington transistor to select the active displaychannel. The large gain of the Darlington allows a small current to sustain the loadcurrent from the LEDs.

Bits 1-32 supply the necessary information to each section. Bit 33 is unused. Bit 34 istied to a 221 ohm ± 1% resistor, used for calibration. After each of the four displaygroups has been serviced, a string of 35 zeroes is sent on the data line to reset thedriver for the next string of data; the driver operates with serial input and does not havea master reset.

The basic display circuit (one LED) includes: the +5 V DISP supply from the controlboard routed through the 1N4001 diode, the collector emitter junction of the enabledDarlington transistor, the LED, and the MM5451 decoder.


1-26 1-266600-0017-000 03/12/98

1.2.2 Display Board (6600-0105-700 & 6600-0420-700)

The display board is the interface between the operator and the control system. Itinforms the operator about the incubator and patient status. The operator controls thesystem by depressing the various switches on the front display. Two integrated circuitssimplify display board operation: the 8243 I/O expander, used in conjunction with theswitches; and the MM5451 LED driver for the displays.

A. Switch Decoding

Signals pass between the microcontroller and the display board through I/O expanderU2, at a rate of approximately 1 MHz. The I/O port is activated by a logic low on thechip select line (CS1). Command words are latched into port 2 on the high to lowtransition of the PROG line and decoded to set a high impedance on the selected portlines. Ports 6 and 7 are connected to the front panel switches. When a switch isdepressed, the corresponding line is pulled low and loaded into the I/O expander’sinput buffer. The data in the buffer is transferred to the microcontroller on the low tohigh transition of the PROG line.

B. LED Displays

The LED display driver, U1, controls the LED displays. Data is input to pin 22 synchro-nously with the clock signal (pin 21). The first bit activates the driver, and 35 data bitsfollow. After the 35th bit is loaded, data is latched to provide direct output. Because theoutput is inverted, a logical 1 switches ON the appropriate LED at the output.

Display brightness is factory preset, but can be adjusted using R11.

C. Multiplexing of Displays

To minimize the number of driver lines required, displays are multiplexed through U1.Displays are divided into four groups: control temperature LEDs, air temperature LEDs,patient temperature LEDs and miscellaneous LEDs (mode, alarm and heater power).Port 4 of I/O expander U2 turns on a Darlington transistor to select the active displaychannel. The large gain of the Darlington allows a small current to sustain the loadcurrent from the LEDs.

Bits 1-32 supply the necessary information to each section. Bit 33 is unused. Bit 34 istied to a 221 ohm ± 1% resistor, used for calibration. After each of the four displaygroups has been serviced, a string of 35 zeroes is sent on the data line to reset thedriver for the next string of data; the driver operates with serial input and does not havea master reset.

The basic display circuit (one LED) includes: the +5 V DISP supply from the controlboard routed through the 1N4001 diode, the collector emitter junction of the enabledDarlington transistor, the LED, and the MM5451 decoder.

1.3 ThermaLink Option

The ThermaLink option allows direct output of serial data to various remote monitoringsystems, such as a computer or commercial RS-232 monitor. This option is available onlywith controllers with serial numbers beginning with HBJ and HCE. The ThermaLink optionboard contains the electronic circuitry necessary to provide a 2500 VRMS isolated serialinterface to meet the logic levels specified by EIA RS-232D and CCITTV.28.


1-27 1-276600-0017-000 03/12/98

Older communication boards with test switch

The MAX250 and MAX251 (U1 and U2), together with two 6N136 optocouplers andtransformer TR1, form an isolated RS-232 transmitter and receiver. The MAX250connects to the non-isolated or “logic” side of the interface, translating logic signals toand from the optocouplers, while the MAX251 resides on the isolated or “cable” side,translating data between the optocouplers and RS-232 line drivers and receivers. Inaddition to the optocoupler drivers and receivers, the MAX250 also contains isolationtransformer drive circuitry which supplies power to the isolated side of the interface,and the MAX251.

The transmit signal is input to the MAX250 driver (U1 pin 4) whose output (U1 pin 3)drives optocoupler U4. The optocoupler output (U4 pin 6) is then fed into the MAX251driver (U2 pin 3).

The output of the MAX251 driver (U2 pin 12) is at the logic levels conforming to EIARS-232D and CCITTV.28.

Conversely, the receive signal enters the MAX251 driver (U2 pin 10) and is steppeddown to CMOS/TTL levels at U2 pin 5. This logic level drives optoisolator input (U3 pin3) whose output is fed into U1 pin 10. The output (U1 pin 9) signal is then available tothe control printed circuit board.

A slide switch SW1 is used as a “self test” for the RS-232 interface. In the closedposition, the J30-1 transmit signal is sent through the MAX250/MAX251 transmitter andback into the receiver portions. The signal can be read at J30-2 and verified to becorrect. Any external cable connection must be removed for this self test to function.CR1 and CR2 provide transient protection for MAX251. In normal operation SW1should be in the open (OFF) position.

The nurse call signal is input at J30-5 as a TTL logic level. In the “no alarm” state, thissignal is a logic high, which turns on Darlington Q1, energizing relay K1. This results incontact closure between J31-1 and J31-2. In the “alarm” state, J30-5 is a logic low,which turns off Q1, de-energizes K1 and results in contact closure between J31-2 andJ31-3. K1 provides 2500 VRMS isolation between the relay coil inputs and contactoutputs.

Newer communication boards without test switch

The Communication Board contains the electronic circuitry necessary to provide a 2500VRMS isolated serial interface to meet the logic level specified by EIA RS-232E andCCITTV.28.

Data and power from the main control board enter the communication board viaconnector JP2. Data from the control board is connected to Port P1.0 and INTO (pin 2and 14 respectively) of microcontroller U1. Data from the control board will create aninterrupt in the microcontroller’s software, causing the software to perform a read ofPort P1.0. Data to the control board is sent by Port P1.1 (pin 3) of microcontroller U1.The software is coded to properly format the data sent to the main control board. Theformat data to and from the control board is 1 start bit, 7 data bits (ASCII), 1 parity bit(odd), 1 stop bit, 1200 baud, full duplex.

The data translation is performed by the microcontroller. The microcontroller monitorsthe incoming signals from the RS232 interface. Based upon the signal entering theinterface, the microcontroller determines the type of communication system connectedto the interface. The microcontroller then appropriately converts the data to the properformat.


1-28 1-286600-0017-000 03/12/98

RS232 data to and from the microcontroller is sent via the serial port, RXD and TXD(pin 11 and 13 respectively). The serial port is full duplex, meaning it can transmit andreceive data simultaneously. The remaining output line (WR) is for future expansionand is not currently used.

Components Y1, C1, and C2 make up the oscillator circuitry for the microcontroller.The crystal is operated as an inductive reactance in parallel resonance with capacitorsC1 and C2. The oscillating frequency is 11.0592 Mhz.

Capacitor C5 is used to ensure proper reset of the microcontroller during power up. Aninternal diffused resistor is connected between the reset pin and Vss. C5 and theinternal resistor causes the reset of the microcontroller to be held high for greater than24 machine cycles.

Capacitors C6, C7, C11, and C12 are used to suppress any noise on the data lines or+5V line.

The MAX250 and MAX251 together with three 6N136 optocouplers and a transformer,form an isolated RS-232 transmitters and receiver. The MAX250 is located on the non-isolated side of the communication board. The MAX250 translates the logic signalsbetween the microcontroller and the optocouplers. The MAX250 also contains drivecircuitry for the isolation transformer, which supplies power to the isolated side of theinterface. The MAX250 alternately switches D1 and D2 to ground at a rate of approxi-mately 200 Khz.

The MAX251 resides on the isolated side of the communication board. The MAX251translates data between the optocouplers and the RS-232 interface. The MAX251contains drivers and receivers that conform to EIA RS-232E and CCITT V.28 specifica-tions.

Diode D1 and an internal diode in the MAX251 form two half wave rectifiers. Theanode of the internal diode is connected to pin 1 and the cathode is connected to pin 2.The internal diode and capacitor C4 are utilized for the positive power supply. DiodeD1 and capacitor C3 are utilized for the negative power supply.

Pin 7 of the MAX251 supplies an output of approximately 5 volts. Capacitor C9 pro-vides filtering for the line. This voltage is used to bias the output stage of optocouplersISO1 and ISO2. The output stage of ISO3 is biased by the 5V supply from the maincontrol board. Resistors R1, R2, and R5 are pull up resistors for the collector of theoutput transistors.

The RS232 output pins 11 and 12 will provide a minimum voltage swing of ±5 volts.Resistors R3 and R4 limit the amount of current. The RS232 input pin 10 can have amaximum of +30 volts to -30 volts applied. Recommended input voltage should be +15volts to -15 volts.

Inductors L1, L2, and L3 and capacitors C10, C13, and C14 are used to suppress anyhigh frequency noise on the data lines. Diodes D2, D3, and D4 are bi-directionaltransient voltage suppressors. The diodes will limit the incoming voltage to approxi-mately ± 26 volts.

The nurse call signal from the main control board is connected to the communicationboard at JP2-5. The signal is a TTL logic level. In the “no alarm” state, this signal is alogic high. A logic high turns on darlington transistor Q1, which causes relay K1 toenergize. This results in contact closure between JP1-1 and JP1-2. In the “alarm”state, the incoming logic level is low. A logic low turns off darlington transistor Q1,which denergizes relay K1. This results in contact closure between JP1-1 and JP1-8.Resistor R6 limits the current into the transistor. Capacitor C15 suppresses noise onthe control line. Diode D5 shorts the back EMF from the coil of the relay when de-energized.


2-1 2-16600-0017-000 03/12/98

2/Set Up and CheckoutWARNING w Two people are required to lift the Care Plus Incubator. Follow safe lifting

techniques to avoid injury.

2.1 Receiving

Refer to the setup instructions shipped with the Care Plus Incubator for initial unpack-ing and setup of the unit after shipment. If the unit was shipped with an elevating base,refer to the next section for mounting instructions. If you are not mounting the incubatoron a Care Plus cabinet or elevating base to install the controller, perform only step 4and 5 of section 2.2 or 2.3.

Inspect the Care Plus Incubator and all accessory items for any signs of damage thatmay have occurred during shipment. File a damage claim with the shipping carrier ifdamage has occurred. Also confirm the presence of all accessory items as listed on thepacking slip.

2.2 Mounting the Care Plus on the Elevating Base

Remove the controller from the Care Plus Incubator.

WARNING w Safely mounting or dismounting the Care Plus Incubator requires twopeople.

1. Verify that O-rings or foam gaskets are installed in the depression around each ofthe incubator mounting holes in the incubator platform.

2. Lift the Care Plus Incubator onto the Elevating Base. Make sure that the front of theElevating Base (foot pedals) faces the same direction as the front of the incubator.Refer to Figure 2-1.

3. Install the four mounting screws.

WARNING w If mounting hardware is not securely fastened, the incubator could tip offthe Elevating Base or the cabinet.

CAUTION w When handling the controller, avoid bumping the fan or the heater. If theseitems are knocked out of alignment, the fan can grate against the heater or thebase.

4. Install the controller. Lift the levers on the controller and slide it into the incubatoras shown in Figure 2-1. Push the levers down to lock the controller in place.

5. Perform checkout procedures in section 2.6


2-2 2-26600-0017-000 03/12/98

Figure 2-1Mounting the Care Plus Incubator on an elevating base

2.3 Mounting the Care Plus on the Cabinet

WARNING w Safely mounting or dismounting the Care Plus Incubator requires twopeople.

1. Verify that O-rings or foam gaskets are installed in the depression around each ofthe incubator mounting holes in the cabinet top.

2. Lift the Care Plus Incubator onto the cabinet. Make sure that the cabinet doors facethe same direction as the incubator’s front door. Refer to Figure 2-2.

3. Install the four mounting knobs.

WARNING w If mounting hardware is not securely fastened, the incubator could tip offthe Elevating Base or the cabinet.

CI.0

7.03

6

MountingScrew

IncubatorPlatform

Controller

Foot PedalControls

Lever(Lift to RemoveController)


2-3 2-36600-0017-000 03/12/98

CAUTION w When handling the controller, avoid bumping the fan or the heater. If theseitems are knocked out of alignment, the fan can grate against the heater or thebase.

4. Install the controller. Lift the levers on the controller and slide it into the incubatoras shown in Figure 2-2. Push the levers down to lock the controller in place.

5. Perform checkout procedures in section 2.6.

MountingKnob

CI.0

2.18

9

Figure 2-2Mounting the Care Plus Incubator on a cabinet

2.4 Mounting the Cabinet Rail System

Note: This section applies to cabinets with threaded mounting holes. If your cabinetdoes not have four threaded mounting holes on each corner, refer to the rail mountinginstructions 2.5.

Note: On units with the continuous tilt feature, rails cannot be mounted on the frontcorners of the cabinet.

CAUTION w The maximum load on cabinet rail systems must not exceed 23 kg (50 lbs).This includes the weight of items placed on rail mount or overhead shelves.

Controller

ControllerLever


2-4 2-46600-0017-000 03/12/98

A. Mounting the Basic Rails

The short and long rails, and the overhead shelf use the same basic assembly procedure.

Note: The rail kits include extra hardware to adapt them for the earlier cabinets. You willhave eight, rectangular plates, 16 internal tooth lockwashers, and 16, #10 x 5/8 inch trusshead screws left over.

1. Make sure that you have the correct rail. The rails are not symmetrical. Markings oneach rail tell you which side of the cabinet to put it on (Left Rear or Right Rear).

2. Remove the four screws and lockwashers from the corner of the cabinet where youintend to mount the rail.

3. Align a stiffener plate with the threaded mounting holes on the cabinet. Use the tapeon the stiffener to hold it in place. Refer to Figure 2-3.

4. Place the rail over the stiffener plate and align the holes in the rail with those in thestiffener plate. Use the tape on the stiffener to hold it in place.

CAUTION w The tape on the stiffener plate will not support any weight. The only reason for thetape is to help you line the parts up.

5. Put split ring lockwashers on four, #10 x 3/4 inch socket head screws, and install thescrews from the outside of the cabinet.

Note: Verify that all four screws are tight before mounting any accessories on the rail.

6. Repeat steps 1 through 5 for the second rail.

Figure 2-3Mounting the basic rail system

CI.0

2.18

8

ScrewLockwasher

Tape

ThreadedMountingHole

StiffenerPlate

Tape

DovetailRail


2-5 2-56600-0017-000 03/12/98

B. Mounting the Overhead Shelf

1. Mount the basic rails.

2. Loosen the four acorn nuts on the inside of the overhead shelf. Refer to Figure 2-4.

3. Remove the plastic end caps from each rail.

4. Slide the locking lugs into the rails.

5. Align the top of the shelf with the top of the rails and hand tighten the acorn nuts.

6. Use a 9/16 inch wrench to tighten the acorn nuts to 22.6 ± 0.6 Nm (200 ± 5 in-lbsor 16 ± 0.5 ft-lbs). Make sure that the shelf remains level.

7. Replace the plastic end caps.

Locking Lug

RailC

I.02.

035

End Cap

Figure 2-4Mounting the overhead shelf

2.5 Mounting the rail system on cabinets with pre-stampedknock outs

CAUTION w The maximum load on cabinet rail systems must not exceed 23 kg (50 lbs).This includes the weight of items placed on rail mount or overhead shelves.

Note: Check the rail markings before beginning. The rails are not symmetrical and willonly align with the mounting holes on the cabinet corners marked on the rail, (Left Rearor Right Rear).

The rails attach to the corners of the cabinet with eight #10-32 screws supplied witheach rail.

Acorn Nut


2-6 2-66600-0017-000 03/12/98

1. Located on each corner of the cabinet are eight pre-stamped knock outs. Use apunch and hammer to remove the knock outs. Twist off the tab and debur theholes.

Note: Some knockouts must be removed from the inside and some must beremoved from the outside. Make sure you punch from the side with the stampedmarks.

2. Align a cabinet stiffener plate on the outside of the cabinet corner where you willmount the first rail.

3. Place the rail to be mounted over the exterior stiffener plate and align the holes.Secure the rail from inside the cabinet using four backing plates, eight #10-32screws and eight #10 lock washers.

4. Repeat steps 1 through 3 for the second rail.

5. Align the holes in the shelf with the holes at the top of the rails (four on each rail).Secure the shelf with the eight 1/4-20 mounting screws provided.

Figure 2-5Mounting the rails and the overhead shelf

Screw

Dovetail Rail

Stiffener Plate

Overhead Shelf

CI.0

2.03

9


2-7 2-76600-0017-000 03/12/98

2.6 Checkout Procedure

WARNING w After completing a repair the appropriate calibration procedure must beperformed. After completing any portion of the calibration and adjustmentprocedures, perform the Checkout Procedure to make sure that the CarePlus Incubator is operating correctly. In addition, a final Electrical SafetyCheck, section 3.5, must be performed. Record the information for futurereference.

Note: Refer to Section 3.4, Calibration, if the results of the Checkout Procedureindicate that the display brightness, the alarm volume, the alarm frequency, the airsafety circuit trip point, or the ADC reference voltage need adjustment.

A. Mechanical Checks

WARNING w Disconnect the power to the incubator for the mechanical portion of theCheckout Procedure.

Important: See Figure 2-6, for the location of mechanical controls and other incubatorcomponents.

1. Disconnect the power cord for the Care Plus Incubator for the mechanical portionof the preoperative checkout procedure.

2. Examine the power cord for damage. Replace the power cord if damage is evident.If there is damage at the incubator end of the power cord, check the power inletconnector for any signs of overheating or damage. Replace if damage is evident.

3. Examine the incubator for obvious signs of damage.

4. Lock the two front casters and check that the unit is held in place. Release thelocks and verify the unit moves smoothly.

5. On units mounted on the cabinet, open the cabinet front doors and verify that thefour incubator mounting knobs that attach the Care Plus to the cabinet are securedtightly in place.

On units mounted on the Elevating Base, open drawers (if present) and verify thatthe four incubator mounting screws, visible from the underside of the incubatorplatform, are tightly fastened.

6. Check the front door seals. With the door closed, check that the clear plastic sealson the upper and lower edges fit tightly.

7. Rotate both front door latches toward the center of the incubator, verify the redstamp is visible on both latches, and lower the door. Make sure that the inner wallis securely fastened to the door and that the deflector panel is installed on the innerwall.

WARNING w The front door inner wall must be in place with the lower deflector panelattached while a patient occupies the incubator.


2-8 2-86600-0017-000 03/12/98

8. Make sure that the front door is securely fastened to the incubator. Opening thedoor exposes the two spring-loaded metal hinge pins that slide into holes in thebase platform. If the door is not properly attached, pull both pins out towards thesides of the incubator and line them up with the hinge. Release the pins and verifythat they snap into position.

9. Check that the mattress and the mattress tray are properly installed. Verify that youmust lift the tray slightly to slide it out of the hood. This prevents the tray fromsliding out accidentally. Slide the mattress tray back into the hood.

10. Check the portholes. Open the portholes by pressing on the latch. The covershould swing open. If arm cuffs are installed, the elastic cuff band should fit into thegroove around the porthole without obstructing the cover. Close the porthole andverify that the mounting posts hold the porthole securely to the hood and that thelatch holds the porthole closed.

11. If the optional inner walls are installed, check that they are securely attached to theouter walls. To attach the inner wall, align the inner wall fasteners with the mount-ing posts on the outer hood and push in on the plunger portion of the fastener. Alsoverify that the deflector panel is attached to the rear inner wall.

12. If the upper inner wall is not used, make sure that hole plugs are inserted into theunused top mounting holes.

13. Check the hood seals. Examine the seals at the bottom of the left, right and backsides of the hood. They should seal tightly when the hood is closed.

14. Check that the tubing access covers are also installed on either side of the hood.

15. Check the hood tilt latch. Open the front door. Depress the hood tilt release buttonand rotate the hood back approximately 30 degrees, until it locks into position withan audible click. Push against the hood and make sure that it is held in place. Toclose the hood, support the hood and press the hood tilt release. Gently lower thehood.

16. Close the front door and rotate the latches toward the sides of the incubator. Verifythat the red stamps on the latches are masked by the opaque patches on the hood.

17. Check the operation of the tilt mechanism.

• On units with the two position tilt option:

Press in the locking button in the center of the tilt handle and push down on thehandle. Release the locking button and verify that the handle locks in the 45degree position. Press the locking button again and rotate the handle down-wards. Release the locking button and verify that the handle locks in the 90degree position. Depress the locking button and lift up on the tilt handle toreturn to the horizontal position. Repeat this step for the second tilt handle.

• On units with the continuous tilt option:

Check that the tilt knob assembly is secured to the incubator with latch. Rotateeach tilt knob upward until the bed reaches its highest position. Check that theactuating arm and bed lifter are firmly seated in the cover platform. Rotate thetilt knobs downward and check that the mattress tray slides out when both tiltmechanisms are at their lowest positions.

18. Check that the controller is latched in position. The controller latches should be allthe way down, parallel with the sides of the controller.


2-9 2-96600-0017-000 03/12/98

19. Depending on which model the unit is, locate the internal humidifier fill port, on theleft side of the unit, or the external humidifier on the front of the unit to the left of thecontroller. (For checkout for units with the optional Servo-controlled Humidifier, seethe Servo-controlled Humidifier O,M & S manual). For the internal humidifier:

a. Grasp the handle on the lower edge of the fill port and pull it to the open posi-tion. Make sure that it does not come out all the way unless you rotate it clock-wise.

b. Rotate the handle and fill port clockwise and pull the fill port completely out.

c. Inspect the O-ring for wear or damage. Replace it if necessary.

d. Insert the fill port back into the unit.

e. Rotate it counterclockwise to the drain position.

f. Rotate the fill port back to the upright position and push it back into the lowerunit.

For the external humidifier:

a. Slide the humidifier assembly out of the front of the base.

b. Inspect the fill tray, slide, lid, and seals for wear and damage. If necessary,replace components.

c. Reassemble the humidifier.

d. Slide the humidifier assembly back into the base. Push it until you feel a slightresistance, then push until it snaps into position.

20. Unscrew the two filter mounting knobs on the rear of the incubator, lift off thevented filter cover panel, and check the condition of the filter. If the filter is dirty, hasbeen used with an infectious patient, or has been in use for three months it must bereplaced. When you replace the filter, mark the date on the label supplied with thereplacement filter. Affix the label to the exterior of the filter cover panel.


2-10 2-106600-0017-000 03/12/98

Figure 2-6Operating Controls, Indicators and Connectors

CI.0

2.18

4

Air Temp. Sensor

Tilt Handle

Locking Button

Portholes

Tilt Knob

Front Door Latch

CI.0

2.19

0

Right Side ViewLeft Side View

CI.0

2.04

8

CI.0

2.04

2

Patient ProbeConnector

Tubing Access Covers

Inner Wall Fastener

Hood Tilt Release

Power Switch

Power Input

ThermaLink Connector

Filter Mounting Knobs(Cord Wrap)

Oxygen Inlet

Air TemperatureSensor Connector

Controller Latches

Hole Plugs(Single Walled Units)

Deflector Panel

Front View

Continuous TiltTwo Position Tilt


2-11 2-116600-0017-000 03/12/98

Item (Figure 2-6) Function

Hood tilt latch and Prevents hood from opening accidently. Also secures hood in thehood tilt release tilted position; You must press and hold the hood tilt release

button while raising or lowering the hood.

Door hinge pins Spring loaded metal pins inside the front door hinges. Open door(not shown) and pull hinge pins toward the sides of the incubator to remove

the door.

Tilt handles and Depress locking button in center of handle and rotate handle forlocking buttons Trendelenburg and Fowler positioning.

Tilt Knobs Rotate knob upward to raise that end of the bed. The bed remainslocked in the selected tilt position automatically.

Portholes Press the latch to open the porthole.

Tubing access Route cables and tubes into or out of the unit through the tubingcovers access covers.

Door latches Turn door latches toward the center of the incubator to open thefront door.

Oxygen inlet Connect tubing between flowmeter outlet and oxygen inlet to raisehood oxygen concentration.

Patient probe Push probe connector firmly into socket until it clicks. Grasp theconnection connector and pull to disconnect.

Air temperature Keyed connector for air temperature sensor; to connect the airsensor connection temperature sensor, align the connectors and push them together.

Disconnect the sensor by pressing in the back of the connectorwhile pulling back on the “T” handle.

Controller latches Pull latches up (perpendicular to controller sides) to slide out thecontroller. Push down to secure controller.

Filter cover Vented panel on rear of unit. Remove knobs and panel to accessfilter.

Power switch Turns incubator on and off.

Inner wall Used to secure inner walls. Line up with mating mounting posts infastener outer hood and press in plunger to snap in place. Pull out the

plunger to release.

Hole plugs Used to plug the holes in the top of the hood on single walledunits.

B. Accessory Checks

1. Check that all accessories are securely mounted.

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

3. If an Ohmeda manometer will be used, verify that it reads 0 Kpa at atmosphericpressure. If it is necessary to zero the manometer, unscrew the plastic bezel overthe plastic cover. Adjust the zeroing screw located on top of the manometer, abovethe 4 Kpa marking.

4. Set up any required suction or gas supply systems. Check them for leaks asoutlined in the appropriate operation and maintenance manuals.


2-12 2-126600-0017-000 03/12/98

Figure 2-7Control Panel

C. Controller Checks

Important The Enable switch must be pressed to activate the temperature adjustment, theOverride, or the control mode switches. These switches remain active as long as theenable indicator is illuminated (approximately 12 seconds after the last time one ofthese switches is pressed).

Note: When the patient probe is initially plugged in for checkout, LLLL will be displayedin place of the patient temperature, if its reading is below 22.0°C (71.6°F).

Note: On controllers with serial numbers beginning with HBJ and HCE, all alarms exceptpower failure and system failure are preceded with a 30 second operator prompt tone.

Patient Temperature Air Temperature Control Temperature

Alarms

100%75%50%25%

Patient Temp

Control Temp

High Air Temp

Air Circulation

Probe Failure

System Failure

Power Failure

Heater

AirControl

Mode

Controls

PatientControl

AirControl

AirOverride

> 37° C

Enable°F / °C

PatientControl

CI.0

2.18

1

AlarmSilenceSwitch

AlarmLEDs

ControlTemperatureSwitchesEnable Indicator

Enable Switch

Patient ControlMode Indicator

PatientTemperatureDisplay

AirTemperatureDisplay

ControlTemperatureDisplay

Air ControlModeIndicator

°F/°C Switch

Override SwitchOverride Indicator

Patient Control Mode SwitchAir Control Mode Switch

Units With HCE Serial Numbers

Heater Power LEDs (% ofmax power: minute average)


Heater100% 75% 50% 25%

AlarmPatient TempControl TempHigh Air TempAir CirculationProbe FailureSystem FailurePower Failure

AirControl

PatientControl

Overrideto 39°C(102.2°F)

A

M

?Enable°F/°C

188.88188.88 188.88

Patient ControlMode Switch

Patient ControlMode Indicator

ControlTemperatureSwitches

CI.0

2.03

6

AlarmSilenceSwitch

Heater PowerLEDs (% ofmax power:minuteaverage)

AlarmLEDs

Override Indicator

Enable SwitchEnable IndicatorOverride Switch

°F/°C SwitchAir Control Mode IndicatorAir Control Mode Switch

AirTemperatureDisplay

PatientTemperatureDisplay

ControlTemperatureDisplay

Units with HAG and HBJ Serial Numbers


2-13 2-136600-0017-000 03/12/98

1. Make sure the power cord is connected to the socket on the right side of thecontroller.

2. Plug the patient probe into the labeled connection on the left side of the controller.

3. Line up the air temperature sensor connector. Plug the air temperature sensor intothe labeled connection on the left side of the controller.

4. Route the patient probe cord through the tubing access cover and place the patientprobe inside the incubator.

5. Plug the power cord into an appropriately rated power source (see rating plate forproper voltage etc.).

6. Switch the power ON and verify the following sequence:

a. An alternating two tone audible alarm sounds for approximately five seconds, allthe indicators illuminate and 188.88 appears in the three temperature displays.

b. All indicators are extinguished except for the air control and the enable indica-tors. The temperature displays change to show from left to right:

PatientTemperature Air Temperature Control Temperature

XX.XX 60.H 39.0°C(software version no. (AC freq. 50 Hz (max. manualfor example 01.01) for 50 Hz models) control temp.)

c. An operator prompt tone sounds, and the control temperature display flashes33.0°C. The operator prompt tone will sound every two seconds until a controltemperature is entered by pressing either the M or ? switch.

7. Adjust the control temperature to silence the prompt tone.

8. Check display illumination and the audible alarm by depressing and holding theAlarm Silence switch until all of the indicator LEDs illuminate, and 188.88 appearsin the three temperature displays (approximately five seconds). The alternating twotone alarm should sound.

9. Check the Enable switch. Press the Enable switch. The enable indicator shouldilluminate and go out after approximately 12 seconds. Verify that pressing the Mand ? switches has no effect when the enable indicator is extinguished.

10. Check the analog to digital calibration and the line voltage. Depress and hold theEnable switch until the following values appear in the temperature displays (ap-proximately five seconds):

Patient Temperature Air Temperature Control Temperature25.05°C (± 0.2°C) 37.97°C (± 0.2°C) From 09.00 to 11.00(low calibration (high calibration (Service use only)point) point)

Note: An alarm will sound to indicate that the actual temperatures are not dis-played.

11. Check the patient probe. Warm the patient probe by placing it between yourfingers. Verify that the displayed patient temperature increases.

12. Check the normal range of air control temperatures. Press the Enable switch toactivate the M and ? switches. The enable indicator will illuminate. Press and holdthe ? switch. Verify that the lowest control temperature attainable is 20.0°C. If theenable indicator has gone out, press the Enable switch again. Depress the Mswitch and verify that the air control temperature cannot be set above 37.0°C.


2-14 2-146600-0017-000 03/12/98

13. Check the extended range of air control temperatures. With the control temperatureset to 37.0°C, sequentially press the Enable and Override switches. On controllerswith serial numbers beginning with HBJ and HCE, the enable indicator shouldilluminate and the override indicator should blink (on all other controllers both theenable and the override indicators should illuminate and remain illuminated).Depress the M switch and verify that the maximum air control temperature is now39.0°C. The override indicator will blink or remain lit as long as the control tempera-ture setting remains at, or above, 37.0°C.

14. Check the °F/°C switch. Adjust the control temperature to 36.0°C and press the F/Cswitch. Verify that the control temperature is now displayed as 96.8°F. Press theswitch a second time to return to a Celsius display.

15. Switch to the patient control mode of operation. Press the Enable and the PatientControl switches. Then, verify the following sequence:

a. The enable and the patient control indicators illuminate.

b. The control temperature display flashes 36.5°C and an operator prompt tonesounds every two seconds. Adjust the control temperature to silence the prompttone. The enable indicator will be extinguished approximately 12 seconds afterthe last time the M or ? switch is pressed.

Note: A patient temperature alarm will be triggered if the patient probe tempera-ture differs from the control temperature by more than 1.0°C. If the probetemperature is below 30.0°C or above 42.0°C the heater will not switch ON.

16. Change the range of patient control temperatures. Press the Enable switch toactivate the M and ? switches. The enable indicator will illuminate. Press and holdthe ? switch. Verify that the lowest control temperature attainable is 35.0°C. If theenable indicator goes out, press the Enable switch again. Then depress the Mswitch. Verify that the patient control temperature cannot be set above 37°C.

Note: The maximum patient control temperature can be raised to 37.5°C byplacing control board dipswitch 3 in the ON position. (Section 3.3.L)

17. Check the patient temperature alarm. Press the Enable switch and adjust thepatient control temperature until it exceeds the patient temperature by more than1.0°C. An intermittent single tone alarm should sound, the patient temperatureshould flash, and the patient temperature alarm indicator should illuminate. Pressthe Enable switch and adjust the patient control temperature until it is within 0.8° Cof the patient temperature. The alarm should cancel.

Note: Service personnel can configure the alarm to trigger if the difference exceeds0.5°C, and to reset when the difference is less than 0.3°C. See Section 3.3K,Setting the Patient Temperature Alarm.

18. Check the probe failure alarm.

a. Unplug the patient probe from the controller. Verify that an intermittent alarmsounds, the probe failure LED illuminates, HHHH flashes in the patient tempera-ture display, and the heater power LEDs are extinguished. Plug the probe backin and verify that the alarm cancels.

b. Unplug the air temperature sensor from the controller. Verify that an intermittentalarm sounds, 00.0°C flashes in the air temperature display, the probe failureLED illuminates, and the heater power LEDs are extinguished. Align the con-nectors and plug the air temperature sensor back into the controller. Verify thatthe alarm cancels.

19. Check the power failure alarm and the battery backed memory. First verify that youare still in the patient control mode. Then adjust the patient control temperature to36.0°C. Switch to the air control mode and adjust the control temperature to35.0°C. Unplug the incubator. An intermittent, nonsilencable alarm should sound,


2-15 2-156600-0017-000 03/12/98

and the power failure LED should illuminate. All other displays and indicators willbe extinguished. Wait two minutes and plug the incubator back in. Verify that thealarm cancels and that the unit returns to the air control mode of operation with acontrol temperature of 35.0°C. Switch to the patient control mode and verify acontrol temperature of 36.0°C.

Note: A fully charged battery should supply the power failure alarm for approxi-mately 10 minutes. If the alarm is tested for the full 10 minutes, the incubator mustbe run for at least two hours to recharge the battery before it is used with a patient.Total recharge time is 8 to 10 hours.

20. Check the Alarm Silence switch. Unplug the air temperature sensor and press theAlarm Silence switch. Verify that the alarm is silenced for one minute. Reconnectthe air temperature sensor.

21.‡Check the RS-232 circuitry. Short pins 2 and 3 of the RS-232/Nurse Call connector.Press the override switch while powering up the unit. Release the switch when acontinuous alarm sounds. If the RS-232 option is functioning, the temperaturedisplays will cycle to a frame that shows “rs 232 PASS”. Conversely, if the RS-232circuitry is not functioning or is not installed, the temperature displays will cycle toframe that shows “rs 232 FAIL”. Turn off the unit to exit this test mode. Removeshort from pins 2 and 3.

22.‡Check the Nurse Call circuitry. Under the “no alarm” condition, verify contactclosure between pins 1 and 6 and no contact closure between pins 1 and 9 of theRS-232/Nurse Call connector. Trigger an alarm by unplugging the air temperaturesensor. Verify contact closure between pins 1 and 9 and no contact closurebetween pins 1 and 6.

D. Operational Checks

1. Make sure that the incubator is in the air control mode.

2. Verify that the front door, the portholes, and the hood are closed.

3. Set the control temperature as close to the air temperature as possible. Allow theair temperature reading to stabilize. Verify that the air temperature remains within0.5°C of the control temperature for five minutes after stabilization.

‡ Option available only on controllers with serial numbers beginning with HBJ and HCE.


2-16 2-166600-0017-000 03/12/98

Notes


3-1 3-16600-0017-000 03/12/98

3/Calibration and AdjustmentWARNING w Use extreme care while performing calibration and adjustment proce-

dures, or while working on the Care Plus Incubator with power connected.An electrical shock hazard does exist; be certain to observe all standardsafety precautions.

3.1 Maintenance scheduleThe unit should be maintained in accordance with the procedures detailed in theService Manual. Quarterly and two year maintenance must be performed by a techni-cally competent individual as described in the Repair Policy.

Operator maintenance

This schedule lists the minimum frequencies. Always follow hospital and local regula-tions for required frequencies.

Weekly or After Each Patient

Disinfect the humidifier if used.

Clean the incubator and check the air filter. Disinfect the incubator if required or afteruse with infectious patients.

Quarterly

Replace the air filter. When you replace the filter, mark the date on the label suppliedwith the replacement filter and affix it to the filter cover panel.

Note: This is the minimum replacement frequency. The filter must also be replacedwhenever it appears dirty, or has been used with an infectious patient.

Service maintenance

This schedule lists the minimum frequencies. Always follow hospital and local regula-tions for required frequencies.

Quarterly

Perform the electrical safety and checkout procedure from the Service Manual. Ifpossible verify an acceptable sound level within the infant compartment. Every otherquarterly inspection, check the calibration as detailed in the Service Manual.

Every Two Years

Replace the battery. Inspect all seals and gaskets. Replace motor grommets.

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

Note: Whenever performing service on the incubator, check the female end of thepower cord and the power cord inlet connector for any sign of overheating or damage.If either of these parts show any sign of damage, replace both parts.


3-2 3-26600-0017-000 03/12/98

3.2 Special Tools and Equipment

The following tools (or their functional equivalents) are required to complete the recom-mended service procedures. If you do not already have these items, they can beordered from Ohmeda.

Description Stock Number

Digital Multimeter, 3 1/2 digit ................................................................... 7000-0000-023

Leakage Current Tester with AAMI Test Load ......................................... 0175-2305-000

Static Control Work Station (recommended) ........................................... 0175-2311-000

Beige touch up paint (Munsell 10Y9-1) 8 oz ............................................ 0220-0211-300

Light grey touch up paint (Munsell .16GY8.56-0.44 chroma) .................. 6600-0714-200

0.1% Accuracy Variable Resistance Box

Soldering Iron

Hair dryer (1000 watts), or heat gun (glass of hot water, >45°C, can beused as substitute)

Optional items include:

Description Stock Number

Oscilloscope, 15 MHz, dual trace ............................................................ 0175-2302-000

Ohmeda Temperature Simulator Box (variable resistance box withswitches preset to various temperatures) ................................................ 0217-2788-800

DB9 Male Test Connector (pins 2 & 3 shorted) ....................................... 6050-0001-709

Cable with 1/8" mini phone jack (5 ft. long) included with simulator ........ 6600-0203-700

Note: This cable has a phone jack on both ends. You may have to remove one of thejacks, because there is no one connector that will accommodate all types of variableresistance boxes.

Figure 3-1Cable for Variable Resistance Box 6000-0203-700

CI.0

2.13

9


3-3 3-36600-0017-000 03/12/98

3.3 Calibration Loop (background information)

Note: The audible alarm sounds continuously in this loop, although the normal incuba-tor alarms are disabled during the calibration loop.

This loop is used to adjust ADC converter calibration, the 2 kHz alarm frequency, theline voltage compensation, and display brightness. To enter the calibration loop,hold down the Enable switch during power up until a continuous alarm sounds.During the calibration loop:

1. The 2 kHz audio alarm sounds continuously. This allows frequency adjustments.

2. A four place (XX.XX°C) patient probe reading appears in the patient temperaturedisplay.

Note: This display appears even if the patient temperature is outside the normaldisplay range.

3. The percent of rated line voltage at which the unit is operating appears in thecontrol temperature display (XX.XX = XXX.X%). When the correct percentage isdisplayed, the line voltage compensation is properly adjusted.

4. Output 34 on the display driver is activated. This allows the display brightnessvoltage to be read and adjusted.

Important: Section 3.41 describes the procedures for control boards with softwarerevision 4.0 and higher. The unit's software revision level is displayed on power up, butthese new boards can be physically identified by having nearly all their componentssurface mounted and their 28 pin test point connector. Section 3.42 contains thecalibration procedures for earlier control boards prior to software revision 4.0, whichcan be identified by their components mounted through the board and two 8 pin testpoint connectors.

3.4.1 Calibration Procedures(Software Revision 04.00 and Higher)

WARNINGS w After completing a repair of the Care Plus, the appropriate calibrationprocedure must be performed. After completing any portion of the cali-bration and adjustment procedures for the Care Plus Incubator, performthe Checkout Procedure to make sure that the unit is operating correctly.In addition, a final Electrical Safety Check, section 3.5, must be per-formed. Record the information for future reference.

w Before any disassembly or repair, disconnect the electrical supply andany gas supply connections. Also remove any accessories. Do not per-form any service or maintenance with the power applied unless specifi-cally told to do so in the procedure.

CAUTION s Use the Static Control Work Station (Stock No. 0175-2311-000) to help ensurethat static charges are safely conducted to ground. The Velostat material isconductive. Do not place electrically powered circuit boards on it.

Important Reference Figure 3-2, for the location of control board potentiometers, test points,and switches.



3-4 3-46600-0017-000 03/12/98

A. Preparation

1. Remove the controller from the incubator. First unplug the patient probe, the airtemperature sensor, the power supply cord, from the controller. Then lift up thecontroller latches and slide it forward, out of the incubator. Place the controller onthe anti-static mat.

CAUTION w When handling the controller, avoid bumping the fan or the heater. If theseitems are knocked out of alignment, the fan can grate against either the heateror the base.

2. Remove the screws and lock washers used to attach the controller cover.

3. Reconnect the power cord and the air temperature sensor to the controller.

4. Verify that control board switches 1, 2, 5, 7 and 8 are in the OFF (left) position.

Note: Leave switch 4, which selects either a 0.5°C or a 1.0°C limit for the patienttemperature alarm, in its original position.

Note: Leave switch 3, which selects a maximum patient control temperature(patient control mode), in its original position.

Figure 3-2Control Board Test Points and Potentiometers (Software revision 04.00 and higher)

CI.2

3.06

6

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


3-5 3-56600-0017-000 03/12/98

B. Check Voltage Supplies

1. Switch ON the incubator. It will proceed through the normal power up tests. Enter acontrol temperature to silence the prompt tone.

2. Adjust control board potentiometer RP7 until TP1-20 measures 9.8 ± 0.05 Vdc withrespect to GND (TP1-24).

3. Verify the following voltages on the control board with respect to GND (TP1-24):

Test Point Voltage

TP1-20 5.0 ± 0.3 Vdc

TP1-1 5.0 ± 0.3 Vdc

TP1-25 9.0 ± 0.3 Vdc

Note: These voltages cannot be adjusted. The control board must be replacedwhen they are not within the specified range.

C. Display Brightness

Note: Because display brightness is factory calibrated for both replacement boards andcomplete controllers, brightness adjustments are only required if the LEDs appear to bedim.

Note: Adjustment and test points vary depending on whether the unit has an old or newdisplay board. The new board, part no. 6600-0512-700, has surface mounted compo-nents. The old boards, part no. 6600-0105-700 & 6600-0420-700, has componentsmounted throught he board.

1. Hold down the Alarm Silence switch until all the displays illuminate (approximatelyfive seconds). Check that all displays are illuminated and of uniform brightness. Ifthe displays are acceptable, proceed to Section D. Otherwise, continue with thisadjustment procedure.

2. Switch OFF the power and remove the front controller panel.

a. Turn the controller upside down and remove the lower three front panel mount-ing screws, shown in Figure 3-3.

b. Turn the controller right side up and remove the remaining front panel mountingscrews, shown in Figure 3-3.

3. Remove ESD shield.

4. Connect meter leads to terminals 10 and 11 of display board connector J8 onsurface mounted board or R9 on through hole mounted boards.

5. Reconnect the power cord.

6. Enter the calibration loop by switching the unit ON while holding down the Enableswitch. Continue to hold the Enable switch until a continuous single tone alarmsounds, indicating that the calibration loop is active.



3-6 3-66600-0017-000 03/12/98

Figure 3-3Display Brightness Adjustment

7. Monitor the voltage at connector J8 pins 10 to 11 or across R11 on the surfacemounted display board or R9 on the through hole mounted display board. Adjustdisplay board potentiometer RP1 (accessible from the edge of the board) on thesurface mounted board or R11 on the through hole mounted board to obtain areading of 3.30 ± 0.2 Vdc.

Important The brightness voltage measured above will differ if the calibrationloop is not used.

8. Replace the display board if an acceptable level of brightness cannot be achieved.

9. Disconnect the power cord and reassemble by performing steps 2 and 3 in reverseorder.

D. Alarm Frequency

Note: The alarm frequency and volume are precalibrated at the factory for both re-placement boards and complete controllers. Frequency adjustments should not nor-mally be required in the field.

1. Verify that the incubator is in the calibration loop.

2. Verify that the frequency output at TP1-4 is 2 kHz ± 0.1 kHz. Adjust RP8 on thecontrol board as required.

Front Panel

ESD Shield

CI.0

2.11

1

Lockwasher

Screw

Screw

Display Board

RP1(surfacemountedboards)

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


3-7 3-76600-0017-000 03/12/98

E. Line Voltage Compensation

1. Verify that the incubator is in the calibration loop. In this loop the control tempera-ture display continuously shows the percent of nominal input voltage at which theunit is operating.

Note: Multiply the displayed value by ten to get the actual percentage (XX.XX =XXX.X%).

2. Determine the rated heater voltage of your unit from the serial number sticker onthe back of the base platform.

3. Measure the line voltage between the appropriate transformer primaries (pins 4and 2 on 120 volt units):

Rated InputVoltage (from serial Nominal Input Measurenumber sticker) Voltage Between Pins

240 volts 240 volts 6 and 2




4. Calculate the percent of the nominal input voltage by dividing the measured voltageby the nominal input voltage and multiplying by 100%.

% of line voltage = (Measured Voltage) x 100%

(Nominal Input Voltage)

5. Adjust control board potentiometer RP2 until the control temperature display showsthe percentage calculated in the previous step ± 2%.

Note: The control temperature reading appears in the format XX.XX, which mustbe multiplied by ten to give the actual percentage, XXX.X%.

F. Analog to Digital Converter (ADC)

a. Procedure using the Ohmeda Temperature Simulator Box

1. Check the readings from the calibration resistors. Depress and hold the Enableswitch until the proper calibration readings appear in the patient and air tempera-ture displays (approximately five seconds):

Patient Temperature 25.05 ± 0.2°C

Air Temperature 37.97 ± 0.2°C

If these values are within tolerance, no calibration is necessary,skip to G Alarm Volume.

2. Verify that the incubator is in the calibration loop. If a 0.1% variable resistance boxis available, proceed to F.b for simpler procedure, otherwise go to step 3.



3-8 3-86600-0017-000 03/12/98

3. The Ohmeda temperature simulator box (Stock No. 0217-2788-800) is a variableresistance box with switch settings corresponding to predetermined temperatures.Select 5900 ohms at setting I7 and plug the box into the patient probe jack.

Adjust RP5 to obtain a reading of 37.37 ± 0.02°C in the PatientTemperature display.

Note: Although the tolerance is ± 0.02, the readings should be adjusted as closelyas possible to the nominal value; the ± 0.02°C allows for system noise, etc.

4. Connect a resistance of 7686 ± 0.1% (Ohmeda Temperature Simulator Box settingI1) to the patient jack connector and adjust RP6 to obtain a reading of 31.09 ±0.02°C in the patient temperature display.

5. Repeat steps 3 and 4 until no further adjustment is required.

6. Switch OFF the power to exit the calibration loop.

7. Switch the incubator ON. After the normal power up sequence, enter a controltemperature to silence the prompt tone.

8. Adjust the resistance box settings for the following resistances. Verify that thecorresponding temperature appears in the patient temperature display.

Resistance Temp. Patient TemperatureInput Sim. Box Display

5496 ± 0.1% I2 39.0 ± 0.1°C

7060 ± 0.1% I3 33.0 ± 0.1°C

6190 ± 0.1% I11 36.2 ± 0.1°C

9. Disconnect the resistance box from the patient probe jack.

10. Switch the unit off. Calibration is complete.

b. Simplified procedure using a 0.1% accurate resistor decade box

1. Check the readings from the calibration resistors. Depress and hold theEnable switch until the proper calibration readings appear in the patientand air temperature displays (approximately five seconds):



If these values are within tolerance, no calibration is necessary,skip to G Alarm Volume.

2. Connect a 2.980 K ohms resistance to the patient sensor input.

3. Turn power off then press the Enable button while turning the power on.

4. Adjust potentiometer RP5 until the control temperature display togglesbetween 000 and 001.

5. Now connect a 32.789 K ohms resistance to the patient sensor input.

6. Adjust potentiometer RP6 until the control temperature display togglesbetween F9E and F9F.

7. Turn power off then back on to exit calibration mode.

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


3-9 3-96600-0017-000 03/12/98

8. Check accuracy with the following values:

Resistance Patient TemperatureInput (ohms) Display

5509 39.0 ± 0.1°C

5981 37.0 ± 0.1°C

6500 35.0 ± 0.1°C



G. Alarm Volume

WARNING w Lowering the volume excessively may prevent caregivers from hearingalarms. The alarm volume and frequency are precalibrated at the factoryfor both replacement boards and complete controllers. Volume adjust-ments should not normally be required in the field.

H. Air Safety Circuit Calibration (High Air Temperature Alarm)

This procedure requires a hot air source. Either a hair dryer (approximately 1000watts), or a heat gun , or a glass of hot water (>45°C) can be used for this purpose.

1. Switch the controller ON.

2. In the air mode, adjust the control temperature to 36.9°C.

3. The heater should switch ON. Verify that the heater power LEDs on the displaypanel and the heater status LED on the control board are both illuminated. Theheater status LED may flicker.

4. If you are using a glass of hot water (>45°C) as the heat source:

a. Unscrew the two mounting screws that attach the air temperature sensor to thehood. Remove the sensor mounting blocks and pull the sensor out of the hood.

b. Place the air temperature sensor in the glass of hot water (>45°C). The rate oftemperature increase should not exceed 0.05°C per second.

5. If you are using a heat gun or blow dryer, switch it on and point it at the air tem-perature sensor. Observe how quickly the displayed air temperature increases. Ifnecessary, reposition the heat gun (dryer) so that the rate of increase does notexceed 0.05°C per second.

6. Monitor the air temperature display. When the high air temperature alarm illumi-nates, verify an air temperature display of 38.0 ± 0.3°C. Also verify that the safetyrelay opens (audible click; heater status LED extinguished).



3-10 3-106600-0017-000 03/12/98

7. Press the alarm silence switch and remove the air temperature sensor from theglass of water or switch OFF the blow dryer.

Important This alarm will not reset unless the alarm silence switch is pressed.

8. Monitor the air temperature display and verify that the alarm resets.

9. If the alarm is triggered at an air temperature other than 38.0 ± 0.3°C, adjust RP1on the control board and repeat this procedure.

10. If necessary, remount the air temperature sensor on the hood.

I. Fan Sensor Adjustment

Adjust RP3 for 2.70 VDC between TP1-24 and TP1-8 using a DC Voltmeter such as aFluke 8060 A, Fluke 87, HP3468 or equivalent meter.

Verify that the fan sensor is working by doing the following:

a. Replace the controller in the incubator. Plug in the air temperature sensor and thepower cord.

b. Switch the incubator ON.

c. Depress the F/C switch approximately 5 seconds until different numbers appear inthe control temperature display (approximately five seconds). This number will bethe fan RPM (typically fan RPM should be between 1300 and 1650) .

J. Thermal Switch Operation

1. Hold a hot soldering iron (minimum temperature 76.7°C) against the thermal switchon the rear of the controller.

2. Listen for an audible click, indicating that the switch has opened. The click shouldoccur within a few seconds. When the thermal switch has opened the heaterindicator light on the control board should be constantly illuminated.

Note: An open thermal switch makes it appear as if the heater is continuouslyenabled. This may trigger error code E13. Switch the unit OFF and continue withstep 3.

3. Remove the soldering iron and allow the switch to cool.

4. Listen for a second click indicating that the switch has closed. When the thermalswitch closes, the heater indicator LED may flicker depending on the status of theheater.

5. If the thermal switch fails these tests, it must be replaced.

K. Setting the Patient Temperature Alarm Threshold

If desired, reset the patient temperature alarm to trigger when the difference betweenthe patient control temperature and the monitored patient temperature exceeds 0.5°C.This is done by setting dipswitch 4 to the ON position.

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


3-11 3-116600-0017-000 03/12/98

L. Setting the Maximum Patient Control Temperature

If desired, the maximum patient control temperature (patient control mode) can be setat 37.5°C instead of 37.0°C. This is done by setting dipswitch 3 to the ON position.

M. Closure

1. Switch OFF the controller.

2. Verify that the power cord, the air temperature sensor, and the patient probe aredisconnected from the controller.

3. Make sure that the dipswitches are configured for normal operation. Switches 1, 2,7 and 8 must be OFF. The position of switches 3 and 4 will vary depending on themaximum patient control temperature and the tolerance selected for the patienttemperature alarm.

Note: If dipswitches 1 and 2 are not OFF, error code E09 (incorrect dipswitchsetting) will be triggered.


4. Replace the controller cover. Use the screws and lock washers removed in SectionA to secure the cover.

5. With the controller release latches in the release position (perpendicular to thecontroller sides), carefully slide the controller back into the incubator.

6. Push the controller latches down into the locked position.

7. Connect the air temperature sensor and the power cord to the controller.

8. If the ThermaLink option is installed, connect the ThermaLink cable.

9. Turn the unit ON. Verify that the fan is circulating air and that the fan is not rubbingagainst the base platform.

10. Complete the Electrical Safety Check in Section 3.5.

11. Perform the Checkout Procedure in Section 2.6.



3-12 3-126600-0017-000 03/12/98

3.4.2 Calibration Procedures(Software Revision 3.1 and Lower)

WARNINGS w After completing a repair of the Care Plus, the appropriate calibrationprocedure must be performed. After completing any portion of the cali-bration and adjustment procedures for the Care Plus Incubator, performthe Checkout Procedure to make sure that the unit is operating correctly.In addition, a final Electrical Safety Check, section 3.5, must be per-formed. Record the information for future reference.

w Before any disassembly or repair, disconnect the electrical supply andany gas supply connections. Also remove any accessories. Do not per-form any service or maintenance with the power applied unless specifi-cally told to do so in the procedure.

CAUTION s Use the Static Control Work Station (Stock No. 0175-2311-000) to help ensurethat static charges are safely conducted to ground. The Velostat material isconductive. Do not place electrically powered circuit boards on it.

Important Reference Figure 3-4, for the location of control board potentiometers and testpoints.

A. Preparation

1. Remove the controller from the incubator. First unplug the patient probe, the airtemperature sensor, the power supply cord, and the ThermaLink cable if appli-cable, from the controller. Then lift up the controller latches and slide it forward, outof the incubator. Place the controller on the anti-static mat.


Softw

are

Revi

sion

03.

10 a

nd L

ower


3-13 3-136600-0017-000 03/12/98

2. Remove the screws and lock washers used to attach the controller cover.

3. Reconnect the power cord and the air temperature sensor to the controller.

4. Verify that control board switches 1, 2, 7 and 8 are in the OFF (open) position.

Note: Leave switch 4, which selects either a 0.5°C or a 1.0°C limit for the patienttemperature alarm, in its original position.

Note: Leave switch 3, which selects a maximum patient control temperature(patient control mode), in its original position.

Figure 3-4Control Board Test Points and Potentiometers (Software revision 03.10 and lower)

R36Section 3.3 E(Alarm Freq.Adj.)

R12*Section 3.3 I(Fan Sensor Adj.)

R37Section 3.3 D(Alarm Vol. Adj.)

R20Section 3.3(+9.8 V Adj.)

R19Section 3.3 F(Line VoltageSignal Adj.)

TP1-1 to 1-8

TP2-1 to 2-8

R25Section 3.3 G(ADC Lo)

R107*Section 3.3 G(ADC Hi)

CI.0

2.13

1

* Adjustments for controllers with serial numbers beginning with HBJ and HCE.

R38Section 3.3 H(High AirTemp. LimitAdj.)


er


3-14 3-146600-0017-000 03/12/98

B. Check Voltage Supplies

1. Switch ON the incubator. It will proceed through the normal power up tests. Enter acontrol temperature to silence the prompt tone.

2. Adjust control board potentiometer R20 until TP1-1 measures 9.8 ± 0.05 Vdc withrespect to GND (TP1-8).

3. Verify the following voltages on the control board with respect to GND (TP1-8):

Test Point Voltage

TP1-3 5.0 ± 0.3 Vdc

TP1-4 5.0 ± 0.3 Vdc

TP1-6 9.0 ± 0.3 Vdc

Note: These voltages cannot be adjusted. The control board must be replacedwhen they are not within the specified range.

C. Display Brightness

Note: Because display brightness is factory calibrated for both replacement boards andcomplete controllers, brightness adjustments are only required if the LEDs appear to bedim.

Note: Adjustment and test points vary depending on whether the unit has an old or newdisplay board. The new board, part no. 6600-0512-700, has surface mounted compo-nents. The old boards, part no.s 6600-0105-700 and 6600-0420-700, have componentsmounted through the board.

1. Hold down the Alarm Silence switch until all the displays illuminate (approximatelyfive seconds). Check that all displays are illuminated and of uniform brightness. Ifthe displays are acceptable, proceed to Section D. Otherwise, continue with thisadjustment procedure.

2. Switch OFF the power and remove the front controller panel.

a. Turn the controller upside down and remove the lower three front panel mount-ing screws, shown in Figure 3-5.

b. Turn the controller right side up and remove the remaining front panel mountingscrews, shown in Figure 3-5.

3. On controllers with serial numbers beginning with HBJ and HCE, remove the ESDshield.

4. Connect meter leads to terminals of resistor R9 on through mounted boards andterminals 10 and 11 of J8 on surface mounted boards.

5. Reconnect the power cord.

6. Enter the calibration loop by switching the unit ON while holding down the Enableswitch. Continue to hold the Enable switch until a continuous single tone alarmsounds, indicating that the calibration loop is active.

Softw

are

Revi

sion

03.

10 a

nd L

ower


3-15 3-156600-0017-000 03/12/98

Figure 3-5Display Brightness Adjustment

7. Monitor the voltage drop across resistor R9 on the through mounted display boardand R11 on the surface mounted board. Adjust display board potentiometer R11(accessible from the edge of the board) on the through mounted boards and RP1on surface mounted boards to obtain a reading of 3.30 ± 0.2 Vdc.

Important The voltage measured above will differ if the calibration loop is not used.

8. Replace the display board if an acceptable level of brightness cannot be achieved.

9. Disconnect the power cord and reassemble by performing steps 2 and 3 in reverseorder.

D. Alarm Frequency

Note: The alarm frequency and volume are precalibrated at the factory for both re-placement boards and complete controllers. Frequency adjustments should not nor-mally be required in the field.


2. Verify that the frequency output at TP2-1 is 2 kHz ± 0.1 kHz. Adjust R36 on thecontrol board as required.

Front Panel

ESD Shield

CI.0

2.11

1

Lockwasher

Screw

Screw

Display Board

R9(throughmountedboards)


er


3-16 3-166600-0017-000 03/12/98

E. Line Voltage Compensation

1. Verify that the incubator is in the calibration loop. In this loop the control temperaturedisplay continuously shows the percent of nominal input voltage at which the unit isoperating.

Note: Multiply the displayed value by ten to get the actual percentage (XX.XX =XXX.X%).

2. Determine the rated heater voltage of your unit from the serial number sticker on theback of the base platform.

3. Measure the line voltage between the appropriate transformer primaries (pins 4 and2 on 120 volt units):

Rated InputVoltage (from serial Nominal Input Measurenumber sticker) Voltage Between Pins





4. Calculate the percent of the nominal input voltage by dividing the measured voltageby the nominal input voltage and multiplying by 100%.

% of line voltage = (Measured Voltage) x 100%

(Nominal Input Voltage)

5. Adjust control board potentiometer R19 until the control temperature display showsthe percentage calculated in the previous step ± 2%.

Note: The control temperature reading appears in the format XX.XX, which must bemultiplied by ten to give the actual percentage, XXX.X%.

F. Analog to Digital Converter (ADC)


2. Attach 0.1% accuracy resistance box to the patient probe jack. Adjust the boxsettings for a resistance of 5900 ohms ± 0.1% (Ohmeda temperature simulator boxsetting I7). The patient temperatue should read 37.37°C.

Note: The Ohmeda temperature simulator box (Stock No. 0217-2788-800) is a variableresistance box with switch settings corresponding to predetermined temperatures.

On controllers with software revision 3.XX, perform steps 3 through 6 and 8through 13. On controllers with software revision 2.XX, perform steps 7through 13.

3. If the temperature displays in the calibration check differed from the targetvalue by less than half a degree centigrade, skip this test and continue withstep 4. Otherwise:

a. Connect a voltmeter between pins 4 and 8 of the control board test connectorTP2.

b. Set the voltage at TP2-4 to 2.058 Vdc by adjusting R25. Then, disconnect theVoltmeter.

Softw

are

Revi

sion

03.

10 a

nd L

ower


3-17 3-176600-0017-000 03/12/98

c. Connect the voltmeter between pins 2 and 8 of the control board test connectorTP1.

d. Set the voltage at TP1-2 to 0.369 Vdc by adjusting R107. Then, disconnect thevoltmeter.

4. With 5900 Ω ± 0.1% input (setting I7), adjust R107 to obtain a reading of 37.37 ±0.02°C in the Patient Temperature display.

Note: Although the tolerance is ± 0.02, the readings should be adjusted as closelyas possible to the nominal value; the ± 0.02°C allows for system noise, etc.

5. Connect a resistance of 7686 ± 0.1% (Ohmeda Temperature Simulator Box settingI1) to the patient jack connector and adjust R25 to obtain a reading of 31.09 ±0.02°C in the patient temperature display.

6. Repeat steps 4 and 5 until no further adjustment is required.

7. On controllers with software revision 2.XX, adjust control board potentiometer R25until 37.37 ± 0.05°C appears in the patient temperature display.

8. On all controllers, switch OFF the power to exit the calibration loop.

9. Switch the incubator ON. After the normal power up sequence, enter a controltemperature to silence the prompt tone.

10. Check the readings from the calibration resistors. Depress and hold the Enableswitch until the proper calibration readings appear in the patient and air tempera-ture displays (approximately five seconds):



11. Adjust the resistance box settings for the following resistances. Verify that thecorresponding temperature appears in the patient temperature display.

Resistance Temp. Patient TemperatureInput Sim. Box Display

5496 ± 0.1% I2 39.0 ± 0.1°C

7060 ± 0.1% I3 33.0 ± 0.1°C

6190 ± 0.1% I11 36.2 ± 0.1°C




er


3-18 3-186600-0017-000 03/12/98

G. Alarm Volume

WARNING w Lowering the volume excessively may prevent caregivers from hearingalarms. The alarm volume and frequency are precalibrated at the factoryfor both replacement boards and complete controllers. Volume adjust-ments should not normally be required in the field.

H. Air Safety Circuit Calibration (High Air Temperature Alarm)

This procedure requires a hot air source. Either a hair dryer (approximately 1000watts), or a heat gun , or a glass of hot water (>45°C) can be used for this purpose.

1. Switch the controller ON.

2. In the air mode, adjust the control temperature to 36.9°C.

3. The heater should switch ON. Verify that the heater power LEDs on the displaypanel and the heater status LED on the control board are both illuminated. Theheater status LED may flicker.

4. If you are using a glass of hot water (>45°C) as the heat source:

a. Unscrew the two mounting screws that attach the air temperature sensor to thehood. Remove the sensor mounting blocks and pull the sensor out of the hood.

b. Place the air temperature sensor in the glass of hot water (>45°C). The rate oftemperature increase should not exceed 0.05°C per second.

5. If you are using a heat gun or blow dryer, switch it on and point it at the air tem-perature sensor. Observe how quickly the displayed air temperature increases. Ifnecessary, reposition the heat gun (dryer) so that the rate of increase does notexceed 0.05°C per second.

6. Monitor the air temperature display. When the high air temperature alarm illumi-nates, verify an air temperature display of 38.0 ± 0.3°C. Also verify that the safetyrelay opens (audible click; heater status LED extinguished).

7. Press the alarm silence switch and remove the air temperature sensor from theglass of water or switch OFF the blow dryer.

Important This alarm will not reset unless the alarm silence switch is pressed.

8. Monitor the air temperature display and verify that the alarm resets.

9. If the alarm is triggered at an air temperature other than 38.0 ± 0.3°C, adjust R38on the control board and repeat this procedure.

10. If necessary, remount the air temperature sensor on the hood.

Softw

are

Revi

sion

03.

10 a

nd L

ower


3-19 3-196600-0017-000 03/12/98

I. Fan Sensor Adjustment

For units with the sensor number 6600-0245-700(these can be identified by the absence of a heat shrink label on the cable near theconnector)

Adjust R12 for 3.00 VDC between TP1-7 and TP1-8 using a DC voltmeter such as aFluke 8060A, Fluke 87 or HP 3468 or equivalent meter.

For units with the sensor number 6600-0457-700(these can be identified by the part no. on a heat shrink label on the cable near theconnector)

Adjust R12 for 2.70 VDC between TP1-7 and TP1-8 using a DC Voltmeter such as aFluke 8060 A, Fluke 87, HP3468 or equivalent meter.

For either sensor, verify that the fan sensor is working by doing the following:

a. Replace the controller in the incubator. Plug in the air temperature sensor and thepower cord.

b. Switch the incubator ON.

c. Depress the F/C switch approximately 5 seconds until different numbers appear inthe control temperature display (approximately five seconds). This number will bethe fan RPM (typically fan RPM should be between 1300 and 1650) .

J. Thermal Switch Operation

1. Hold a hot soldering iron (minimum temperature 76.7°C) against the thermal switchon the rear of the controller.

2. Listen for an audible click, indicating that the switch has opened. The click shouldoccur within a few seconds. When the thermal switch has opened the heaterindicator light on the control board should be constantly illuminated.

Note: An open thermal switch makes it appear as if the heater is continuouslyenabled. This may trigger error code E13. Switch the unit OFF and continue withstep 3.

3. Remove the soldering iron and allow the switch to cool.

4. Listen for a second click indicating that the switch has closed. When the thermalswitch closes, the heater indicator LED may flicker depending on the status of theheater.

5. If the thermal switch fails these tests, it must be replaced.


er


3-20 3-206600-0017-000 03/12/98

K. Setting the Patient Temperature Alarm Threshold

If desired, reset the patient temperature alarm to trigger when the difference betweenthe patient control temperature and the monitored patient temperature exceeds 0.5°C.This is done by setting dipswitch 4 to the ON position.

L. Setting the Maximum Patient Control Temperature

If desired, the maximum patient control temperature (patient control mode) can be setat 37.5°C instead of 37.0°C. This is done by setting dipswitch 3 to the ON position.

M. Closure

1. Switch OFF the controller.

2. Verify that the power cord, the air temperature sensor, and the patient probe aredisconnected from the controller.

3. Make sure that the dipswitches are configured for normal operation. Switches 1, 2,7 and 8 must be OFF. The position of switches 3 and 4 will vary depending on themaximum patient control temperature and the tolerance selected for the patienttemperature alarm.

Note: If dipswitches 1 and 2 are not OFF, error code E09 (incorrect dipswitchsetting) will be triggered.

4. On older units with the ThermaLink option installed, make sure the slide switch onthe ThermaLink board is in the OFF position (newer units have no test switchlocated on the board).


5. Replace the controller cover. Use the screws and lock washers removed in SectionA to secure the cover.

6. With the controller release latches in the release position (perpendicular to thecontroller sides), carefully slide the controller back into the incubator.

7. Push the controller latches down into the locked position.

8. Connect the air temperature sensor and the power cord to the controller.

9. If the ThermaLink option is installed, connect the ThermaLink cable.

10. Turn the unit ON. Verify that the fan is circulating air and that the fan is not rubbingagainst the base platform.


12. Perform the Checkout Procedure in Section 2.6.

Softw

are

Revi

sion

03.

10 a

nd L

ower


3-21 3-216600-0017-000 03/12/98

3.5 Electrical Safety Check

A. Leakage Current

Use approved equipment and techniques to test the unit’s leakage current and groundcontinuity. Follow the directions supplied by the test equipment manufacturer to verifythe following:

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

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

B. Ground Resistance Check

Use a low range ohmmeter or electrical safety analyzer to measure the resistancebetween the ground pin on the line cord plug and exposed metal of the controller. Theground resistance must be less than 0.2 ohms


3-22 3-226600-0017-000 03/12/98

Notes

4/Troubleshooting

4-1 4-16600-0017-000 03/12/98

4/TroubleshootingWARNING w Use extreme care while performing calibration and adjustment proce-

dures, or while working on the Care Plus Incubator with power connected.An electrical shock hazard does exist; be certain to observe all standardsafety precautions.

CAUTIONS w When handling the controller, avoid bumping the fan or the heater. If theseitems are knocked out of alignment, the fan can grate against either the heateror the base.

s Use the Static Control Work Station (Stock No. 0175-2311-00) to help ensurethat static charges are safely conducted to ground. The Velostat material isconductive. Do not place electrically powered circuit boards on it.

Note: Controllers that have the new white 5 blade fan may experience fan vibration ifthe wrong style fan knob is installed. Make sure that the small (0.62" O.D., 0.25" thick)aluminum knob, 6600-0448-000, is installed with the white fan.

Note: Self test programs stop when a system error code is detected. Therefore asecond error code will not be displayed for another failure. The same failure can triggermore than one error code. The actual code that appears is determined by the point inthe test loop where the fault occurs.

Note: On older units with test switch on board, SW1 on the ThermaLink board shouldbe in the OFF position (newer units have no test switch).

The Care Plus features three levels of testing for maximum reliability and ease oftroubleshooting. Self tests are performed on power up to check microcontroller,EPROM, and RAM function. They are performed continuously during operation to verifyproper ADC, heater control, safety circuit, temperature sensor, alarm, RAM, andsoftware operation.

Control panel switches activate on demand tests that can be used to assess error codes.Specifically you can verify ADC calibration and check for drift; check the individual ADCchannels; monitor the occurrence of any software upsets, and check the line voltage. Oncontrollers with serial numbers beginning with HBJ and HCE, you can check the fan RPM.On controllers with serial numbers beginning with HAG you can compare readings fromboth air flow or air temperature thermistors to verify a sensor failure. On all controllers, aseparate RAM memory test loop continuously repeats the power up tests.

When required, you can operate the controller outside the incubator to directly measurecontrol board signals. During controller testing, it is important to remember that thealarm criteria discussed in this section apply regardless of whether or not the controlleris installed in the unit. Failure to connect the patient probe (or an equivalent load) inpatient control mode, or the air temperature sensor in either operational mode willtrigger the probe failure alarm. Air or patient temperature readings outside the alarmlimits will still activate the corresponding alarms. In patient control mode the heater willnot switch ON unless the patient temperature reading is within the 30 to 42°C range.

Important Section 4.11 contains error code information for control boards with softwarerevision 4.0 and higher. The unit's software revision is displayed on powerup, butthese new boards can be physically identified by their surface mounted compo-nents and 28 pin test point connector. Section 4.12 has the information for earliercontrol boards prior to software revision 4.0, which can be identified by theirthrough mounted components and two 8 pin test point connectors.

4/Troubleshooting

4-2 4-26600-0017-000 03/12/98

4.1.1 Alarms and Error Codes (Software Revision 04.00 and Higher)

There are two types of alarms on the Care Plus incubator. The first group of alarms areindicated by the alarm LEDs on the control panel. When one of these alarms is activethe corresponding LED illuminates and an audible alarm sounds.

Error codes are a subset of the system failure alarm. When the system failure alarmilluminates for anything other than a gross microcontroller failure, the correspondingerror code appears in the control temperature display.

A. Front Panel Alarms

Note: All alarms, with the exception of the system failure and power failure alarms, arepreceded by a 30 second operator prompt tone.

1. Patient Temperature Alarm (active in the patient mode only)

This alarm is active only in the patient control mode. It is triggered when thedifference between the patient temperature and the control temperature exceeds1°C. The alarm self resets when the patient temperature returns to within 0.8°C ofthe control temperature.

Note: The patient temperature alarm can be adjusted to trigger if the temperaturedifference exceeds 0.5°C and reset when the difference is less than 0.3°C (Refer toSection 3.4.1K).

Note: If the patient temperature is outside the 22 to 42°C range, either HHHH orLLLL, respectively, will appear in the patient temperature display.

Audio Signal: Intermittent single tone if patient temperature within the 30 to42°C range. Outside this range, an alternating two tone alarmsounds.

Alarm Silence: 15 minutes if temperature difference is < 2°C

5 minutes if temperature difference is 2°C or higher.

1 minute if patient temperature < 30°C or > 42°C.

Heater Status: Heater is automatically shut off if the patient temperature is notbetween 30 and 42°C.

2. Control Temperature Alarm (active in air control mode only)

The control temperature alarm is active only in the air control mode. It is sup-pressed for 30 minutes when power is first applied and for 15 minutes after eachmode or control temperature change. The alarm is triggered when the reading fromthe air control thermistor exceeds the control temperature by more than 1.5°C orfalls more than 3°C below the control temperature. The alarm self resets with ahysteresis of 0.2°C.

Audio Signal: Intermittent single tone

Alarm Silence: 15 minutes

Heater Status: Normal heater operation, dependent on selected controltemperature and air temperature.

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r

4/Troubleshooting

4-3 4-36600-0017-000 03/12/98

3. High Air Temperature Alarm

This alarm is triggered if the air display temperature exceeds the alarm limit in thetable. This alarm is not self resetting; you must press the alarm silence switchbefore the alarm will reset.

A transient alarm may be triggered if you change from a mode with a 40°C alarm limitto a mode that has a 38°C alarm limit.

Control Temp.Mode Range Alarm Limit

Patient 35.0 to 37.0° C 40.0°CControl (Max. DET 39.0°C)

35.0 to 37.5°C 40.0°C(Dipswitch 3 ON;Section 3.3.L;Max. DET still 39.0°C)

Air Control 20.0 to 37.0°C 38.0°C(Normal Range)

37.0 to 39.0°C 40.0°C(Override switch)

Audio Signal: Alternating two tone


Heater Status: Heater is automatically shut off.

4. Air Circulation Alarm

This alarm triggers when the fan sensor detects that the fan has stopped spinningor is not installed. The fan sensor is mounted facing the hub. The fan is designedwith cutouts so that as the fan spins, the sensor “sees” alternating areas of reflec-tance and non-reflectance. This signal is then processed and input to themicrocontroller as an interrupt. The microcontroller counts the interrupts for 10second intervals to determine the fan’s RPM. If the RPM drops below 800 for 2consecutive intervals, the air circulation alarm is triggered. The alarm resets whenthe RPM is detected to be above 800.

To display the fan RPM, depress and hold the F/C switch approximately 5 secondsuntil the fan RPM appears in the control temperature display.

The air circulation alarm can trigger for several reasons. Check the following:Blower motor is turningWhite fan blade is installed.Verify calibration per section 3

If the unit can’t be calibrated, replace the fan sensor. If the problem persists,replace the pc board.

Note: When replacing either the sensor or the board, the fan sensor circuit must berecalibrated before the unit is put back in service.

The air circulation alarm is most commonly triggered by a blower motor failure or amissing fan.



Heater Status: Heater is automatically shut off


4/Troubleshooting

4-4 4-46600-0017-000 03/12/98

5. Probe Failure Alarm

In the air control mode, the probe failure alarm is triggered by a disconnected airtemperature sensor. In the patient control mode, the probe failure alarm is triggeredby either a disconnected or faulty patient temperature probe (short or open) or adisconnected air temperature sensor. The alarm self resets when the condition isremedied.

The patient temperature probe is judged to be disconnected or faulty if its signal isoutside the 5 to 50°C range ( approximately 884 mV to 410 mV). The air tempera-ture sensor is assumed to be disconnected if both the air control and the air displaysignals are outside this range. This means that the probe failure alarm will betriggered instead of error codes 10 or 11 if both circuits in the air temperaturesensor are open or shorted.

If neither the probe (patient control mode only) nor the sensor are disconnected,one or the other is faulty. Check the patient temperature probe (patient controlmode only) by observing the patient temperature display and verifying that it isconsistent with the temperature of the probe. If LLLL or HHHH appear in thedisplay, check the actual probe reading by depressing and holding the Air Controlswitch until a value appears in the patient temperature display (approximately fiveseconds). If the temperature is outside the 5 to 50°C range, replace the patienttemperature probe.

Check the air temperature sensor by depressing and holding the Override switchuntil the air control thermistor reading appears in the patient temperature displayand the air display thermistor reading appears in the air temperature display(approximately five seconds). If both readings are outside the 5 to 50°C range,replace the air temperature sensor.


Alarm Silence: 1 minute


6. System Failure Alarm

The system failure alarm is triggered if one or more of the system parametersmonitored by the microcontroller self tests fail. This section describes the actualtests and gives a list of probable causes for each code.

If the microcontroller fails, there may be some cases where the only indication is acontinuous, nonsilenceable audio alarm (i.e. no alarm indicator illuminates and noerror code appears). This occurs because the microcontroller controls the displayindicators. To ensure patient safety, a microcontroller independent safety relay willswitch off the heater if the temperature exceeds preset safety limits.

WARNING w If a system failure alarm occurs, the unit must be removed from use untilit has been serviced.

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r

4/Troubleshooting

4-5 4-56600-0017-000 03/12/98


Alarm Silence: Cannot be silenced


7. Power Failure Alarm

The power failure alarm is triggered when the line frequency signal pulse is absenton buffer U4 pin 5. During a power failure alarm the NI-CAD battery powers thecontrol logic and RAM circuits for up to 10 minutes. If power is restored within thistime, the unit will return to the mode of operation and the control temperature ineffect before the power loss.

The power failure alarm can be caused by a disconnected plug , faulty wiring, afaulty transformer, or an open circuit breaker.



Heater Status: There is no power to the heater

B. Error Codes

Important The recommended service policy is to limit repair procedures to sensor or boardreplacement, except for the EPROM, which is socketed. Additional information isprovided for the purpose of identifying the faulty assembly.

Error codes are a subset of the system failure alarm. When an error code is triggered, analternating two tone alarm sounds, the heater is automatically shut off, and normalincubator operation stops. However, the patient and air temperature displays will con-tinue to update, and the various on demand test functions are still available.

This section individually discusses each error code, specifically covering the triggeringconditions, any applicable on demand tests, and test points.

1. E01, Instruction Test Failure

A software routine executes selected instructions from the 8032 microcontroller. Theresults are then checked, and if any mistakes are found this error is triggered.

There are no related test points, however the RAM memory test loop cycles repeat-edly through this test. To begin the loop, switch off the unit. Then turn it back onwhile depressing the Override switch until a continuous alarm sounds (approximatelyfive seconds). If the error recurs, replace the microcontroller (U17) and repeat thetest. Replace the control board if the problem persists.

2. E02, ADC High Calibration Failure

The reading from the ADC calibrate high resistor (R58, 5.76 kOhm) has exceededthe limits of 37.96 ±0.3°C.

To see if the ADC requires calibration, depress the Enable switch until the lowcalibration reading (25.05 ±0.3°C) appears in the patient temperature display, andthe high calibration reading (37.96 ±0.3°C) appears in the air temperature display(approximately five seconds). If either reading exceeds or nearly exceeds the limits,calibration is required. The second possibility is that resistor R58 may be out oftolerance. If the problem persists, replace the control board.


4/Troubleshooting

4-6 4-66600-0017-000 03/12/98

3. E03, ADC Low Calibration Failure

The reading from the ADC calibrate low resistor (R57, 10 kOhm), has exceeded thelimits of 25.05 ± 0.3°C.

To see if the ADC requires calibration, depress the Enable switch until the lowcalibration reading (25.05 ± 0.3°C) appears in the patient temperature display andthe high calibration reading (37.96 ± 0.3°C) appears in the air temperature display(approximately five seconds). If either reading exceeds or nearly exceeds the limits,calibration is required. The second possibility is that resistor R57 may be out oftolerance. If the problem persists, replace the control board.

4. E04, EPROM Checksum Failure

The results of the EPROM memory checksum differ from the correct result storedat memory locations 3FFE and 3FFF on U21.

There are no related test points, however the RAM memory test loop cyclesrepeatedly through this test. To begin the loop, switch off the unit. Then turn it backon while depressing the Override switch until a continuous alarm sounds. If theerror recurs, replace the EPROM (U21), and repeat the RAM test loop. If the errorstill recurs, replace the control board.

5. E05, RAM Test Failure

The data read out of a RAM memory location differs from the test pattern written to it.

There are no related test points, however the RAM memory test loop cyclesrepeatedly through this test. To begin the loop, switch off the unit. Then turn it backon while depressing the Override switch. If the error recurs replace the controlboard.

6. E07, ADC Converter Failure

This alarm is triggered if the Conversion Complete Signal (STATUS) from the ADCdoes not occur within two seconds of the Start Conversion signal (RUN/HOLD).

Do not attempt to monitor these signals; the Start Conversion and the ConversionComplete pulses are extremely narrow with durations of only a few nano seconds.Verify that no conversions are being completed by heating or cooling either the airtemperature sensor or the patient temperature probe and observing that thetemperature displays do not update.

Since the ADC module is not socketed, control board replacement is recom-mended.

7. E08, S/O Circuit Not Working

The logic level of the safety circuit S/O signal does not agree with the level thatwould be expected based on the air display temperature. The S/O signal (TP1-6)should be low only when the air display temperature is outside the 5 to 50°C range(greater than 884 mV or less than 410 mV at TP1-5).

If the air display temperature were actually outside this range, error code E10would be triggered.

The most probable cause is a faulty comparator circuit (U10) in the S/O circuit.Since this is not a socketed chip, control board replacement is recommended.

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r

4/Troubleshooting

4-7 4-76600-0017-000 03/12/98

8. E09, Incorrect Dip Switch Setting

The signals from dipswitches 1 and 2 are logic high. The most probable cause isthat dipswitches 1 and 2 are improperly configured. Set both dipswitches to theOFF (open) position.

If the dipswitches are correctly configured, either the dipswitch or transciever U3may be faulty. Board replacement is recommended, since these circuits are notsocketed.

9. E10, Air Display Sensor Bad

The air display signal is outside the 5 to 50°C range (greater than 884 mV or lessthan 410 mV at TP1-5) while the air control signal remains within the 5 to 50°Crange.

12

CI.0

2.13

8

Red Dot

Figure 4-1Air Temperature Sensor Connector (end view)

Observe the displayed air temperature. If it is outside the 5 to 50°C range, replacethe air temperature sensor. Alternatively, perform a continuity check on the sensorby measuring the resistance between pins 4 and 5 on the sensor connector (Figure4-1), or between pins 10 and 11 on the control board J4 connector. Replace thesensor if you do not obtain a reading between 25.7 and 3.6 kOhms (20°C = 12.5kOhms).

Check that the J4 connector is properly mated to the control board. If the problempersists, replace the control board.

10. E11, Air Control Sensor Bad

The air control signal is outside the 5 to 50°C range (greater than 884 mV or lessthan 410 mV at TP1-5) while the air display signal remains within the 5 to 50°Crange.

Depress and hold the Override switch until the air control temperature appears inthe air temperature display (approximately five seconds). If the displayed air controltemperature is outside the 5 to 50°C range, replace the air temperature sensor.Alternatively, perform a continuity check on the sensor by measuring the resistancebetween pins 1 and 2 (Figure 4-1) on the sensor connector or between pins 6 and7 on the control board J4 connector. Replace the sensor if you do not obtain areading between 25.7 and 3.6 kOhms (20°C = 12.5 kOhms).

Check that the J4 connector is properly mated to the control board. If the problempersists replace the control board.

5

34


4/Troubleshooting

4-8 4-86600-0017-000 03/12/98

11. E12, Heater Not Switching On

The microcontroller has commanded the heater to switch on (Heat TP1-17 low), butthe heater status signal from U23 pin 8 remains low indicating that the heater is off.

This is a difficult code to troubleshoot, since the control signals and the continuityacross the solid state relay change from those required to power the heater tothose that shut down the heater as soon as this failure is detected.

The most probable cause of this failure is a faulty solid state relay. If the problempersists after relay replacement, replace the control board.

12. E13, Heater Not Switching Off

The microcontroller has commanded the heater to switch off (Heat TP1-17 high).However, the heater status signal from U23 pin 8 remains high indicating that theheater is on.

This error code can be triggered without an actual failure having occurred, becauseof a thermal switch in the heater neutral that opens at a temperature of 76.7°C.When the thermal switch opens, it causes a logic high heater status signal, whichilluminates the heater status LED and signals the microprocessor that the heater ison.

The thermal switch normally opens for a few minutes when a hot incubator isswitched off because of residual radiant heat and the lack of a cooling air flow. Ifthe incubator is restarted before the thermal switch has cooled, E13 may appear assoon as this alarm is enabled (approximately three and a half minutes after powerup; normally, a period of three and a half minutes is sufficient to cool the incubator).

Check to see if the thermal switch has opened as soon as the error occurs, beforeit has had time to cool down. The thermal switch opens at a temperature of 76.7°Cand is located on the back of the controller. Because the decimal point is notilluminated, you must divide the reading by 10 to obtain the temperature.

The second possibility is that the thermal switch has failed in an open position.Disconnect the power cord and do a continuity check between the two terminals ofthe thermal switch. The resistance should be less than 1 Ohm.

The third possibility is a shorted solid state relay. Replace the relay. If the problempersists, replace the control board.

13. E14, Alarm Oscillator Failure

An alternating two tone alarm signal has been activated, but the 2 kHz signal atTP1-4 is not toggling.

To troubleshoot this failure, an alternating two tone alarm must be active. If there isno error code displayed, trigger an alarm by disconnecting the patient temperatureprobe while in the patient control mode.

If you hear the alarm (i.e. the 2 kHz signal is present), the microcontroller (U17), orthe transiever (U4) may be faulty. Since these are not socketed chips, controlboard replacement is recommended.

If you do not hear the alarm (i.e. the 2 kHz signal is missing), the timing circuit orone of the circuits that gate the timing circuit inputs may be faulty. Since thesechips are not socketed, control board replacement is recommended.

6600-0017-000 08/28/96

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r

4/Troubleshooting

4-9 4-96600-0017-000 03/12/98

14. E15, Software Upset

A software upset has caused the watchdog timer to time out and the system isunable to recover because critical parameters (e.g. control temperature) stored inthe RAM may have been altered.

This error does not necessarily indicate a hardware failure. Power the incubator up.If the error does not recur, allow the unit to run for half an hour. Then check thenumber of recoverable software upsets that have occurred by depressing andholding the Override switch until a new value appears in the control temperaturedisplay (approximately five seconds). If FF appears in the control temperaturedisplay, no software upsets have occurred. Complete the Checkout Procedure andreturn the unit to service.

If another value appears in the control display, replace the control board .

15. E16, Safety Relay Test Failure

On power up, the safety relay does not open. Repeat the test by turning off thepower, waiting approximately 5 minutes, and turning the power back on.

If the failure recurs, replace the control board.


The software is not cycling through all of the routines and is unable to recover.

Power the incubator up. If the error does not recur, allow the unit to run for half anhour. Then check the number of recoverable software upsets that have occurred bydepressing and holding the Override switch until a new value appears in the controltemperature display (approximately five seconds). If FF appears in the controltemperature display, no software upsets have occurred. Complete the CheckoutProcedure and return the unit to service.


17. E18, Air Temperature Sensor Out of Tolerance

This failure is normally caused by a faulty air temperature sensor. Power the unitup from a cold start with an air control temperature of 39°C. When the error occurs,observe the difference between the air control and air display thermistor readingsby pressing and holding the Override switch until the air control temperatureappears in the patient temperature display (approximately five seconds). Comparethis temperature to the air display temperature. If the difference exceeds 0.5°C,replace the air temperature sensor and repeat the test. If the error persists, replacethe control board.


The watchdog timer has timed out 256 times since power up. This error can becaused by a software upset and does not necessarily indicate a hardware failure.


If another value appears in the control display, replace the control board.


4/Troubleshooting

4-10 4-106600-0017-000 03/12/98

4.1.2 Alarms and Error Codes (Software Revision 03.10 and Lower)

There are two types of alarms on the Care Plus incubator. The first group of alarms areindicated by the alarm LEDs on the control panel. When one of these alarms is activethe corresponding LED illuminates and an audible alarm sounds.

Error codes are a subset of the system failure alarm. When the system failure alarmilluminates for anything other than a gross microcontroller failure, the correspondingerror code appears in the control temperature display.

A. Front Panel Alarms

Note: On controllers with with software revision 3.00 or higher, all alarms, with theexception of the system failure and power failure alarms, are preceded by a 30 secondoperator prompt tone.

1. Patient Temperature Alarm (active in the patient mode only)

This alarm is active only in the patient control mode. It is triggered when thedifference between the patient temperature and the control temperature exceeds1°C. The alarm self resets when the patient temperature returns to within 0.8°C ofthe control temperature.

Note: The patient temperature alarm can be adjusted to trigger if the temperaturedifference exceeds 0.5°C and reset when the difference is less than 0.3°C (Refer toSection 3.4.1K).

Note: If the patient temperature is outside the 22 to 42°C range, either HHHH orLLLL, respectively, will appear in the patient temperature display.

Audio Signal: Intermittent single tone if patient temperature within the 30 to42°C range. Outside this range, an alternating two tone alarmsounds.

Alarm Silence: 15 minutes if temperature difference is < 2°C

5 minutes if temperature difference is 2°C or higher.

1 minute if patient temperature < 30°C or > 42°C.

Heater Status: Heater is automatically shut off if the patient temperature is notbetween 30 and 42°C.

2. Control Temperature Alarm (active in air control mode only)

The control temperature alarm is active only in the air control mode. It is sup-pressed for 30 minutes when power is first applied and for 15 minutes after eachmode or control temperature change. The alarm is triggered when the reading fromthe air control thermistor exceeds the control temperature by more than 1.5°C orfalls more than 3°C below the control temperature. The alarm self resets with ahysteresis of 0.2°C.



Heater Status: Normal heater operation, dependent on selected controltemperature and air temperature.

6600-0017-000 08/28/96

Softw

are

Revi

sion

03.

10 a

nd L

ower

4/Troubleshooting

4-11 4-116600-0017-000 03/12/98

3. High Air Temperature Alarm

This alarm is triggered if the air display temperature exceeds the alarm limit in thetable. This alarm is not self resetting; you must press the alarm silence switchbefore the alarm will reset.

A transient alarm may be triggered if you change from a mode with a 40°C alarm limitto a mode that has a 38°C alarm limit.

Control Temp.Mode Range Alarm Limit

Patient 35.0 to 37.0° C 40.0°CControl (Max. DET 39.0°C)

35.0 to 37.5°C 40.0°C(Dipswitch 3 ON;Section 3.3.L;Max. DET still 39.0°C)

Air Control 20.0 to 37.0°C 38.0°C(Normal Range)

37.0 to 39.0°C 40.0°C(Override switch)



Heater Status: Heater is automatically shut off.

4. Air Circulation Alarm

On controllers with software revision 3.00 and higher, this alarm triggers when thefan sensor detects that the fan has stopped spinning or is not installed. The fansensor is mounted facing the hub. The fan is designed with cutouts so that as thefan spins, the sensor “sees” alternating areas of reflectance and non-reflectance.This signal is then processed and input to the microcontroller as an interrupt. Themicrocontroller counts the interrupts for 10 second intervals to determine the fan’sRPM. If the RPM drops below 800 for 2 consecutive intervals, the air circulationalarm is triggered. The alarm resets when the RPM is detected to be above 800.

To display the fan RPM, depress and hold the F/C switch approximately 5 secondsuntil the fan RPM appears in the control temperature display.

The air circulation alarm can trigger for several reasons. Check the following:Blower motor is turningWhite fan blade is installed.Verify calibration per section 3

If the unit can’t be calibrated, replace the fan sensor. If the problem persists,replace the pc board.

Note: When replacing either the sensor or the board, the fan sensor circuit must berecalibrated before the unit is put back in service.

On controllers with software revision 02.00, this alarm triggers when the flow ofcooling air over the air flow sensor stops. The air flow sensor contains a heatedand an unheated thermistor. During normal operation, the air flow over the sensorcools the heated thermistor. If the air flow stops, the heated thermistor is no longercooled and the temperature difference between the two thermistors increases.When the difference reaches 21°C, the air circulation alarm is triggered. The alarmresets when the difference drops below 19°C.

6600-0017-000 08/28/96


er

4/Troubleshooting

4-12 4-126600-0017-000 03/12/98

To display the temperature of both thermistors, depress and hold the F/C switchuntil the temperature of the heated thermistor appears in the air temperaturedisplay and the temperature of the unheated thermistor appears in the controltemperature display (approximately five seconds). These displays do not have adecimal point so the readings must be divided by ten to convert to degrees C.

The air circulation alarm is most commonly triggered by a blower motor failure or amissing fan.




5. Probe Failure Alarm

In the air control mode, the probe failure alarm is triggered by a disconnected airtemperature sensor. In the patient control mode, the probe failure alarm is triggeredby either a disconnected or faulty patient temperature probe (short or open) or adisconnected air temperature sensor. The alarm self resets when the condition isremedied.

The patient temperature probe is judged to be disconnected or faulty if its signal isoutside the 5 to 50°C range ( approximately 884 mV to 410 mV). The air tempera-ture sensor is assumed to be disconnected if both the air control and the air displaysignals are outside this range. This means that the probe failure alarm will betriggered instead of error codes 10 or 11 if both circuits in the air temperaturesensor are open or shorted.

If neither the probe (patient control mode only) nor the sensor are disconnected,one or the other is faulty. Check the patient temperature probe (patient controlmode only) by observing the patient temperature display and verifying that it isconsistent with the temperature of the probe. If LLLL or HHHH appear in thedisplay, check the actual probe reading by depressing and holding the Air Controlswitch until a value appears in the patient temperature display (approximately fiveseconds). If the temperature is outside the 5 to 50°C range, replace the patienttemperature probe.

Check the air temperature sensor by depressing and holding the Override switchuntil the air control thermistor reading appears in the patient temperature displayand the air display thermistor reading appears in the air temperature display(approximately five seconds). If both readings are outside the 5 to 50°C range,replace the air temperature sensor.


Alarm Silence: 1 minute


6. System Failure Alarm

The system failure alarm is triggered if one or more of the system parametersmonitored by the microcontroller self tests fail. This section describes the actualtests and gives a list of probable causes for each code.

If the microcontroller fails, there may be some cases where the only indication is acontinuous, nonsilenceable audio alarm (i.e. no alarm indicator illuminates and noerror code appears). This occurs because the microcontroller controls the displayindicators. To ensure patient safety, a microcontroller independent safety relay willswitch off the heater if the temperature exceeds preset safety limits.

Softw

are

Revi

sion

03.

10 a

nd L

ower

4/Troubleshooting

4-13 4-136600-0017-000 03/12/98

WARNING wwwww If a system failure alarm occurs, the unit must be removed from use untilit has been serviced.




7. Power Failure Alarm

The power failure alarm is triggered when the line frequency signal pulse is absenton I/O expander U15 pin 15. (On controllers with serial numbers that begin withHAF, the line frequency pulse is absent on the microcontroller U19, Pin 12.) Duringa power failure alarm the NI-CAD battery powers the control logic and RAM circuitsfor up to 10 minutes. If power is restored within this time, the unit will return to themode of operation and the control temperature in effect before the power loss.

The power failure alarm can be caused by a disconnected plug , faulty wiring, afaulty transformer, or, on controllers with serial numbers beginning with HBJ andHCE, an open circuit breaker.



Heater Status: There is no power to the heater

B. Error Codes

Error codes are a subset of the system failure alarm. When an error code is triggered,an alternating two tone alarm sounds, the heater is automatically shut off, and normalincubator operation stops. However, the patient and air temperature displays willcontinue to update, and the various on demand test functions are still available.

This section individually discusses each error code, specifically covering the triggeringconditions, any applicable on demand tests, and test points.

1. E01, Instruction Test Failure

A software routine executes selected instructions from the 8032 microcontroller.The results are then checked, and if any mistakes are found this error is triggered.

There are no related test points, however the RAM memory test loop cyclesrepeatedly through this test. To begin the loop, switch off the unit. Then turn it backon while depressing the Override switch until a continuous alarm sounds (approxi-mately five seconds). If the error recurs, replace the microcontroller (U19) andrepeat the test. Replace the control board if the problem persists.

2. E02, ADC High Calibration Failure

The reading from the ADC calibrate high resistor (R5, 5.76 kOhm) has exceededthe limits of 37.96 ±0.3°C. This corresponds to a voltage of approximately 540 mVat the ADC input (U1 pin 35).

To see if the ADC requires calibration, depress the Enable switch until the lowcalibration reading (25.05 ±0.3°C) appears in the patient temperature display, andthe high calibration reading (37.96 ±0.3°C) appears in the air temperature display(approximately five seconds). If either reading exceeds or nearly exceeds the limits,calibration is required. The second possibility is that resistor R5 may be out oftolerance. If the problem persists, replace the control board.

6600-0017-000 08/28/96


er

4/Troubleshooting

4-14 4-146600-0017-000 03/12/98

3. E03, ADC Low Calibration Failure

The reading from the ADC calibrate low resistor (R8, 10 kOhm), has exceeded thelimits of 25.05 ± 0.3°C. This corresponds to a voltage of approximately 690 mV atthe ADC input (U1 pin 34).

To see if the ADC requires calibration, depress the Enable switch until the lowcalibration reading (25.05 ± 0.3°C) appears in the patient temperature display andthe high calibration reading (37.96 ± 0.3°C) appears in the air temperature display(approximately five seconds). If either reading exceeds or nearly exceeds the limits,calibration is required. The second possibility is that resistor R8 may be out oftolerance. If the problem persists, replace the control board.

4. E04, EPROM Checksum Failure

The results of the EPROM memory checksum differ from the correct result storedat memory locations 3FFE and 3FFF on U16.

There are no related test points, however the RAM memory test loop cyclesrepeatedly through this test. To begin the loop, switch off the unit. Then turn it backon while depressing the Override switch until a continuous alarm sounds. If theerror recurs, replace the EPROM (U16), and repeat the RAM test loop. If the errorstill recurs, replace the control board.

5. E05, RAM Test Failure

The data read out of a RAM memory location differs from the test pattern written to it.

There are no related test points, however the RAM memory test loop cyclesrepeatedly through this test. To begin the loop, switch off the unit. Then turn it backon while depressing the Override switch. If the error recurs replace the controlboard.

6. E07, ADC Converter Failure

This alarm is triggered if the Conversion Complete Signal from the ADC does notoccur within two seconds of the Start Conversion signal from I/O expander #2.

Do not attempt to monitor these signals; the Start Conversion and the ConversionComplete pulses are extremely narrow with durations of only a few nano seconds.Verify that no conversions are being completed by heating or cooling either the airtemperature sensor or the patient temperature probe and observing that thetemperature displays do not update.

Since the ADC (U14) chip and the ADC module are not socketed, control boardreplacement is recommended.

7. E08, S/O Circuit Not Working

The logic level of the safety circuit S/O signal does not agree with the level thatwould be expected based on the air display temperature. The S/O signal (TP2-5)should be low only when the air display temperature is outside the 5 to 50°C range(greater than 884 mV or less than 410 mV at TP2-7).

If the air display temperature were actually outside this range, error code E10would be triggered.

The most probable cause is a faulty comparator circuit (U5) in the S/O circuit. Sincethis is not a socketed chip, control board replacement is recommended.

Softw

are

Revi

sion

03.

10 a

nd L

ower

4/Troubleshooting

4-15 4-156600-0017-000 03/12/98

8. E09, Incorrect Dip Switch Setting

The signals from dipswitches 1 and 2 are logic high (corresponds to logic lowinputs at U17 for the inverted signals). The most probable cause is that dipswitches1 and 2 are improperly configured. Set both dipswitches to the OFF (open) position.

If the dipswitches are correctly configured, either the dipswitch or an inverter (U11Bor U11C) may be faulty. Board replacement is recommended, since these circuitsare not socketed.

9. E10, Air Display Sensor Bad

The air display signal is outside the 5 to 50°C range (greater than 884 mV or lessthan 410 mV at TP2-7) while the air control signal remains within the 5 to 50°Crange.

Observe the displayed air temperature. If it is outside the 5 to 50°C range, replacethe air temperature sensor. Alternatively, perform a continuity check on the sensorby measuring the resistance between pins 4 and 5 on the sensor connector, orbetween pins 10 and 11 on the control board J4 connector. Replace the sensor ifyou do not obtain a reading between 25.7 and 3.6 kOhms (20°C = 12.5 kOhms).

Check that the J4 connector is properly mated to the control board. If the problempersists, replace the control board.

10. E11, Air Control Sensor Bad

The air control signal is outside the 5 to 50°C range (greater than 884 mV or lessthan 410 mV at TP2-7) while the air display signal remains within the 5 to 50°Crange.

Depress and hold the Override switch until the air control temperature appears inthe air temperature display (approximately five seconds). If the displayed air controltemperature is outside the 5 to 50°C range, replace the air temperature sensor.Alternatively, perform a continuity check on the sensor by measuring the resistancebetween pins 1 and 2 (Figure 4-1) on the sensor connector or between pins 6 and7 on the control board J4 connector. Replace the sensor if you do not obtain areading between 25.7 and 3.6 kOhms (20°C = 12.5 kOhms).

Check that the J4 connector is properly mated to the control board. If the problempersists replace the control board.

11. E12, Heater Not Switching On

The microcontroller has commanded the heater to switch on (Heat TP2-2 low), butthe heater status signal from U7A pin 11 remains low (high on controllers that haveserial numbers that do not begin with HBJ), indicating that the heater is off.

This is a difficult code to troubleshoot, since the control signals and the continuityacross the solid state relay change from those required to power the heater tothose that shut down the heater as soon as this failure is detected.

The most probable cause of this failure is a faulty solid state relay. If the problempersists after relay replacement, replace the control board.


er

4/Troubleshooting

4-16 4-166600-0017-000 03/12/98

12. E13, Heater Not Switching Off

The microcontroller has commanded the heater to switch off (Heat TP2-2 high).However, the heater status signal from U7A pin 11 remains high (logic low oncontrollers that have Software Revision 02.00), indicating that the heater is on.

This error code can be triggered without an actual failure having occurred, becauseof a thermal switch in the heater neutral that opens at a temperature of 76.7°C.When the thermal switch opens, it causes a logic high heater status signal (logiclow on controllers that have Software Revision 02.00), which illuminates the heaterstatus LED and signals the microprocessor that the heater is on.

The thermal switch normally opens for a few minutes when a hot incubator isswitched off because of residual radiant heat and the lack of a cooling air flow. Ifthe incubator is restarted before the thermal switch has cooled, E13 may appear assoon as this alarm is enabled (approximately three and a half minutes after powerup; normally, a period of three and a half minutes is sufficient to cool the incubator).

Check to see if the thermal switch has opened as soon as the error occurs, beforeit has had time to cool down. The thermal switch opens at a temperature of 76.7°Cand is located on the back of the controller. On controllers that have SoftwareRevision 02.00, check the temperatures of the air flow thermistors to see if they arenear this range by depressing and holding the F/C switch until the temperature ofthe unheated air flow thermistor appears in the air temperature display and thetemperature of the heated thermistor appears in the control temperature display(approximately 5 seconds). Because the decimal point is not illuminated, you mustdivide the reading by 10 to obtain the temperature.

The second possibility is that the thermal switch has failed in an open position.Disconnect the power cord and do a continuity check between the two terminals ofthe thermal switch. The resistance should be less than 1 Ohm.

The third possibility is a shorted solid state relay. Replace the relay. If the problempersists, replace the control board.

13. E14, Alarm Oscillator Failure

An alternating two tone alarm signal has been activated, but the 2 kHz signal atTP2-1 is not toggling.

To troubleshoot this failure, an alternating two tone alarm must be active. If there isno error code displayed, trigger an alarm by disconnecting the patient temperatureprobe while in the patient control mode.

If you hear the alarm (i.e. the 2 kHz signal is present), the microcontroller or the I/Oexpander (U15) may be faulty. Since these are not socketed chips, control boardreplacement is recommended.

If you do not hear the alarm (i.e. the 2 kHz signal is missing), the timing circuit orone of the circuits that gate the timing circuit inputs may be faulty. Since thesechips are not socketed, control board replacement is recommended.

Softw

are

Revi

sion

03.

10 a

nd L

ower

4/Troubleshooting

4-17 4-176600-0017-000 03/12/98


A software upset has caused the watchdog timer to time out and the system isunable to recover because critical parameters (e.g. control temperature) stored inthe RAM may have been altered.

This error does not necessarily indicate a hardware failure. Power the incubator up.If the error does not recur, allow the unit to run for half an hour. Then check thenumber of recoverable software upsets that have occurred by depressing andholding the Override switch until a new value appears in the control temperaturedisplay (approximately five seconds). If FF appears in the control temperaturedisplay, no software upsets have occurred. Complete the Checkout Procedure andreturn the unit to service.


15. E16, Safety Relay Test Failure (applies only to controllers with serial numbersbeginning with HBJ)

On power up, the safety relay does not open. Repeat the test by turning off thepower, waiting approximately 5 minutes, and turning the power back on.

If the failure recurs, replace the control board.


The software is not cycling through all of the routines and is unable to recover.



17. E18, Air Temperature Sensor Out of Tolerance

This failure is normally caused by a faulty air temperature sensor. Power the unitup from a cold start with an air control temperature of 39°C. When the error occurs,observe the difference between the air control and air display thermistor readingsby pressing and holding the Override switch until the air control temperatureappears in the patient temperature display (approximately five seconds). Comparethis temperature to the air display temperature. If the difference exceeds 0.5°C,replace the air temperature sensor and repeat the test. If the error persists, replacethe control board.


The watchdog timer has timed out 256 times since power up. This error can becaused by a software upset and does not necessarily indicate a hardware failure.


If another value appears in the control display, replace the control board.


er

4/Troubleshooting

4-18 4-186600-0017-000 03/12/98

19. E20, Air Flow Sensor Failure (applies to controllers that have Software Revision02.00).

The temperatures of the heated and the unheated air flow sensor thermistors differby less than 5°C for two minutes.

Depress and hold the F/C switch until new values appear in the air temperatureand control temperature displays (approximately five seconds). The heated ther-mistor signal appears in the air temperature display and the unheated thermistorsignal appears in the control temperature display. Divide both values by 10 toconvert them to degrees centigrade. If the resulting temperatures differ by less than5°C, replace the air flow sensor. Check continuity across the sensor resistor (J5pins 6 and 5) to verify that it contains a bad circuit. If the resistor has not opened orthe problem persists, replace the control board.

20. E21, Air Flow Sensor Open or Shorted (applies to controllers that have SoftwareRevision 02.00).

Note: This failure can be triggered if a very cold incubator (<12°C) is put intoservice without being allowed to warm up.

The temperature of either thermistor in the air flow sensor is outside the 12 to120°C range, indicating a short or open circuit.

Depress and hold the F/C switch until the heated thermistor signal appears in theair temperature display and the unheated thermistor signal appears in the controltemperature display (approximately five seconds). If the readings are outside thespecified range, replace the air flow sensor. Perform a continuity check on thethermistors in the old sensor to verify that it indeed contains a bad circuit. If theresistance indicates either an open or a short between J5, pins 8 and 7 or pins 4and 3, discard the sensor. If the sensor tests out as good or the problem persists,replace the control board.

4.2 Power Up TestsWhen power is first applied, the following self tests are performed. Specific test infor-mation for troubleshooting purposes is given in Section 4.1.B.

1. Instruction Test (E01)

2. EPROM Checksum Test (E04)

3. RAM Test (E05)

The power up test sequence is accompanied by a series of power up displays:

1. An alternating two tone audible alarm sounds for approximately five seconds, allthe indicators illuminate and 188.88 appears in the temperature displays.

2. All indicators go out except the air control and the enable indicators. The tempera-ture displays change to show from left to right:


XX.XX 60.H 39.0°C(software revision (AC frequency (max. manual01.01 etc.) 50.H for 50 Hz control temp.)

models)

3. An operator prompt tone sounds and the control temperature display flashes33.0°C. The operator prompt tone will sound every two seconds until a controltemperature is entered.

Softw

are

Revi

sion

03.

10 a

nd L

ower

4/Troubleshooting

4-19 4-196600-0017-000 03/12/98

4.3 On Line TestingThe incubator continuously performs the following tests during normal operation. Anerror in any of the tests triggers the system failure alarm. The corresponding error codewill appear in place of the control temperature. Specific test information for trouble-shooting purposes is given in Section 4.1.B.

1. ADC Calibration Test (E02 and E03)

2. ADC Failure (E07)

3. S/O Circuit Not Working (E08)

4. Incorrect Dipswitch Setting (E09)

5. Air Display Sensor Bad (E10)

6. Air Control Sensor Bad (E11)

7. Heater Not Switching On or Off (E12 or E13)

8. Alarm Oscillator Test (E14)

9. Software Upset, Watchdog Timer (E15)

10. Software Upset, Not Cycling Through All Routines (E17)

11. Air Temperature Sensor Out of Tolerance (E18)

12. Software Upset, Excessive Watchdog Resets (E19)

13. Air Flow Sensor Failure (E20) on controllers with Software Revision 02.00

14. Air flow Sensor Open or Shorted (E21) on controllers with Software Revision 02.00

4.4 ThermaLink Option Self Test

The ThermaLink Option is available only on controllers with serial numbers beginningwith HBJ and HCE. To test the RS-232 portion of the option on older communicationboards equipped with the test switch, set switch SW1 to the ON position. Newer boardshave no switch and can be tested by shorting pins 2 and 3 on the “D” connector.Disconnect cable to other equipment before testing. Press the override switch whilepowering up the unit. Release the switch when a continuous alarm sounds. If the RS-232 is functioning, the temperature displays will cycle to a frame that shows:

rs 232 PASS

Conversely, if the RS-232 is not functioning, the temperature displays will cycle to aframe that shows:

rs 232 FAIL

At the end of this test on older units with the switch, be sure to set the SW1 to the OFFposition for normal operation.

4/Troubleshooting

4-20 4-206600-0017-000 03/12/98

4.5 On Demand Testing

There are two types of on demand testing: a combination RAM Memory display loopthat cycles through the power up tests and checks display board functions; and specialswitch activated displays, which display various parameters to aid in diagnosingproblems. The specific troubleshooting applications of individual on demand tests arediscussed in Section 4.1.B.

A. RAM Memory Display Loop

1. Self Tests

To enter this loop depress and hold the Override switch while powering up the unit.The microcontroller cycles through a series of self tests, including:

All of the power up testsInstruction Test (E01)EPROM Checksum Test (E04)RAM Test (E05)

The following on line self testsADC High Calibration Failure (E02)ADC Low Calibration Failure (E03)ADC Failure (E07)Air Display Sensor Bad (E10)Air Control Sensor Bad (E11)Heater Not Switching On (E12)Heater Not Switching Off (E13)Alarm Oscillator Failure (E14)ThermaLink Self Test*

Important Unless you specifically want to repeat the power up tests, troubleshooting shouldbe performed in the normal operational modes.

2. Displays

The display loop runs simultaneously with the self tests, displaying frames of dataand testing for proper LED operation. Frames are cycled as follows:

Temperature Displays

Frame Patient Temp. Air Temp. Control Temp.

1. ——— All displays blank; Alternating two tone alarm ———

2.* rs 232 PASS /FAIL

3. Patient Temp. Air Display Temp. Air Control Temp.

4. Low Cal. Point High Cal. Point %Nom. Voltage x .1

5. ——— All displays read 188.88 and all LEDs illuminate ———

* Only on controllers with software revision 03.00 or higher. If the unit does not have ThermaLink installed, “RS232 FAIL”will appear during this test.

4/Troubleshooting

4-21 4-216600-0017-000 03/12/98

B. Switch Activated Displays

In normal operation, the Alarm Silence, the Enable, the Override, the F/C, the PatientControl, and the Air Control switches activate service displays when held down formore than five seconds. An alarm also sounds to indicate that actual patient and airtemperatures are not displayed. The normal display reappears when you release theswitch.

The following table summarizes the data that will be displayed when each switch isdepressed and held for at least five seconds. It is intended as a quick reference. Switchapplications for troubleshooting are discussed in Section 4.1.B under the individualerror codes.

Important Continue to hold down the switch for as long as you wish to view the specialservice display. The normal display reappears when you release the switch.

Patient Air ControlSwitch Temperature Temperature Temperature

Alarm* 188.88 188.88 188.88Silence

Enable Low cal. point High cal point % of nominal voltage(nominal 25.05°C) (nominal 37.97°C) XX.XX = XXX.X%;

100 ± 2% at 115 VAC(Ok if between 90 &110%)

Override Air control temp Air display temp FF - # software upsets(XX.XX C Format) (XX.XX C Format) (hexadecimal down

counter)

Air Patient temp XX.YY Air control tempControl (XX.XX C Format; (XX = avg. power, or DET (updated

includes temps out- YY =% max. power) every 10 min)side normal range)

°F/°C Patient temp Heated air flow Temp of referenceXX.XX C Format; sensor thermistor.† air flow sensorincludes temps Decimal point not thermistor.‡outside normal shown, divide by Decimal point notrange) 10 to obtain °C shown, divide by

10 to obtain °C

Patient ADC counts for ADC counts for ADC counts forControl patient temperature unheated air line voltage

thermistor. flow sensorthermistor§

* All display board LEDs illuminate to test proper operation.

† On units with Software Revision 03.00 or higher, display shows 00.00

‡ On units with Software Revision 03.00 or higher, display shows Fan RPM

§ On units with Software Revision 03.00 or higher, display is blank

4/Troubleshooting

4-22 4-226600-0017-000 03/12/98

4.6 Test Points

Control board test points are accessible when the controller is removed from the unit.Specific application of test point readings to various error codes is discussed in Section4.1.B. Individual test points and their expected readings are as follows:

Important: The 1.0 reference voltage varies by up to 20 percent between units. Hencethermistor resistance rather than signal voltage should be used to check temperaturemeasurements.

Reference the appendix tables for summaries of the resistance versus temperature.

Tests Points - Software Revision 04.00 or HigherTest Point Description & Reading

TP1-1 + 5 Volts Stby (5 ± 0.3 Vdc)TP1-2 Alarm signal, when jumped with TP1-1 will short audio transducer

to temporarily silence alarm (FOR USE DURING SERVICE ONLY!)TP1-4 2 kHz Frequency (2 kHz ± 100 Hz)*

(measure during calibration loop)TP1-5 Air Display SignalTP1-6 S/O Air Display Sensor Short or Open Signal (low = sensor

circuit shorted or open)TP1-7 OT Air Display Over Temperature Signal (high = high temp.

alarm active)TP1-8 Fan Sensor (3.0 Vdc)*TP1-17 Heater Control Signal (Low = Heater ON)

TP1-20 9.8 ± 0.05 Vdc*TP1-21 + 8 Volts Unregulated (8 ± 1.5 Vdc)TP1-24 GroundTP1-25 Battery Voltage (+9 Volts STBY (9 ± 0.3 Vdc)TP1-28 + 5 Volts Disp (5 ± 0.3 Vdc)

* Refer to calibration section for adjustment procedure

4/Troubleshooting

4-23 4-236600-0017-000 03/12/98

Test Points - Software Revision 03.10 and LowerTest Point Description & Reading

TP1-1 9.8 ± 0.05 Vdc*TP1-2 A/D Hi (.37 Vdc)† (On controllers that do not have HBJ or HCE

serial numbers, TP1-2 is Line Compensation, reading 0.7 Vdc)TP1-3 + 5 Volts Disp (5 ± 0.3 Vdc)TP1-4 + 5 Volts Stby (5 ± 0.3 Vdc)TP1-5 + 8 Volts Unregulated (8 ± 1.5 Vdc)TP1-6 + 9 Volts Stby (9 ± 0.3 Vdc)TP1-7 Fan Sensor (3.0 Vdc)* (controllers HBJand HCE serial

numbers only)TP1-8 Logic GroundTP2-1 2 kHz Frequency (2 kHz ± 100 Hz)*

(measure during calibration loop)TP2-2 Heater Control Signal (Low = Heater ON)TP2-3 + 1 Volt Thermistor Reference (1.0 ± 0.2 Vdc)TP2-4 + 2 Volt A/D Reference Signal (about 2.0 Vdc)†TP2-5 S/O Air Display Sensor Short or Open Signal (low = sensor

circuit shorted or open)TP2-6 OT Air Display Over Temperature Signal (high = high temp.

alarm active)TP2-7 Air Display SignalTP2-8 Logic GroundTP3-1 SW1-1 (U17, P6.0)TP3-2 SW1-2 (U17, P6.1)TP3-3 SW1-3 (U17, P6.2)TP3-4 SW1-4 (U17, P6.3)TP3-5 SW1-5 (U17, P7.0, not used)TP3-6 SW1-6 (U17, P7.1)TP3-7 SW1-7 (U17, P7.2)TP3-8 SW1-8 (U17, P7.3)TP3-9 + 5 Volts Stby (5 ± 0.2 Vdc)TP3-10 to TP3-12 (not used)

* Refer to calibration section for adjustment procedure.

† Nominal value, adjusted as part of ADC calibration.

4/Troubleshooting

4-24 4-246600-0017-000 03/12/98

Notes

5/Repair Procedures

5-1 5-16600-0017-000 03/12/98

5/Repair Procedures

WARNINGS w Before any disassembly or repair, disconnect the electrical supply andany gas supply connections. Also remove any accessories. Do not per-form any service or maintenance with the power applied unless specifi-cally told to do so in the procedure.

w Disconnect power to the incubator and allow the heater to cool ad-equately before servicing or cleaning to avoid the danger of a burn.

w Never oil or grease oxygen equipment unless a lubricant that is made andapproved for this type of service is used. Oils and grease oxidize readily,and in the presence of oxygen, will burn violently. Vac Kote is the oxygenservice lubricant recommended (Stock No. 6700-0092-200).

CAUTIONS w Insulation on the electrical wiring can deteriorate with age. When performingthe Checkout Procedure, check for brittle or deteriorated insulation on thepower cord.

s Use the Static Control Work Station (Stock No. 0175-2311-00) to help ensurethat static charges are safely conducted to ground. The Velostat material isconductive. Do not place electrically powered circuit boards on it.

5.1 Hood Repair

Important In cases where total disassembly is not required, replacing an end porthole forexample, perform only the necessary steps.

Note: You must depress the hood tilt button to open or close the hood.

Refer to Figures 5-1, 5-2 and 5-3.

1. Turn the power switch OFF and unplug the unit.

2. If the incubator was previously on, allow it to cool for at least 15 minutes.

3. Remove the front door by opening it to reveal the two spring loaded hinge pins thatattach the door to the lower unit. Pull both pins out towards the sides of the hoodand lift off the door.

4 Remove the inner wall as shown in Figure 5-1.

CAUTION w Inner wall fasteners are permanently attached to the inner wall and cannot beremoved without damaging them.

a. Remove the rear inner wall by pulling out the plunger portion of the inner wallfasteners.

b. To remove the upper inner wall, open the hood and pull out the plunger portionof the inner wall fasteners while supporting the wall.

5/Repair Procedures

5-2 5-26600-0017-000 03/12/98

Figure 5-1Remove the Inner Wall

5. To remove the outer hood (Figure 5-2):

a. Lower the outer hood.

b. Remove the air temperature sensor from the hood by: unscrewing the nut andscrew that anchors the sensor cable; removing the two Phillips head screwsthat hold the sensor mounting blocks and spacers in position; and then slidingthe air temperature sensor out of the hood.*

* For units with a humidity sensor mounted, follow the Humidity Sensor Replacement instructions in the humidifier manual.The humidity sensor must be disconnected from the humidifier controller and removed from the hood by sliding the cablethrough the hole in the hood.

c. Remove the nut and screw that attach the hood to the hood tilt latch (rear, righthand corner of the incubator).

d. Remove the two Phillips head screws used to secure the back of the hood tothe base hinges.

Note: Use Loctite when replacing the hinge screws. First fully tighten the lefthinge screw then back it out one to one and a half turns. Push the hood to theleft, then tighten the right screw just until screw head touches snug aqainst thehinge bracket.

CaptiveFasteners

RearInner Wall

CI.0

2.07

1

CI.0

2.05

0

UpperInner Wall

Hood TiltRelease

Plunger

Inner Wall

Pull outPlungerto Remove

CI.0

2.07

0

HolePlugs

Detail of Captive Fastener

Mounting Post

MountingPosts

Single Walled Unit Double Walled Unit

5/Repair Procedures

5-3 5-36600-0017-000 03/12/98

Figure 5-2Remove the Outer Hood

6. Remove hood hardware as follows (Figure 5-3):

a. To remove the portholes, unscrew the mounting posts on either side. Ondouble-walled units this means you may have to remove the inner wall.

b. To remove the side or rear seals, first remove the outer hood. Then remove thehinge covers, the nut and screw that secure the hood tilt latch, and the Phillipshead screws that hold the lower bars in position.

Note: Since this is a lengthy procedure it is recommended that all seals bereplaced at the same time.

c. Inner wall fasteners should not be removed. To install a new fastener, insert thesocket portion into the proper hole and push the plunger in.

Mounting BlockAir Temperature Sensor

Shims

Screw

Hinge Cover

Hinge Screw

Hinge CI.0

2.15

0

Mounting Block

Screws

Cable Anchor

Nut

Filter Cover

FilterMountingKnobs

5/Repair Procedures

5-4 5-46600-0017-000 03/12/98

Figure 5-3Remove hood hardware

d. To remove the porthole cuff, open the porthole and slip the larger cuff band outfrom under the outer ring on the porthole housing.

e. To remove the porthole seal, open the porthole and slip the seal over the outerring of the porthole housing.

Reverse the steps for assembly. Slip the seal over the outer ring on the portholehousing. To install new porthole cuffs, slip the larger cuff band over the outer ring of theporthole housing. To reattach the inner wall fasteners, line up the fasteners with themating mounting posts and push in the plunger portion of the fastener. When reattach-ing the hood tilt latch, do not over tighten the nut as this may inhibit the up and downmovement of the hood.

PortholeHingeCover Nut Seal

Lower Bar(Rear,Exterior)

HolePlug

MountingPosts

SealTrimStrip

Lower Bars(Interior)

Lower Bar(Side,Exterior)

CI.0

2.15

5

5/Repair Procedures

5-5 5-56600-0017-000 03/12/98

Figure 5-4Front Door Disassembly

Plunger

Pull outPlungerto Remove

InnerWall

MountingPost

Detail of Captive Fastener

CI.0

2.07

0

5.2 Front Door Repair

Important The front door seals are permanently attached and cannot be replaced individually.If they are damaged, a new outer front door must be installed.

1. Remove the front door by opening it to reveal the two spring loaded hinge pins thatattach the door to the base. Pull both pins toward the sides of the hood and lift offthe door.

2. Pull out the plunger portion of the inner wall fasteners to remove the inner wall.

CAUTION w Inner wall fasteners are permanently attached to the inner wall and cannot beremoved without damaging them.

3. To remove the hinge pin and hinge pin assembly, remove the three Phillips headscrews that secure it to the front door.

4. To remove a front door latch, loosen the set screw that secures the external knob.The curved washer and the internal latch will then slide off as shown in Figure 5-4.

5. To remove the portholes, unscrew the mounting posts on either side of the port.

6. Inner wall fasteners should not be removed. To install a new fastener, insert thesocket portion into the proper hole and push the plunger in.

HingeAssembly

CI.0

2.19

2

Curved WasherScrew (6)

Mounting Post

External Knob

Outer Front Door

Porthole

Inner WallDeflector Panel

5/Repair Procedures

5-6 5-66600-0017-000 03/12/98

5.3 Air Temperature Sensor Replacement

WARNING w Two people are required to lift the Care Plus Incubator. Follow safe liftingtechniques to avoid injury.

Note: The air temperature sensor is located inside the infant compartment and shouldnot be confused with the fan sensor or the air flow sensor located on the rear of thecontroller.Temperature sensor replacement changes for units with a humidity sensorinstalled. See Servo-controlled Humidifier O, M &S manual for additional information.

1. Remove the inner walls on double walled units.

2. Lower the outer hood and close the front door.

3. Slip the sensor cable out of the retaining clip on the underside of the incubator.

Note: Early units use a screw and cable anchor to secure the cable. This requiresthat you unscrew the mounting knobs securing the incubator to the cabinet and laythe unit down on its side to remove the screw.

4. Remove the two Phillips head screws and shims that attach the air temperaturesensor mounting blocks to the outer hood. Then slide the air temperature sensorout of the hood (Figure 5-2).

5. Unscrew the filter mounting knobs. Remove the filter cover and filter.

6. Unplug the air temperature sensor from the controller.

7. Pull the old air temperature sensor assembly out of the incubator.

8. Connect the new air temperature sensor to the controller.

9. Slip the new cable into the retaining clip. In older units, replace the screw and cableanchor with one of the new clips (Stock No. 6600-0145-400) and remount theincubator.

10. Route the cable out the rear of the base, through the hole near the air filter, andaround the filter. Refer to Figure 6-8 for cable routing.

11. Replace the filter. Secure the filter cover with the filter mounting knobs. The hole onthe top of the filter cover should line up with the cable.

12. Open the front door and rotate the hood to the open position.

13. Insert the air temperature sensor through the hole in the outer hood. Slide thesymmetrical mounting block, backed by the two shims, over the sensor from theinside of the hood. Align the cable guard on the other block with the sensor cableon the outside of the hood. Secure the blocks with the two remaining Phillips headscrews.

14. Anchor the sensor cable to the outer hood.

15. On double walled units, replace the inner wall.

5/Repair Procedures

5-7 5-76600-0017-000 03/12/98

Figure 5-5Base Platform Cover Removal

Filter

Humidifier

Mattress

Controller

FilterCover

Base Platform

TiltAssemblies

Slide

Lid

MattressTray Base

PlatformCover

Locking Tilt Units

CI.0

2.18

5C

I.02.

072

Continuous Tilt Units

Bed Lifter

Actuator Rod

5/Repair Procedures

5-8 5-86600-0017-000 03/12/98

5.4 Base Platform Cover Replacement

1. Remove the front door by opening it to reveal the two spring loaded hinge pins thatattach the door to the base. Pull both pins toward the sides of the hood and lift offthe door.

2. Depress the hood tilt release button and rotate the hood back into the lockedposition.

3. Remove the mattress and the mattress tray.

4. For locking tilt assembly units, remove each tilt assembly by pulling up on the tilthandle. The assemblies will slide out of their retaining sockets.

For continuous tilt assembly units, unlatch the knob assembly and swing it awayfrom the incubator, grasp the actuator rod and lift the bed lifter/actuator rod assem-bly straight up to remove it.

5. Lift out the base platform cover.

6. Reverse steps 1 through 5 for reassembly.

5.5 Controller Access

1. Disconnect the power cord, the patient probe, the air temperature sensor, and, if itis installed, the ThermaLink cable from the controller.

2. Lift up the controller latches and slide the controller forward, out of the incubator.


3. Remove the Phillips head screws and lock washers used to attach the controllercover.

4. Lift off the controller cover.

s5.6 Control Board Replacement

CAUTION w Make sure the control board connectors are properly aligned before applyingpower.

1. Access the controller as described in Section 5.5.

2. Disconnect control board connectors J1, J2, J3, J4, J5 and, if applicable, J6.

3. Remove the four lock nuts that secure the control board.

4. Lift the board out of the controller.

5/Repair Procedures

5-9 5-96600-0017-000 03/12/98

Solid State Relay

Black

Red

Relay Mounting Nuts

5. Position the new control board so that J3 is at the front of the controller. Replacethe four lock nuts to secure the board to its mounting standoffs (Figure 5-6).

6. Reconnect J1, J2, J3, J4, J5 and, if applicable, J6. Connector pins are numberedfor proper alignment.

Note: If you have an old version Thermalink board installed (which can be identifiedby having a test switch on the board), you must first remove key pin 4 from theribbon cable (6600-0240-700) connector before attaching it to J6 on the controlboard.

7. Make sure that switches 1, 2, 7 and 8 are set to OFF (open position). This selects amaximum control temperature of 39°C and disables the calibration and serviceloops. Make sure that dipswitches 3 and 4 are in the same position as on theprevious board.

8. Perform the Calibration Procedure in Section 3.4.

9. Replace the controller cover, using the Phillips head screws and lock washerspreviously removed.

10. Pull up on the controller latches. Carefully slide the controller back into the incuba-tor. Push down on the latches to secure the controller.

11. Perform the Checkout Procedure in Section 2.6. Listen for any grating soundcaused by the fan rubbing against the base platform. Adjust the fan position ifrubbing is present.

12. Perform the Electrical Safety Check in Section 3.5.

Figure 5-6Controller Interior

Yellow

Orange

Lock Nuts(ControlBoard)

Screws(Solid StateRelay)

J1C

I.02.

116

ControlBoard

J3

J2J5J4

5/Repair Procedures

5-10 5-106600-0017-000 03/12/98

s5.7 Display Board Replacement

A. Replacement on units with HBJ and HAG serial numbers.


2. Turn the controller upside down and remove the lower three front panel mountingscrews, shown in Figure 5-7.

3. Turn the controller right side up and remove the remaining front panel mountingscrews, shown in Figure 5-7.

4. Lift off the front panel.

5. Disconnect J3 from the control board. On controllers that have serial numbers thatbegin with HAG, remove the nut that anchors the ground wire to the upper leftcorner of the display board.

Figure 5-7Replace the Display Board

Front Panel Mounting Screws (2)

Lock Washer

ESD ShieldFront PanelMounting Screw (3)Display Board

Board MountingNuts (5)

CI.0

2.11

7

5/Repair Procedures

5-11 5-116600-0017-000 03/12/98

6. On controllers that have serial numbers that begin with HBJ:

a. Remove the screws, nuts and washers that secure the ESD shield.

b. Remove the ESD shield and the nylon spacers.

7. Remove the existing display board.

8. Disconnect J8 from the existing display board.

9. Connect J8 to the replacement display board.

10. Place the new board component side down on the board standoffs with J8 pointingtoward the bottom of the controller.

11. Connect the cable from J8 to control board connector J3.

12. Connect the temperature sensor and power cord to the controller. Plug the powercord into a power outlet and switch the controller ON.

13. If the display is too dim, complete section 3.4C to adjust the brightness.

14. Switch the controller OFF and unplug the power cord and temperature sensor.

15. On HBJ serial number units:

a. Replace the nylon spacers on the standoffs.

b. Check to be sure there are no rips in the ESD shield. Thread the cable from J8through the slot in the ESD shield.

c. Replace the ESD shield, taking care not to rip it.

d. Replace the five lock nuts that anchor the board to the controller.

Figure 5-8Display Panel Grounds controllers with HAG serial number

Tab

Screw

Screw

ControllerGround

Lock Washer

Lock Washer

Display BoardGround

Display Board(Solder Side)

Lock Nuts (5)C

I.02.

140

5/Repair Procedures

5-12 5-126600-0017-000 03/12/98

16. On HAG serial number controllers:

a. Replace the five lock nuts that anchor the board to the controller. Use the upperleft hand nut to anchor one end of the short (display board) ground wire.

17. Replace the 5 mounting screws to reattach the front panel as in Figure 5-7.





B. Replacment on units with HCE serial numbers only


2. Turn the controller upside down and remove the lower three front panel mountingscrews, shown in Figure 5-7.

3. Turn the controller right side up and remove the remaining front panel mountingscrews, shown in Figure 5-7.

4. Lift off the front panel.

5. Remove the screws, nuts and washers that secure the ESD shield, and remove theESD shield and the nylon spacers. See Figure 5-9.

6. Seperate the existing display board from the control panel assembly by disconnect-ing J7 on the display board.

7. Disconnect J8 from the existing display board.

8. Connect J8 to the replacement display board.

9. Place the new board component side down on the board standoffs with J8 pointingtoward the bottom of the controller.

10. Connect the control panel assembly ribbon cable to J7 on the display board

11. Connect the cable from J8 to control board connector J3.

12. Connect the temperature sensor and power cord to the controller. Plug the powercord into a power outlet and switch the controller ON.

13. If the display is too dim, complete section 3.4C to adjust the brightness.

14. Switch the controller OFF and unplug the power cord and temperature sensor.

Units

with

HCE

ser

ial n

o. c

ontro

llers

Onl

y

5/Repair Procedures

5-13 5-136600-0017-000 03/12/98

15. To replace the ESD shield:

a. Replace the spacers on the standoffs.

Note: Earlier versions of the display board used plastic spacers. If youare replacing the display board with the newer, surface mounted board(6600-0512-700) these spacers must be replaced with the metal spacersprovided with the board.

b. Check to be sure there are no rips in the ESD shield. Thread the cable from J8through the slot in the ESD shield.

c. Replace the ESD shield, taking care not to rip it.

d. Replace the four lock nuts that anchor the board to the controller.

Figure 5-9Display Panel controllers with HCE serial number

16. Replace the 5 mounting screws to reattach the front panel as in Figure 5-7.





CI.0

2.19

7

ESDShield

DisplayBoard

ControlPanelAssembly

Units with HCE serial num

ber controllers OnlySpacerStandoff

5/Repair Procedures

5-14 5-146600-0017-000 03/12/98

5.8 Solid State Relay Replacement

(Figure 5-6)

Note: There are several manufacturers for the solid state relay. The replacement relaymay not be identical to the one being replaced.

The solid state relay is located on the same side of the controller as the power socket.It is attached to the controller with two Phillips screws and two lock nuts.


2. Remove the two screws used to mount the relay and the metal oxide varister (ifpresent).

3. Lift the relay out of the controller.

4. Remove the screws that attach the wires to the solid state relay.

5. Install the new metal oxide varister across terminals 1 and 2 on the relay andconnect the wires to the new solid state relay as follows:

Wire Color Pin

Orange 1

Yellow 2

Red 3

Black 4

6. Use the two Phillips screws and the two lock nuts to attach the new relay to theside of the controller. Pins 3 and 4 should be toward the front of the controller.





5/Repair Procedures

5-15 5-156600-0017-000 03/12/98

5.9 Heater and/or Heater Gasket Replacement

CAUTION w If gaskets are not installed properly, water can leak in during cleaning anddamage the electronics.

A. Heater and/or heater gasket replacement for controllers withserial numbers that begin with HBJ and HCE.


2. Unscrew the fan mounting knob at the end of the fan shaft. Remove the fan.

3. Disconnect the thermal switch wires and the heater wires.

4. Remove the right heater mounting nut to disconnect the harness ground wire.

5. Remove the four mounting screws that attach the back of the controller to thechassis.

6. Slide the back of the controller away from the chassis until it clears the motor shaft.

7. Remove the remaining two heater mounting nuts.

8. Pull off the heater.

Note: The heater gasket will also come off.

9. Align the heater gasket with the new heater. Then slide the heater into the back ofthe controller.

10. Secure the heater to the back of the controller as shown in Figure 5-10.

11. Slide the back of the controller over the motor shaft and replace the four mountingscrews into the chassis.

12. Reattach the thermal switch wires, heater wires, and ground wire.

13. The fan is keyed to fit the shaft. Slide the fan back onto the shaft so that the flatsurface with the holes faces toward the heater.

14. Replace and tighten the fan mounting knob to secure the fan.





Units with HBJ and HCE controller serial num

bers

5/Repair Procedures

5-16 5-166600-0017-000 03/12/98

Figure 5-10Heater, Thermal Switch and Fan Sensor Replacement

Controllers With Software Revision03.00 or Higher

Fan Knob

Studs

Heater

Heater Gasket

Rear Controller Seal

Rear Controller

Fan

Rear Controller Air Seal

Fan Motor Bracket

Motor Mount

Motor Shaft Seal

Fan Motor Shaft

Ferrel

Thermal Switch

Thermal Switch Screws

Thermal Switch Gasket

Fan SensorAssembly

Fan Motor

CI.0

2.11

2

FanKnob

Studs

Heater

Heater Gasket

Fan

Controller Ground

WasherLock Nut

Thermal Switch Gasket

Air Flow Sensor

Thermal SwitchThermal Switch Screws

Gasket (Airflow Sensor)

Controllers with Software Revision 02.00

Thermal SwitchHardware

To J5

AirflowSensorHardware

CI.0

2.15

7

Note: Air flow sensors are no longer available.They must now be replaced with the opticalsensor, which involves the replacement of thecontrol PCB, the rear controller, fan motorshock mounts, fan, seals and gaskets. SeeSection 6 for Optical Sensor/Rear ControllerReplacement Kit.

5/Repair Procedures

5-17 5-176600-0017-000 03/12/98

B. Heater and/or heater gasket replacement for controllers withserial numbers that begin with HAG.

CAUTIONS w If early model heaters are not installed with the nuts on the inside of the con-troller and the screws on the outside, water can leak in during cleaning anddamage the electronics.

w If gaskets are not installed properly, water can leak in during cleaning anddamage the electronics.


2. Unscrew the fan mounting knob at the end of the fan shaft. Remove the fan.

3. Remove the top two heater mounting nuts on the back of the controller.

4. Disconnect the white wires from the heater.

Note: On some very early models, the heater wires are terminated with ringterminals. If you are replacing one of these heaters, remove the ring terminals fromthe wires and replace them with Faston 250 terminals.

5. Remove the lower heater mounting nut. The nut is accessed through a hole in themotor mounting bracket.

Note: On early units you must remove the control board and the motor bracket toinstall a new heater.

6. Pull off the old heater.

Note: The heater gasket will also come off.

7. Align the heater gasket with the new heater and slide the new heater into the backof the controller.

8. Secure the heater to the rear of the controller as shown in Figure 5-10.

9. If necessary, remount the motor bracket and the control board.

10. Reattach the white wires to the heater.

11. The fan is keyed to fit the shaft. Slide the fan back onto the shaft so that the collarpoints toward the heater.

12. Replace and tighten the fan mounting knob to secure the fan.

13. Reattach the controller cover, using the six Phillips head screws and lock washerspreviously removed.


15. Perform the Checkout Procedure in Section 2.6. Listen for any grating soundcaused by the fan rubbing against the base platform. Adjust the heater and fanposition if rubbing is present.


Units with HAG serial num

ber controllers Only

5/Repair Procedures

5-18 5-186600-0017-000 03/12/98

5.10 Thermal Switch Replacement

CAUTION w If gaskets are not installed properly, water can leak in during cleaning anddamage the electronics.

Note : It is not necessary to remove the heater.


2. Unscrew the fan mounting knob and remove the fan.

3. Disconnect the wires attached to the thermal switch.

4. Remove the screws securing the thermal switch and pull the thermal switch out ofthe controller as shown in Figure 5-10. Position your hand inside the controller tocatch the mounting nuts and lock washers when you remove the screws. Retainthe gasket for use with the new thermal switch.

5. Align the gasket with the new thermal switch and replace the mounting hardwareas shown in Figure 5-10.

6. Reconnect the thermal switch to the wires from J1 pin 2 and the heater. Make surethat there is clearance between the thermal switch wires and the motor.

7. Perform Section 3.4.J of the calibration procedures.



10. Perform the Checkout Procedure in Section 2.6. Listen for any grating soundcaused by the fan rubbing against the base platform. Adjust the heater and fanposition if rubbing is present.


5.11 Fan Sensor Replacement

(Applies only to controllers with fan sensor as shown in figure 5-10)

CAUTION w If the gaskets are not properly installed, water can leak in during cleaning anddamage the electronics.

Note : It is not necessary to remove the heater.


2. Remove the fan from the motor shaft, by removing the knob and sliding the fan offthe shaft.

5/Repair Procedures

5-19 5-196600-0017-000 03/12/98

3. Disconnect the heater wires and the thermal switch wires and the harness groundwire. Then remove the back of the controller from the chassis by removing the fourmounting screws.

4 Disconnect the fan sensor cable from the control board (J5) and remove the cablefrom the two p-clips.

5. Remove the two screws that hold the fan sensor mount to the motor.

6. Mount the replacement fan sensor assembly to the motor with the screws andwashers from the existing assembly.

7. Route the replacement fan sensor cable through the two p-clips and connect it toJ5 on the control board.

8. Attach the back of the controller to the chassis with the four mounting screws. Thenreconnect the heater wires, the thermal switch wires and harness ground wire.

9. Slide the fan back on the motor shaft and secure by tightening the knob.

10. Calibrate the fan sensor as described in Section 3.4I.

11. Replace the controller cover, using the Phillips head screws and lockwasherspreviously removed.

12. Perform the Checkout Procedure in Section 2.6 Controller Check. Listen for anygrating sound caused by the fan rubbing against the base platform. Adjust theheater and fan position if rubbing is present.

13. Perform Electrical Safety Check in Section 3.5.

5.12 Air Flow Sensor Replacement

(Applies only to controllers with air flow sensor shown in figure 5-11. Replacement airflow sensors are no longer available).

CAUTION w If the gaskets are not properly installed, water can leak in during cleaning anddamage the electronics.

Note: It is not necessary to remove the heater.


2. Remove all screws, (nuts on some units) and harness clips that hold the sensor inplace.

3. Disconnect the air flow sensor cable from the control board (J5).

4. Install the new sensor and gasket, making sure that the sensor is oriented asshown in Figure 5-11.

5. Connect the air flow sensor cable to the control board and replace the controllercover.

6. Replace the controller cover using the Phillips head screws and lockwasherspreviously removed.

6600-0017-000 08/28/96

5/Repair Procedures

5-20 5-206600-0017-000 03/12/98

Figure 5-11Air Flow Sensor Installation

ThermistorButton

Air FlowSensor

CI.0

2.15

8

7. Verify that the air flow sensor works as follows:

a. Remove the fan and replace the controller in the incubator, making sure that theair temperature sensor and the power cord are plugged in.

b. Switch the incubator ON. The operator prompt tone will sound. Do not adjustthe control temperature; running the incubator with the heater OFF provides amore thorough test of the air flow sensor.

c. Allow the unit to run for 10 minutes. The front panel air circulation alarm indica-tor should illuminate and an alternating two tone alarm should sound.

d. Depress the °F/°C switch until a different pair of numbers appear in the airtemperature and control temperature displays (approximately five seconds).Continue pressing the °F/°C button and record the numbers that appear in theair and control temperature displays.

e. Subtract the two numbers. The difference must be greater than 230.

f. Switch the unit OFF. Remove the controller and replace the fan. Slide thecontroller back into the incubator and reconnect the power cord and air tem-perature sensor.

g. Switch the unit ON and adjust the control temperature to 39°C. Allow theincubator to run for 10 minutes.

h. Again depress the °F/°C switch until a different pair of numbers appears in theair and control temperature displays (approximately five seconds). Continuepressing the °F/°C button and record the numbers that appear in the air andcontrol temperature displays.

i. Subtract the two numbers. The difference must be less than 190.

5/Repair Procedures

5-21 5-216600-0017-000 03/12/98

8. If the conditions of steps “e” and “i” are not met, the air flow sensor must be replaced.

9. Perform the Checkout Procedure in Section 2.6. Listen for any grating sound causedby the fan rubbing against the base platform. Adjust the heater and fan position ifrubbing is present.


5.13 Fan Motor ReplacementA. Fan motor replacement for units with fan sensors


2. Unscrew the fan mounting knob and remove the fan (refer to Figure 5-10).

3. Disconnect the heater wires, thermal switch wires and harness ground wire. Thenremove the back of the controller from the chassis by removing the four mountingscrews.

4. Remove the old air seal. Use isopropyl alcohol to remove any adhesive residue onthe rear controller.

5. Remove the two mounting screws for the fan sensor.

6. Disconnect the fan motor connector from J1, and the motor ground wire from thecontroller chassis.

7. Remove the four motor mounting screws and slide the motor out of the bracket andthe fan sensor assembly.

8. Pull the small cooling fan off the short motor shaft.

9. Note the orientation of the shock mounts before removing them from the motor bracket.

Figure 5-12Fan Motor Replacement on HBJ and HCE controllers

CI.0

2.11

3

Sensor AssemblyMounting Hardware

Fan Sensor Assembly

Shaft Air Seal

Motor Shaft

ScrewWasherShock MountFerrule

Fan MotorMountingBracket

Fan Motor

5/Repair Procedures

5-22 5-226600-0017-000 03/12/98

10. Install the new shock mounts in the motor bracket. Then install the ferrules in theshock mounts.

11. Attach the new motor to the bracket as shown in Figure 5-11.

12. Push the cooling fan onto the shorter motor shaft.

13. Reinstall the fan sensor assembly on the motor.

14. Install the new air seal.

15. Slide the long motor shaft through the air seal and into the hole in the rear of thecontroller. Attach the back of the controller to the chassis.

16. Reconnect the heater, thermal switch and ground wires.

17. The fan is keyed to slide onto the motor shaft. Slide the fan onto the shaft so theflat surface with the holes on the fan points toward the motor.

18. Replace the fan mounting knob. Fully tighten the knob.

19. Connect the motor connector to the connector from J1 and the motor ground wireto the controller chassis.

20. Calibrate the fan sensor as described in Section 3.4 I.



23. Perform the Checkout Procedure in Section 2.6. Listen for any grating soundcaused by the fan rubbing against the base platform. If rubbing is present, adjustthe motor and fan position by loosening the motor bracket mounting screws andmoving the motor and bracket.


B. Fan motor replacement for controllers with air flow sensors.


2. Unscrew the fan mounting knob and remove the fan.

3. Disconnect the fan motor connector going to J1 on the control board.

4. Turn the controller on its side and remove the four screws, standard washers andlock nuts used to attach the fan motor bracket to the controller.

5. Remove the control board.

6. Slide the motor assembly toward the front of the controller, until the shaft clears theback of the controller. Then lift the assembly out of the controller.

7. Remove the old air seal. Use isopropyl alcohol to remove any adhesive residue onthe rear controller.

8. Install the new air seal.

5/Repair Procedures

5-23 5-236600-0017-000 03/12/98

Figure 5-13Fan Motor Replacement on controllers with air flow sensor

12. Install the new shock mounts in the motor bracket. Then install the ferrules in theshock mounts.

13. Attach the new motor to the bracket as shown in Figure 5-13, making sure themotor wires reach the wire harness connector.

14. Push the cooling fan onto the shorter motor shaft.

15. Slide the long motor shaft through the air seal and into the hole in the rear of thecontroller.

16. Secure the motor bracket to the controller with the four bracket mounting screws,shown in Figure 5-13.

Motor MountingScrew

Motor Bracket

Washer

Cooling Fan

CI.0

2.15

9

9. Remove the four motor mounting screws and slide the motor out of the bracket.

10. Pull the small cooling fan off the short motor shaft.

11. Note the orientation of the shock mounts before removing them from the motorbracket.

Air SealMotor

KnobFan

Fan

J1

Screws (BracketMounting)

5/Repair Procedures

5-24 5-246600-0017-000 03/12/98

17. The fan is keyed to slide onto the motor shaft. Slide the fan onto the shaft so thecollar on the fan points toward the motor.

18. Replace the fan mounting knob. Fully tighten the knob.

19. Replace the control board.

20. Connect the motor connector to the connector going to J1 on the control board.


22. Pull up on the controller latches. Carefully slide the controller back into the incubator.Push down on the latches to secure the controller.

23. Perform the Checkout Procedure in Section 2.3. Listen for any grating sound causedby the fan rubbing against the base platform. If rubbing is present, adjust the motorand fan position by loosening the motor bracket mounting screws and moving themotor and bracket.


5.14 Battery Replacement1. Access the controller as described in Section 5.5.

2. Remove the battery by sliding the battery away from the contacts.

3. Install the new battery by lining the terminals up with the contacts and sliding thebattery into the bracket.

4. Reattach the controller cover, using the Phillips head screws and lock washerspreviously removed.

5. Pull up on the controller latches. Carefully slide the controller back into the incubator.Push down on the latches to secure the controller.

6. Perform the Checkout Procedure in Section 2.3. Listen for any grating sound causedby the fan rubbing against the base platform. Adjust the heater and fan position ifrubbing is present.


5.15 Continuous Tilt Knob Assembly ServiceNote: It is recommended that only one tilt knob assembly be disassembled at a time, sothat the right and left hand parts are kept separate.

Note: To replace the tilt knob the entire assembly need not be taken apart. Remove theknob by prying it off the assembly. The cable protector ring may also be pried off. Rein-stall the ring by snapping the ridge on the inside of the ring into the groove in the knob.Reinstall the knob by pressing it firmly onto the acme screw. Do not use soap or otherlubricants since they will interfere with the knob’s over torque clutch feature.

Disassembly

1. To remove the tilt knob assembly, pull up the latch on the tilt knob assembly, andswing it out away from the incubator. Then lift the assembly up off the mountingbracket hinge pin. Refer to Figure 5-5.

5/Repair Procedures

5-25 5-256600-0017-000 03/12/98

2. Using a 1/8" hex key, remove the three locking screws that secure the case bracketto the back of the knob assembly case and remove the bracket. Refer to Figure 5-14.

Figure 5-14Right hand Tilt Knob Assembly

3. Check that the latch on the bracket has a positive detent action. If it does not,replace the spring washer.

4. Remove the actuator interface from the rectangular holes in the lever arms.

5. Pry the large ‘E’ clip off the acme screw.

6. Hold the knob assembly case vertically and turn the knob to screw the acme screwout of the acme slide. Remove the acme screw and knob from the case.

7. If debris has built up in the acme screw threads, wipe it away. Do not lubricate theacme screw.

Make note of whether you can see any dots punched on the side of the linkageparts connected to the acme slide. These are orientation marks.

8. Remove the acme slide and linkage assembly from the knob case.

9. Push out the long pin that holds the linkage in the acme slide and inspect it forsigns of wear. Replace it if necessary.

10. Pry the small ‘E’ clip off the 1/4" groove pin that connects the two lever arms to theelbow link and remove the groove pin. Inspect the groove pin for wear. Replace it ifnecessary.

CI.0

2.18

3

KnobCableProtectorRing Acme

Screw

Acme Slide

Delrin Washer

LockingScrew

CaseBracket

LongPin Latch

KnobAssemblyCase

Actuator InterfaceElastic Lock Nut

Latch Pivot BushingSpring Washer

Lever ArmSmall E-Clip

Elbow Link

1/4" Groove Pin

Steel Washer

Large E-Clip

5/Repair Procedures

5-26 5-266600-0017-000 03/12/98

Re-assembly

Note: The tilt knob assembly requires no lubrication. Do not lubricate the knob assembly.

1. Assemble the linkage so that the punched dots on the elbow link and the two leverarms all face the same side.

2. Insert the 1/4" groove pin and snap on the small ‘E’ clip to fasten the linkage partstogether.

3. Insert the linkage into the acme slide and secure it by inserting the long straight pinthrough the holes in the slide and the elbow link.

4. For right hand tilt knob assembly, place the acme slide/linkage assembly into theknob case as shown in Figure 5-14 with the dots on the the linkage facing out, sothat you can see them.

For left hand tilt knob assembly, place the acme slide/linkage assembly into the knobcase with the dots on the the linkage facing in, so that you can not see them.

5. Ensure that the delrin washer is on the outside of the knob case between the knoband the case. Insert the acme screw through the hole in the knob case and the steelwasher on the inside of the case, then thread the acme screw into the acme slide.

6. Place the large ‘E’ clip around the acme screw so that it snaps into the groove onthe screw and holds the steel washer against the wall of the case.

7. Place the actuator interface through the rectangular holes in the lever arms and intothe pivot socket in the case. The open slot in the actuator interface lines up with thelever arm.

8. Secure the case bracket on the back of the knob case with the three locking screwsremoved earlier.

9. Re-mount the tilt knob assembly on the incubator.

10. Check that the tilt knob assembly is secured to the incubator with the latch. Rotateeach tilt knob upward until the bed reaches its highest position. Check that theactuating arm and bed lifter are firmly seated in the cover platform. Rotate the tiltknobs downward and check that the mattress tray slides out when both tilt mecha-nisms are at their lowest positions.

5/Repair Procedures

5-27 5-276600-0017-000 03/12/98

5.16 Cabinet Caster Replacement

WARNING w Two people are required to safely replace a caster. Remove the incubatorand all accessory equipment from the cabinet before replacing a caster.

1. Remove all accessories from the incubator.

2. Remove the incubator mounting knobs (located inside the cabinet), which attachthe incubator to the cabinet.

3. Lift the incubator off the cabinet.

4. Lay the cabinet on its side.

5. Remove the four lock nuts that attach the caster to the cabinet.

6. Remove the old caster.

7. Slide the new caster over the mounting studs.

8. Replace and tighten the lock nuts to secure the caster. Torque to 75 in-lbs.

9. Turn the cabinet right side up.

10. Attach the incubator to the cabinet with the incubator mounting knobs.

5/Repair Procedures

5-28 5-286600-0017-000 03/12/98

Notes

6/Illustrated Parts

6-1 6-1

6/Illustrated Parts

6.1 Hood Components

Item Stock Number1. Front door replacement kit (outer door with hdwe-beige).................. 6600-0148-800

Front door replacement kit (outer door with hdwe-grey) ................... 6600-0504-800Front door replacement kit, Care Plus Access (outer door with hdwe) ...................................... 6600-0082-850†

2. Porthole kit (1) ................................................................................... 6600-0227-800Porthole kit (6) ................................................................................... 6600-0226-800

3. Tubing access cover (beige) obsolete-use greyTubing access cover (grey) ............................................................... 6600-0330-501

4. Screw, 10-24 x 1.000 ........................................................................ 6600-0118-4005. Nylon washer, 0.192 in ID ................................................................. 6600-0103-4006. Nut, ESN, 10-24, SST ....................................................................... 6600-0088-400

Misc. Hood Hardware Stock NumberInner wall fastener (20/pkg) ..................................................................... 6600-0102-800Mounting post .......................................................................................... 6600-0161-700Replacement porthole bumpers (12/pkg) ................................................ 6600-0401-800

4

5

6

3

2

1

CI.0

2.11

4

† Care Plus Access models can be identified by their large hood with 3 tubing access holes on each side.

Figure 6-1Incubator Assembly, Front View

6/Illustrated Parts

6-2 6-2

Item Stock Number1. Hood inner frame, left or right half (beige) obsolete-use grey

Hood inner frame, left or right half (light grey) .................................. 6600-0227-5012. Screw, 10-24 x .875 .......................................................................... 6600-0087-4003. Screw 10-24 x 1.00 ........................................................................... 6600-0118-4004. Screw, 10-24 x 1/2 ............................................................................ 0140-6630-1085. Hood seal (3 ft strip) .......................................................................... 6600-0143-5006. Outer frame, left side (beige) obsolete-use grey

Outer frame, left side (light grey) ....................................................... 6600-0049-4017. Retainer, upper wall (sgle. & dble. wall units) ................................... 6600-0148-5008. Hole plug (sgle. wall units) ................................................................ 6600-0189-7009. Mounting Post (dble. wall units) ........................................................ 6600-0161-70010. Latch flag mask ................................................................................. 6600-1837-10011. Nut, ESN, 10-24, SST ....................................................................... 6600-0088-40012. Hood hinge cover (beige) obsolete-use grey

Hood hinge cover (light grey) ............................................................ 6600-0165-50113. Outer frame, rear (beige) obsolete-use grey

Outer frame, rear (light grey) ............................................................. 6600-0048-40114. Outer frame, right side (beige) obsolete-use grey

Outer frame, right side (light grey) ..................................................... 6600-0050-40115. Trim, outer frame (3 ft strip-black) obsolete-use grey

Trim, outer frame (3 ft strip-dark grey) .............................................. 6600-0166-50116. Baffle, acoustic (beige) obsolete-use grey

Baffle, acoustic (light grey) ................................................................ 6600-0382-501

Not shownHood replacement kit (items 1 - 16, beige) obsolete-use greyHood replacement kit (items 1 - 16, grey) ................................................ 6600-0047-851Hood replacement kit (no hardware) ....................................................... 6600-0033-850Hood replacement kit, Care Plus Access (no hardware)* ........................ 6600-0081-850

*Care Plus Access models can be identified by their larger hood with 3 tubing access holes on each side.

6/Illustrated Parts

6-3 6-3

Figure 6-2Hood Seals and Related Hardware

11

1213

14

15

16284 3 1

7

10

6

5

9

CI.0

2.19

5

CI.0

2.26

6

CI.0

2.26

5

7

8

7

9

6/Illustrated Parts

6-4 6-4

Item Stock Number1. Deflector panel w/ fasteners .............................................................. 6600-0155-7002. Lower wall (front or rear w/ deflector panel) ...................................... 6600-0106-800

Lower wall, Care Plus Access* (front or rear w/deflector panel) ....... 6600-0608-8003. Inner wall, hood (includes all items shown) ....................................... 6600-0040-800

Inner wall, Care Plus Access* (includes upper and lower wall) ......... 6600-0610-8004. Upper inner wall w/ fasteners ............................................................ 6600-0116-8005. Inner wall fastener (20/pkg – also includes 16 deflector spacers) ..... 6600-0102-800

* Care Plus Access models can be identified by their larger hood with 3 tubing access holes on each side.

Figure 6-3Inner Wall Assembly, Hood

5

CI.0

2.19

3

1

4

2

3

6/Illustrated Parts

6-5 6-5

98

45

7

111212

6

3

10

CI.0

2.19

2

Item Stock Number1. Porthole replacement kit(1/pkg) ........................................................ 6600-0227-800

Porthole replacement kit (6/pkg) ....................................................... 6600-0226-8002. Latch assembly ................................................................................. 6600-0273-8003. Porthole seal (6/pkg) ......................................................................... 6600-0221-8004. Left door hinge housing (see detail on next page)5. Gasket, hinge .................................................................................... 6600-0069-5006. Front door replacement kit (outer door with hdwe)(beige) ................ 6600-0148-800

Front door replacement kit (light grey hinge)..................................... 6600-0504-800Front door replacement kit,Care Plus Access (outer door with hdwe)† ......................................................... 6600-0082-850

7. Latch, hood, replacement kit (black knob) (2/pkg) ............................ 6600-0146-800Latch, hood, replacement kit (dark grey knob) (2/pkg)* .................... 6600-0503-800

8. Mounting post .................................................................................... 6600-0161-7009. Lower wall (front or rear deflector panel) ........................................... 6600-0106-800

Lower wall (front or rear deflector panel)-Care Plus Access† ................. 6600-0608-80010. Deflector panel w/ fasteners .............................................................. 6600-0155-70011. Screw, 10-32 x .75, TR...................................................................... 6600-0089-40012. Right door hinge housing (see detail on next page)

Parts Not ShownPorthole bumpers, (pkg of 12) ................................................................. 6600-0401-800Porthole spring kit (includes pins, springs and retaining rings for

6 portholes) ....................................................................................... 6600-0456-800

*Includes latch flag mask (Item 10 on page 6-2).† Care Plus Access models can be identified by their large hood with 3 tubing access holes on each side.

Figure 6-4Front Door and Related Hardware

11

6/Illustrated Parts

6-6 6-6

Item Stock Number1. Left door hinge housing (beige) ......................................................... 6600-0036-402

Left door hinge housing (light grey) ................................................... 6600-0036-4012. Right door hinge housing (beige) ...................................................... 6600-0035-402

Right door hinge housing (light grey) ................................................ 6600-0035-4013. Hinge pin rod* .................................................................................... 6600-0140-5004. Hinge pin spring, CPRSN .................................................................. 6600-0059-4005. Hinge pin release .............................................................................. 6600-0141-500

* Apply Loctite 27741 , Stock No. 0220-5025-300

Figure 6-5Hinge Detail

1 3 2 4 5

CI.0

2.14

2

6/Illustrated Parts

6-7 6-7

Compartment probe and related items

CI.0

2.16

0

23

4

5

6

710

8

9

1

Item Stock Number1. Internal Humidifier fill port kit (w/ o-ring) ............................................ 6600-0070-8002. Nut, Hex, 8-32 ................................................................................... 0202-1008-3003. Cable clamp ...................................................................................... 6600-0144-4004. Screws, #8 x 1" TRH self-tapping ..................................................... 6600-0083-4005. Probe housing, rear cover ................................................................. 6600-0131-5006. Shim .................................................................................................. 6600-0222-5007. Probe housing, front cover ................................................................ 6600-0132-5008. Screw, 8-32 x 1/2, TRS, P ................................................................. 0140-6627-1089. Screw, 1/4-20 x .500, R* ................................................................... 6600-0078-40010. Compartment probe kit†, air temperature sensor

(includesitems 6, 7, 8 and 9) ............................................................. 6600-0071-800

† For humidity sensor parts, see Servo-controlled Humidifier O,M &S manual.

* Apply Loctite 24321, Sock No. 0220-5031-300 to threads, fully tighten, then loosen 1/4 turn.

Figure 6-6Incubator Assembly, Rear View

6/Illustrated Parts

6-8 6-8

6.2 Base Platform Components

Item Stock Number1. Mattress tray ...................................................................................... 6600-0175-5002. Mattress w/cover ............................................................................... 6600-0152-5003. Tilt handle assembly (beige) ............................................................. 6600-0078-800

Tilt handle assembly (grey) ............................................................... 6600-0078-8014. Base platform cover service kit (beige) ............................................. 6600-0111-800

Base platform cover service kit (grey) ............................................... 6600-0111-801Base platform cover service kit, French 220/240 V (beige) ............... 6600-0364-800

5. Hood tilt latch (beige) ........................................................................ 6600-0123-500Hood tilt latch (grey) .......................................................................... 6600-0123-501

6. Spring, hood tilt release, CPRSN ...................................................... 6600-0061-4007. Plunger, hood tilt release................................................................... 6600-0125-5008. Hair pin clip* ...................................................................................... 6600-0104-4009. Order these kits to replace a damaged base platform on units with an external

humidifier or a servo humidifier. If replacing a base platform on a unit with theinternal humidifier (fill port located in the left rear corner) you need to order anupgrade kit. See page 6-10.Base replacement kit (external humidifier) English (beige) ............... 6600-0237-800Base replacement kit (external humidifier) English (light grey) ......... 6600-0237-801Base replacement kit (external humidifier) International (beige) ....... 6600-0238-800Base replacement kit (external humidifier) International (light grey) . 6600-0238-801

10. External humidifier complete (includes items 11-14)† ....................... 6600-0218-80011. Humidifier fill tray (reservoir/sump) ................................................... 6600-0768-50012. Humidifier slide .................................................................................. 6600-0435-50013. Humidifier lid ...................................................................................... 6600-0434-50014. Humidifier seals (2/pkg) ..................................................................... 6600-0220-80015. Filter cover replacement kit (beige) ................................................... 6600-0235-800

Filter cover replacement kit (grey) ..................................................... 6600-0235-801

* Clip on after plunger is installed.

† For Servo-controlled Humidifier, see Servo-controlled Humidifier O,M & S manual.

6/Illustrated Parts

6-9 6-9

Figure 6-7Base Platform, external humidifier and Cover Assembly

CI.0

2.16

9

1

2

14

13

12

11

10

987

6

15

4

5

3

6/Illustrated Parts

6-10 6-10

Item Stock Number1. Internal humidifier fill port kit (port & O-ring)* .................................... 6600-0070-8002. Internal humidifier O-ring* ................................................................. 6600-0065-4003. Screw, 8-32 x 1/4* ........................................................................... . 0140-6627-1044. Screw, 8-32 x 3/8, TRS, P* ............................................................... 6600-0261-4005. Stop clip, sliding tray* ........................................................................ 6600-0162-5006. Nut, elastic 4-40, ST* ........................................................................ 6600-0256-4007. Screw, 4-40 x 1/4, TRS, P* ............................................................... 6600-0125-4008. Nut, KEP, 4-40 W/E* ......................................................................... 6600-0073-4009. Spacer (stopper water fill)* ................................................................ 0217-2848-10010. Filter & replacement date sticker ....................................................... 6600-0043-80011. Filter cover assembly (beige) obsolete-use grey

Filter cover assembly (grey) (Kit includes parts listed below) ........... 6600-0235-801 Filter cover ...................................................................................... 6600-0070-501 Filter cover knob ............................................................................. 6600-0068-501 Knob spring .................................................................................... 6600-0156-400 Nylon washer, .75 OD x .25 ID x .62 ............................................. 6600-0162-400 Knob mounting screw† [† use Loctite #680 (0220-5037-300)] ....... 6600-0252-500

12. Cable clamp ...................................................................................... 6600-0145-40013. Screw, 8-32 x 3/8 .............................................................................. 0140-6127-10614. Washer, Int. Lock #8 ......................................................................... 6600-0262-40015. Controller latch brackets (order separately)

A. Controller latch bracket (left) ......................................................... 6600-0225-500B. Controller latch bracket (right) ....................................................... 6600-0226-500

16. Screw 6-32 x 3/8 ............................................................................... 0142-4163-10617. Cable clamp ...................................................................................... 0208-0335-30018. Screw, #8 x 3/8, TR, PH................................................................... . 0142-2164-20619. Cap and chain ................................................................................... 0217-3785-70020. Nipple, 1/8 NPT x 3/16 hose . ........................................................... 6600-0102-40021. Nut, 1/8 NPT x .125 ........................................................................... 6600-0176-50022. Left external humidifier rail ................................................................ 6600-0677-500

Right external humidifier rail .............................................................. 6600-0676-50023. Screw ................................................................................................ 6600-0078-40024. Washer .............................................................................................. 0202-3216-30025. Pleur-Evac hanger ............................................................................. 6600-0201-500

Not Shown Stock NumberProbe pull kit, “T” handle air temperature sensor .................................... 6600-0138-800Base replacement/upgrade kit (external humidifier style base,labels all lang, complete humidifier, O&M manual) .................................. 6600-0107-800

Note: Newbase has no sliding tray, see page 6-16 for refresherinstructions with beaded chain

* Items 1 - 9 are service parts for the old style internal humidifier base platform. If you mustreplace the base platform itself, you must order the upgrade kit listed in parts not shown. If yourunit has the new external humidifier, to replace the base platform order the kits listed on page 6-8.

Note: To accomodate the larger CarePlus Access hood we now supply thetemperature sensor with longer cables.When this cable is used with a stan-dard size hood, there is more slack inthe cable. Route cable as shown onstandard hood units.

6/Illustrated Parts

6-11 6-11

Figure 6-8Base Platform Hardware (bottom view of platform)

22

13 14

232425

1512 1716

18

20

19

21

11

Obsolete Base Platform

321 4 5 3 6 7

8

CI.0

2.11

9C

I.02.

120

Current Base Platform

10

9

6/Illustrated Parts

6-12 6-12

Continuous Tilt Assembly

Item Stock Nmber1. Acme screw, left ................................................................................ 6600-0509-400

Acme screw, right .............................................................................. 6600-0511-4002. Washer, .758” ID ............................................................................... 6600-0505-4003. Large ‘C’ clip ...................................................................................... 6600-0506-4004. Acme slide, left .................................................................................. 6600-0510-400

Acme slide, right ................................................................................ 6600-0512-4005. Pin ..................................................................................................... 6600-0507-4006. Front bracket, left .............................................................................. 6600-0662-500

Front bracket, right ............................................................................ 6600-0667-5007. Support bracket, left .......................................................................... 6600-0666-500

Support bracket, right ........................................................................ 6600-0668-5008. Lock washer, split SST ...................................................................... 6600-0473-4009. Flat washer, .252 ID, .50 OD ............................................................. 6600-0455-40010. Actuator arm ...................................................................................... 6600-0658-50011. Bed lifter ............................................................................................ 6600-0659-50012. Screw 1/4-20 x.62 BTHD cap (left side) ........................................... 6600-0573-40013. Screw 1/4-20 x 1 BTHD cap (right side) ............................................ 6600-0562-40014. Metal spacer ...................................................................................... 6600-0553-40015. Plastic spacer .................................................................................... 6600-0554-40016. Bumper .............................................................................................. 6600-0513-40017. Screw, lock 10-24 x .5” ...................................................................... 6600-0543-40018. Latch, left ........................................................................................... 6600-0670-500

Latch, right ......................................................................................... 6600-0672-50019. Actuator interface .............................................................................. 6600-0661-50020. Clevis groove pin .250 x .312 ............................................................ 6600-0508-40021. Washer, shoulder brass .140 ID x .187 OD....................................... 6600-0591-40022. Nut, elastic hex 6-32.......................................................................... 6600-0111-40023. Lever arm .......................................................................................... 6600-0660-50024. ‘E’ ring .25 SH SST ........................................................................... 6600-0542-40025. Elbow link SST .................................................................................. 6600-0665-50026. Tilt front cover, left (light grey) ........................................................... 6600-0663-501

Tilt front cover, left (beige) ................................................................. 6600-0663-500Tilt front cover, right (light grey) ......................................................... 6600-0669-501Tilt front cover, right (beige) .............................................................. 6600-0669-500

27. Delrin washer .75 x 12.5 x .062 ......................................................... 6600-0514-40028. Ring, cable protector ......................................................................... 6600-0671-50029. Tilt knob (light grey) ........................................................................... 6600-0664-501

Tilt knob (beige) ................................................................................. 6600-0664-50030. Spring washer ................................................................................... 6600-0592-40031. Seal, O2 tilt (left side only) ................................................................. 6600-0865-500

Not shownContinuous tilt upgrade kit, beige (includes base platform cover) ........... 6600-0514-800Continuous tilt upgrade kit, grey .............................................................. 6600-0505-801Continuous tilt upgrade kit, beige ............................................................ 6600-0505-802Left tilt assembly, beige ........................................................................... 6600-0417-700Left tilt assembly, grey ............................................................................. 6600-0417-701Right tilt assembly, beige ......................................................................... 6600-0418-700Right tilt assembly, grey ........................................................................... 6600-0418-701

6/Illustrated Parts

6-13 6-13

Figure 6-9Continuous Tilt Assembly

715

813

9

14

CI.0

2.18

7

10

11

10

11

13

98

12

CI.0

2.18

6

1 28

CI.0

2.25

3

29

272345

1718 3116 6

20

26

23

25232419222130

6/Illustrated Parts

6-14 6-14

6.3 Cabinet Components

Item Stock Number1. Screw, WD, #10 x 1 in ....................................................................... 6600-0044-4002. Nut, 8-32 x .34 ................................................................................... 0202-1131-3003. Cabinet side, left (beige) ................................................................... 6600-0216-500

Cabinet side, left (light grey) .............................................................. 6600-0216-5014. Cabinet bottom (beige) obsolete-use grey

Cabinet bottom (light grey) ................................................................ 6600-0144-5015. Screw, 8-32 x 3/8 .............................................................................. 6600-0261-4006. Cabinet side, right (beige) ................................................................. 6600-0217-500

Cabinet side, right (light grey) ........................................................... 6600-0217-5017. Washer, 1/4" ...................................................................................... 0202-4526-3358. Nut, 1/4-20......................................................................................... 6600-0074-4009. Casters without locks (black) ............................................................. 6600-0039-400

Casters without locks (dark grey) ...................................................... 6600-0566-40010. Casters with locks (black) .................................................................. 6600-0038-400

Casters with locks (dark grey) ........................................................... 6600-0567-40011. Bolt, 1/4-20 x 2.25 ............................................................................. 6600-0047-400

Note: Item #1 – Torque all 16 screws to 19 ± 4 in-lbs ± 5 in-lbsItem #8 – Torque all 16 nuts to 50 in-lbs ± 5 in-lbs

Figure 6-10Cabinet Assembly (base and sides)

11

2 31

7810 9

CI.0

2.12

1

10

6

4

5

6/Illustrated Parts

6-15 6-15

Note: Three versions of the cabinet top currently exist in the field: a wood top, a 1.25”thick plastic top, and a 1.75” thick plastic top. Be careful to choose the correct hard-ware for your version cabinet top from the list below. To replace any cabinet topversion, order item 1 below.

1.83”1.62” (old)

3

4

5 1

CI.0

2.03

5

2

1.75”

CI.0

2.19

6

Item Stock Number1. Plastic cabinet top kit, 1.75” thick (with hdwe., beige) ....................... 6600-0200-800

Plastic cabinet top kit, 1.75” thick (with hdwe., grey) ......................... 6600-0200-8012. Incubator mounting knob, 1.83” long (4) ........................................... 6600-0585-500

Incubator mounting knob, 1.62” long (4)(wood top and old 1.25 thick plastic top only) ................................... 6600-0405-500

3. Lock washer, #10 (1.75” plastic top only) .......................................... 6600-0435-400Lock washer, #10 ext. (1.25” plastic top only) ................................... 0202-3210-300

4. Screw, #10-24 x 5/16” (plastic tops only) .......................................... 0140-6530-105Screw, wood #10 x .75” (wood top only) ........................................... 6600-0225-400

5. Gasket (4) (plastic tops only) ............................................................. 6600-0463-500

Not shownComplete cabinet with blue doors (grey) ................................................. 6600-0036-902Complete cabinet with grey doors (grey) ................................................. 6600-0036-903

Figure 6-11Cabinet Assembly

6/Illustrated Parts

6-16 6-16

Item Stock Number1. Label (complete set; all languages)(black background) .................... 6600-0746-100

Label (complete set; all languages)(light grey background)...................................................................... 6600-0746-101

2. Refresher instruction tray (all plastic tops) (beige) obsolete-use greyRefresher instruction tray (light grey) ................................................ 6600-0384-501

3. Refresher instruction bookletEnglish (old display, with HBJ and HAG serial numbers) .................. 6600-1811-101English (new display, with HCE serial numbers) ............................... 6600-1811-111Spanish (old display, with HBJ and HAG serial numbers) ................ 6600-1811-103Spanish (new display, with HCE serial numbers) .............................. 6600-1811-113French (old display, with HBJ and HAG serial numbers) .................. 6600-1811-102French (new display, with HCE serial numbers) ............................... 6600-1811-112German (old display, with HBJ and HAG serial numbers) ................ 6600-1811-104German (new display, with HCE serial numbers) .............................. 6600-1811-114Italian (old display, with HBJ and HAG serial numbers) .................... 6600-1811-105Italian (new display, with HCE serial numbers) ................................. 6600-1811-115Swedish (old display, with HBJ and HAG serial numbers) ................ 6600-1811-106Swedish (new display, with HCE serial numbers) ............................. 6600-1811-116Japanese (new display, with HCE serial numbers) ........................... 6600-1811-117Russian (new display, with HCE serial numbers) .............................. 6600-1811-118Greek (new display, with HCE serial numbers) ................................. 6600-1811-119Dutch (new display, with HCE serial numbers) ................................. 6600-1811-120Portuguese (new display, with HCE serial numbers) ........................ 6600-1811-121

4. Screw, no. 10-24 x 5/16 phillips head ............................................... 0140-6530-1055. Lock washer ...................................................................................... 6600-0435-4006. Slide holder plate (for cabinet mounting) (beige) obsolete-use grey

Slide holder plate (for cabinet mounting) (light grey) ......................... 6600-0303-501

6/Illustrated Parts

6-17 6-17

Figure 6-12Refresher instruction tray assembly

2

3

4

5

6

1

FLIP

CI.0

7.03

4

6/Illustrated Parts

6-18 6-18

Item Stock Number1. Screw, 8-32 x 3/8, TRS, P ................................................................. 6600-0261-4002. Washer, 0.118 ID, 0.438 OD ............................................................. 6600-0080-4003. Nut, ext. lock, 8-32 x .34.................................................................... 0202-1131-3004. Cabinet shelf (beige) obsolete-use grey

Cabinet shelf (light grey) ................................................................... 6600-0075-5015. Cabinet apron (beige) obsolete-use grey

Cabinet apron (light grey) .................................................................. 6600-0211-5016. Screw, WD, #10 x 1 in* ..................................................................... 6600-0044-4007. Magnet .............................................................................................. 6600-0042-4008. Screw, #6, FL, PH** .......................................................................... 6600-0465-4009. Left door (blue) .................................................................................. 6600-0130-400

Left door (beige) ................................................................................ 6600-0130-401Left door (light grey) .......................................................................... 6600-0130-402

10. Screw 8-32 ........................................................................................ 6600-0045-40011. Screw 4-40 ........................................................................................ 6600-0046-40012. Strike, cabinet door ........................................................................... 6600-0043-40013. Plastic hole plug 0.375 in .................................................................. 6600-0085-40014. Right door (blue) ................................................................................ 6600-0129-400

Right door (beige) .............................................................................. 6600-0129-401Right door (light grey) ........................................................................ 6600-0129-402

15. Door hinge, (top right and bottom left) ............................................... 6600-0128-40016. Door hinge, (top left and bottom right) ............................................... 6600-0127-40017. Door handle (black) ........................................................................... 6600-0083-500

Door handle (dark grey) .................................................................... 6600-0083-501

* Torque to 25 in-lbs

** Apply Loctite 24231, Stock No.6600-0058-300R

6/Illustrated Parts

6-19 6-19

Figure 6-13Cabinet Doors and Shelf

1

6 2345

1617

8 11109

14

12 13

15

7

CI.0

2.25

4

CI.0

2.14

4

CI.0

2.14

3

8

8

6/Illustrated Parts

6-20 6-20

Cabinet Rail System and Overhead Shelf

Rail systems Stock NumberSet short rails kit (black caps) .................................................................. 6600-0041-800Set short rails kit (grey caps) ................................................................... 6600-0041-801Single short rail kit, right (grey caps) ....................................................... 6600-0210-800Single short rail kit, left (grey caps) .......................................................... 6600-0211-800

Item Stock Number1. Screw 10-24 x 5/8* ............................................................................ 6600-0258-4002. Lockwasher internal, #10* ................................................................. 0144-1110-1313. Plate, rail back* ................................................................................. 6600-0073-5004. Stiffener plate (light grey) .................................................................. 6600-0074-5005. Rail, vertical long, right rear ............................................................... 6600-0033-4006. Cap cabinet rail, right (black cap) ...................................................... 6600-0119-500

Cap cabinet rail, right (grey cap) ....................................................... 6600-0119-5017. Screw 10-32 x 3/4 ............................................................................. 6600-0305-4008. Split ring lockwasher ......................................................................... 6600-0322-4009. Screw, 1/4-20 x .375 ......................................................................... 6600-0084-40010. Lockwasher internal .......................................................................... 0202-3415-30011. Overhead shelf kit (includes 9, 10, & 11, beige)................................ 6600-0214-800

Overhead shelf kit (includes 9, 10, & 11, light grey) .......................... 6600-0214-801

Not Shown Stock NumberCap cabinet rail, left (black) ..................................................................... 6600-0120-500Cap cabinet rail, left (dark grey) ............................................................... 6600-0120-501Rail, vertical long, left rear ....................................................................... 6600-0032-400

* Used only with knockout style cabinets.

6/Illustrated Parts

6-21 6-21

Figure 6-14Cabinet rails and shelf

1 2 3

9 10

11

6

5

4

78

Old Style

New Style

CI.0

2.19

4C

I.02.

188

CI.0

2.25

5

9 10

6/Illustrated Parts

6-22 6-22

6.4 Accessories and Disposable Parts

Item Stock Number1. Instrument shelf, 12 x 12 (beige) ....................................................... 0217-5365-800

Instrument shelf, 12 x 12 (grey) ......................................................... 6600-0513-8012. Ventilator mounting post .................................................................... 0217-5357-8003. Oxygen flowmeter w/ bracket ............................................................ 0217-5370-8004. Suction regulator w/ DISS connectors + safety trap .......................... 6702-1224-9055. Overhead shelf & rails (beige) ........................................................... 6600-0042-800

Overhead shelf & rails (light grey) ..................................................... 6600-0042-8016. I.V. pole ............................................................................................. 0217-5378-8007. Standard M 2100 Oxygen Blender .................................................... 6750-0022-9008. Power cord ........................................................................................ 0208-0950-3009. Cabinet w/blue doors (grey) .............................................................. 6600-0036-902

Cabinet w/grey doors (grey) .............................................................. 6600-0036-903

Not Shown Stock NumberCleaning tank ........................................................................................... 6600-0202-500Reusable patient probe ............................................................................ 0208-0697-700Disposable patient probe(10/pkg) ............................................................ 6600-0208-700Disposable patient probe (50/pkg) ........................................................... 6600-0196-700Heat reflecting probe patch (50/pkg) ....................................................... 0203-1980-300Wristlets (6/pkg) ....................................................................................... 6600-0507-500Service Manual ........................................................................................ 6600-0017-000Pleur-evac hanger ................................................................................... 6600-0115-800Ventilator cuff (2/pkg) ............................................................................... 0217-3955-600ThermaLink Upgrade Kit‡ ........................................................................ 6600-0399-800

Note: Mounting the Standard M 2100 Oxygen Blender on the rail system requiresthe adapter plate (Stock No. 0217-5363-800) and the bird bracket (Stock No.6600-0031-900).

‡ Available only on controllers with serial numbers beginning with HBJ and HCE

6/Illustrated Parts

6-23 6-23

Figure 6-15Care Plus Incubator with Accessories

6

2

1

3

9

5

4

7

8

CI.0

5p00

4

6/Illustrated Parts

6-24 6-24

CI.0

7p00

1

Figure 6-17Instrument Shelf (beige)0217-5365-800Instrument Shelf (grey)6600-0513-801

Figure 6-19Oxygen Flowmeter w/Bracket0217-5370-800

Figure 6-20Air Flowmeter w/Bracket0217-5372-800

Figure 6-21Vacuum Manifold w/DISS Adapters0217-5369-800

Figure 6-1822 Inch Utility Post0217-5376-800

Figure 6-16Adapter Plate Assembly0217-5363-800

CI.0

7p00

2

CI.0

7p00

1

CI.0

5p00

5

CI.0

5p00

6C

I.05p

007

6/Illustrated Parts

6-25 6-25

Figure 6-22Manifold w/ 1/8 Inch Pipe Thread0217-5359-800

Figure 6-23Vacuum Bottle Slide Bracket0217-5367-800

Figure 6-24Manometer w/ Bracket0217-5377-800

CI.0

7p00

8

Figure 6-25I.V. Pole 12" I.V. Pole 24"0217-5378-800 0217-0491-801 [Not Shown]

Figure 6-26Ventilator Mounting Post0217-5357-800

Figure 6-27Retaining Clips (6 Grey) 6600-0055-851

CI.0

7p00

9

CI.0

7p00

4

CI.0

7p00

3C

I.07p

006

CI.0

5p00

8

6/Illustrated Parts

6-26 6-26

Figure 6-283.5 Inch Utility Post0217-5374-800

CI.0

7p00

7

CI.1

1p01

2

Figure 6-30BiliBlanket™ Plus phototherapy system6600-0219-900

Not Shown Stock NumberHood cover (terry cloth) ........................................................................... 6600-0467-800Iris porthole kit (2/pkg) ............................................................................. 6600-0498-800Tubing organiser ...................................................................................... 6600-0220-900Under shelf light ....................................................................................... 6600-0415-800Power strip (4 outlet) ................................................................................ 6600-0414-800Oxygen cylinder holder ............................................................................ 6600-0422-800Cabinet bumper guard (beige) ................................................................. 6600-0417-800Cabinet bumper guard (grey) ................................................................... 6600-0417-801Phototherapy light II (free standing, 115V) .............................................. 6600-0287-901Phototherapy light II (rail/wall mounting, 115V) ....................................... 6600-0288-901Phototherapy light II (free standing, 220V) .............................................. 6600-0287-902Phototherapy light II (free standing, 240V) .............................................. 6600-0287-903Phototherapy light II (rail/wall mounting,220V) ........................................ 6600-0288-902Phototherapy light II (rail/wall mounting,240V) ........................................ 6600-0288-903Phototherapy light II rail mounting kit ....................................................... 6600-0051-800Duo Vac rail mounting kit ......................................................................... 6600-0018-800In service video ........................................................................................ 6600-0066-000

Figure 6-29Duo-O-Vac6700-0136-900

CI.0

5p00

9

6/Illustrated Parts

6-27 6-27

6.5 Controller ComponentsControllers with air flow sensorItem Stock Number1. Screw, 4-40 x 1/4, TRS, PH .............................................................. 6600-0125-4002. Washer, int lock, #4 ........................................................................... 0202-3407-3403. Washer* ............................................................................................. 6600-0151-4004. Nut, lock, 6-32 w/ ext ......................................................................... 6600-0382-4005. Washer, #6, FL .................................................................................. 6600-0378-4006. Gasket, thermal switch ...................................................................... 6600-0209-5007. Thermal switch .................................................................................. 6600-0073-6008. Screw, 6-32, 3/8 RD, PH ................................................................... 0140-6124-1069. Gasket, air flow sensor* .................................................................... 6600-0208-50010. Optical sensor/rear controller replacement kit@. ............................... 6600-0556-80011. Heater, 120V ‡ ** ............................................................................... 6600-0199-500

Heater, 100V** .................................................................................. 6600-0231-500Heater, 220/230V** ........................................................................... 6600-0177-500Heater, 240V** .................................................................................. 6600-0198-500

12. Gasket, heater ................................................................................... 6600-0142-50013. Washer, int. lock, #10 ........................................................................ 0144-1110-13114. Washer 0.219 ID x 0.500 OD ............................................................ 6600-0067-40015. Nut,10-32 keps, w/ ext ....................................................................... 6600-0066-40016. Nut, 4-40 keps, w/ext. ........................................................................ 6600-0073-40017. Rear Controller Kit (units with air flow sensor) .................................. 6600-0405-800

Rear Controller (units with optical sensor) ........................................ 6600-0470-500* Available as service parts for obsolete air flow sensor.

† The air flow sensor is mounted on the back of the controller and should not be confused withthe air temperature sensor located inside the infant compartment.

‡ This version of the heater comes with mounting studs (as shown). Earlier versions mount withthree, 10-32 x 5/8, TRS, screws (Stock No 0140-6631-110).

** Always order gasket (item 12) when replacing heater.

@ Kit for units with obsolete air flow sensor only. Kit includes optical sensor assembly, rear controller, seals and gaskets,blower fan, motor shock mounts, control P. C. board and all new hardware required. For service parts for units alreadyequipped with optical sensor, see page 6-35.

Figure 6-31Controller Back Panel controllers with HAG serial numbers

11

12

1415

16

321

4 5

13 17

9

67

8

Air flow sensor (obsolete)

CI.0

2.16

2C

I.02.

122

6600-0017-000 08/28/96

10

Optical sensor

6/Illustrated Parts

6-28 6-28

Controllers with HAG serial numbers

Item Stock Number1. Screw, 6-32 x 7/8, TRS, PH* ............................................................. 6600-0150-4002. Washer, #6, FL .................................................................................. 6600-0378-4003. Shock mount † ....................................................................................................................... 6600-0105-4004. Bushing, shock mount † ..................................................................... 6600-0341-5005. Motor bracket, 60 Hz ......................................................................... 6600-0084-500

Motor bracket, 50 Hz ......................................................................... 6600-0239-5006. Motor Kit (with shock mount and bushing) ‡

Motor, 115V, 60 Hz, 1550 RPM ........................................................ 6600-0054-800Motor, 100V, 50 Hz, 1480 RPM ........................................................ 6600-0054-802Motor, 220V/240V, 50 Hz, 1480 RPM ............................................... 6600-0054-801

7. Bracket edge protector 1 foot (3" required) ....................................... 6600-0123-4008. Nut, 6-32 keps w/ ext ......................................................................... 6600-0382-4009. Spacer, 6-32 x 1/2 x 1/4 hex ............................................................. 0402-0233-30010. Spacer, threaded, .50" ...................................................................... 6600-0046-60011. Screw, 8-32 x 3/8, TRS, PH .............................................................. 6600-0261-40012. Slide rail ............................................................................................. 6600-0167-50013. Screw, 6-32, FL, PH .......................................................................... 6600-0465-40014. Screw, 6-32 x 1/4, TRS, PH .............................................................. 0140-6624-10415. Washer, lock, #6 int tooth............................................................... ... 0144-1106-131

* Use Loctite 24231 (Stock No. 6600-0058-300)

† Included in the bushing installation kit (6600-0149-800).

‡ Includes items 1 - 4 in addition to the motor.

Cont

rolle

rs w

ith H

AG S

eria

l No.

6/Illustrated Parts

6-29 6-29

Figure 6-32Controller Plate and Motor Mounting Hardware controllerswith HAG serial number

15

CI.0

2.16

3

4

5

1

32

14

9

10

11

12

13

7

8

6 Controllers with HAG Serial No.

6/Illustrated Parts

6-30 6-30


Item Stock Number1. Cooling fan (CCW rotation) ............................................................... 6600-0056-4002. Screw, 6-32 x 3/8, TRS, P ................................................................. 0140-6624-1063. Washer, lock, #6 int tooth .............................................................. ... 0144-1106-1314. Blower fan (black-air flow sensor) ..................................................... 6600-0141-4005. Blower fan (white-optical sensor) ...................................................... 6600-0008-8506. Fan knob ........................................................................................... 6600-0448-4007. Air seal, motor shaft (round-air flow sensor)* .................................... 0210-6566-3008. Air seal, motor shaft (oval-optical sensor)* ........................................ 6600-0472-0009. Controller latch kit (1/pkg) ................................................................. 6600-0108-800

* Press Adhesive side against rear of controller.

Figure 6-33Controller Latch and Fan Assemblies controllers with HAG serial number

9 CI.0

2.26

9

7

1 2 34

6

5

8

6600-0017-000 08/28/96

Cont

rolle

rs w

ith H

AG S

eria

l No.

6/Illustrated Parts

6-31 6-31

Figure 6-34Transformer and Side Mounted Controller Components controllerswith HAG serial numbers

1

16 14 13

11

CI.0

2.18

2

54

3

2

6 78 1098

12

15


Item Stock Number1. Circuit breaker (On/Off) switch w/ bezel (DPST) ............................... 0690-2500-3652. Retaining ring .................................................................................... 6600-0075-4003. Bezel, patient temp. probe connector ................................................ 6600-0071-5004. Nut, 6-32 keps w/ ext ......................................................................... 6600-0382-4005. Line filter, 6 amp (AC entrance) ........................................................ 6600-0094-7006. Solid state relay kit (includes item 7) ................................................. 6600-0457-8007. Metal oxide vanistor assy .................................................................. 6600-0458-8008. Nut, 8-32 keps w/ ext ......................................................................... 0202-1131-3009. Spacer, threaded, 4-40 x 1/2 ............................................................. 6600-0108-40010. Washer, lock, #4, int tooth ................................................................. 0202-3407-34011. Transformer (100, 120V) ................................................................... 0208-7580-300

Transformer kit (220/240 V) .............................................................. 6600-0145-80012. Washer, lock, #8 int tooth .................................................................. 6600-0262-40013. Screw, 8-32 x 3/8, TRS, PH .............................................................. 6600-0261-40014. Screw, 8-32 x 0.375, FH PH.............................................................. 6600-0071-40015. Screw, 6-32 x 3/8, PH....................................................................... 0400-3135-30016. Screw, 4-40 x 1/4 BD PH .................................................................. 0140-6517-104

Controllers with HAG Serial No.

6/Illustrated Parts

6-32 6-32


Item Stock Number1. Washer, lock, #6 int tooth................................................................ .. 0144-1106-1312. Screw, 6-32 x 1/4, RD, PH ................................................................ 6600-0388-4003. Battery, rechargeable, 6 cell, 7.2V .................................................... 0690-1000-3104. Controller cover (beige) obsolete - use grey

Controller cover (light grey) ............................................................... 6600-0066-5015. Screw, 6-32 x 3/8, RD, PH ................................................................ 0140-6624-1066. Controller rear seal (external) *. ........................................................ 6600-0067-5007. Screw, #6, FL,PH .............................................................................. 6600-0465-4008. High voltage harness (terminated AC entrance and

solid state relay wires, J1 and J2, battery holder) ............................. 6600-0206-7009. Ground wire, display board ............................................................... 6600-0118-70010. Control board, (tested),120V (air flow sensor) .................................. 6600-0106-710

Control board, (tested), 220/240V (air flow sensor) .......................... 6600-0126-710Control board, (tested), 100, 120, 220/240V (optical sensor) ........... 6600-0079-850

11. Patient temp. probe/air temp. sensor harness (Includesprobe jacks, J4 header, and related wires) ....................................... 6600-0122-700

12. Intermediate harness (display/control board cable) .......................... 6600-0211-70013. Battery holder .................................................................................... 6600-0079-700

* Press Adhesive side against rear of controller.

12

13

6

54

7891011

321

1

Figure 6-35Wire Harnesses and Additional Controller Components controllerswith HAG serial number

CI.0

2.16

6

6600-0017-000 08/28/96

Cont

rolle

rs w

ith H

AG S

eria

l No.

6/Illustrated Parts

6-33 6-33


Item Stock Number1. Front cover, controller (beige) ........................................................... 6600-0064-5002. Switch panel replacement kit(includes display panel,

switch panel, and alarm LED gasket), English .................................. 6600-0136-800Switch panel replacement kit, German.............................................. 6600-0136-801Switch panel replacement kit, Spanish.............................................. 6600-0136-802Switch panel replacement kit, French ............................................... 6600-0136-803Switch panel replacement kit, Swedish ............................................. 6600-0136-804Switch panel replacement kit, Italian ................................................. 6600-0136-805

3. Gasket, alarm LED *. ......................................................................... 6600-0210-5004. Support panel, display board............................................................. 6600-0147-5005. Washer, #6 int. lock............................................................................0144-1106-1316. Screw, 6-32 x 3/8, TRS, PH .............................................................. 0140-6624-1067. Display board (tested) ....................................................................... 6600-0105-7108. Ground wire, display board ............................................................... 6600-0118-7009. Nut, 6-32 keps w/ ext ......................................................................... 6600-0382-40010. Intermediate harness (display/control board cable) .......................... 6600-0211-70011. Spacer, 6-32 x 1/2 ............................................................................. 0402-0233-30012. Washer, flat #6 .................................................................................. 0202-4510-34013. Label, Ohmeda logo .......................................................................... 6600-0142-100

* Press Adhesive side against Switch panel.

7

89

10

5

1211

13

CI.0

2.15

1

43

2

1

6

Figure 6-36Control Panel Assembly controllers with HAG serial numbers


6/Illustrated Parts

6-34 6-34

Controllers with HBJ or HCE serial numbers

Item Stock Number1. Screw, 6-32 x 7/8 TRS PH ................................................................ 6600-0150-4002. Washer, flat #6 .................................................................................. 0202-4510-3403. Shock mount ..................................................................................... 6600-0105-4004. Bushing, shock mount ....................................................................... 6600-0341-5005. Motor bracket, 60 Hz ......................................................................... 6600-0517-500

Motor bracket, 50 Hz ......................................................................... 6600-0518-5006. Motor kit, 100/120/220/240V, 60Hz† ................................................. 6600-0054-800

Motor kit, 100/120V, 50 Hz† .............................................................. 6600-0054-802Motor kit, 220/240V, 50 Hz† .............................................................. 6600-0054-801

7. Bracket edge protector (3" long) ....................................................... 6600-0123-4008. Airseal, motor shaft* .......................................................................... 6600-0471-5009. Washer, lock, #6 split ring ................................................................. 6600-0345-40010. Screw, 6-32 x 1/2, RD, PH ................................................................ 0140-6124-10811. Fan sensor kit (includes item 8). ....................................................... 6600-0403-80012. Washer, lock , #8 int tooth ................................................................. 6600-0262-40013. Nut, 8-32, ext tooth lock .................................................................... 0202-1131-30014. Transformer, 100/120V ..................................................................... 0208-7580-300

Transformer kit, 220/240V ................................................................. 6600-0145-80015. Controller Latch Kit (1/pkg) ................................................................ 6600-0108-80016. Spacer, 6-32 ...................................................................................... 6600-0376-40017. Washer, lock, # 6 int tooth , ............................................................... 6600-0399-40018. Nut, 8-32, ext lock ............................................................................. 0202-1131-30019. Circuit breaker bracket ...................................................................... 6600-0864-50020. Screw, 6-32 x 1/4 TRS, PH ............................................................... 0140-6624-10421. Circuit breaker (5 amp)ˆ .................................................................... 6600-0562-60422. Spacer, threaded, 6-32 x 1/4 ............................................................. 6600-0377-40023. Slide rail ............................................................................................. 6600-0167-50024 Controller chassis (beige) obsolete - use grey

Controller chassis (light grey) ............................................................ 6600-0469-50125. Screw, 6 - 32 x 5/16, FL, PH ............................................................. 6600-0403-400

ˆ The 7 amp circuit breaker can be replaced with this 5 amp circuit breaker.

* Press adhesive side against the fan sensor.

† Motor kit contains motor and items 1-4.

Cont

rolle

rs w

ith H

BJ a

nd H

CE S

eria

l No .

6/Illustrated Parts

6-35 6-35

Figure 6-37Motor, fan sensor, circuit breaker and transformer assembly controllerswith HBJ and HCE serial numbers

11109

1

6

234

5

13

2

7

14

12

CI.0

2.12

2

24

22

23

25

202120

15

16

19

18

17

8

Controllers with HBJ and HCE Serial No.

6/Illustrated Parts

6-36 6-36

Controllers with HBJ and HCE serial numbers

Item Stock Number1. Rear controller airseal* ...................................................................... 6600-0472-5002. Nut, 10-32 keps w/ ext ....................................................................... 6600-0066-4003. Washer flat .219 ID .50 OD ............................................................... 6600-0067-4004. Nut, 6-32 keps w/ ext ......................................................................... 6600-0400-4005. Washer, #6 ........................................................................................ 6600-0016-4006. Gasket, thermal switch ...................................................................... 6600-0209-5007. Thermal switch .................................................................................. 6600-0073-6008. Screw, 6-32 x 1/2 RD PH .................................................................. 0140-6124-1089. Controller rear seal (external)* .......................................................... 6600-0067-50010. Heater, 120V † .................................................................................. 6600-0199-500

Heater, 100V † .................................................................................. 6600-0231-500Heater, 220/230V † ........................................................................... 6600-0177-500Heater, 240V † .................................................................................. 6600-0198-500

11. Gasket, heater ................................................................................... 6600-0142-50012. Rear controller (beige) obsolete - use grey

Rear controller (light grey) ................................................................. 6600-0470-501

† Always replace gasket (item 11) when replacing heater

* Press adhesive side against the rear of the controller.

Cont

rolle

rs w

ith H

BJ a

nd H

CE S

eria

l No .

6/Illustrated Parts

6-37 6-37

Figure 6-38Back panel controllers with HBJ and HCE serial numbers

1

23

45

876

10

9

11

12

CI.0

2.12

3


6/Illustrated Parts

6-38 6-38


Item Stock Number1. Nut, precision, 1/4 -32 NEF ............................................................... 6600-0109-4002. Bezel, patient temp probe connector................................................. 6600-0071-5003. Hairpin clip ......................................................................................... 6600-0104-4004. Cable tie ............................................................................................ 6600-0364-4005. ON/OFF switch with bezel (DPST)* (includes nut) ............................ 6600-0229-6006. Switch guard kit (includes label & washer) ........................................ 6600-0046-8507. Capacitor assy kit .............................................................................. 6600-0404-8008. Line filter, 6A (AC entrance) .............................................................. 6600-0094-7009. Screw, 6-32 x 3/8 .............................................................................. 0400-3135-30010. Keps nut, #6 32 ................................................................................. 6600-0400-40011. Connector cover plate ....................................................................... 6600-0473-50012. Screw, 8-32 x 3/8 .............................................................................. 0140-6127-10613. External tooth lock nut, 8-32.............................................................. 0202-1131-30014. Solid state relay kit (includes item 15) ............................................... 6600-0457-80015. Metal oxide varistor assy ................................................................... 6600-0458-80016. Washer .............................................................................................. 0202-0095-30017. Washer, #6 ........................................................................................ 6600-0016-40018. Split lock washer, #6 ......................................................................... 6600-0345-40019. Screw, 6-32 x 7/8 .............................................................................. 6600-0150-40020. Fan knob ........................................................................................... 6600-0448-40021. Blower fan, 5 blade (white) ................................................................ 6600-0008-85022. Hex nut .............................................................................................. 0144-3127-11323. Washer, lock , #10, split ring ............................................................. 6600-0322-40024. Cooling fan (CCW rotation) ............................................................... 6600-0056-40025. Patient temp probe sensor harness kit

(includes air probe jack, J4 header, EMI filter board,related wires, and mounting hdwe) ................................................... 6600-0327-700

26. Nut, 6-32 keps w/ ext ......................................................................... 6600-0400-40027. Washer, lock int tooth , 1/4 ................................................................ 6600-0396-40028. Grounding post kit ............................................................................. 6600-0260-80029. Washer .............................................................................................. 6600-0399-40030. Patient probe jack.............................................................................. 6600-0067-700

* This toggle switch does not contain circuit breakers, and should only be used on controllers thathave external circuit breakers.

Cont

rolle

rs w

ith H

BJ a

nd H

CE S

eria

l No .

6/Illustrated Parts

6-39 6-39

Figure 6-39Controller chassis and fan assembly controllers with HBJ and HCE serial numbers

Open

BlueBlackRedWhite

1617

1819

20

13

45

7 69

14

3

28

2629

8

27

21

2322

21

30

24

1211

15C

I.02

.198

10

25


6/Illustrated Parts

6-40 6-40

Controllers with HBJ and HCE serial numbersItem Stock Number1. Control board (tested) ....................................................................... 6600-0079-8502 Internal tooth lock washer ................................................................. 6600-0399-4003. Screw, 6-32 ....................................................................................... 6600-0389-4004. Screw, 6-32 x 3/8 .............................................................................. 0140-6624-1065. Internal tooth lock washer, #6 ........................................................... 6600-0399-4006. Controller cover (beige) obsolete - use grey

Controller cover (light grey) ............................................................... 6600-0066-5017. High voltage harness (terminated AC entrance

& solid state relay wires, J1 and J2, battery holder) .......................... 6600-0313-700

Parts not shownBattery, rechargeable, 6 cell, 7.2V ........................................................... 0690-1000-310Battery holder .......................................................................................... 6600-0079-700Controller label set (English - black background) .................................... 6600-1186-100Controller label set (English - light grey background) .............................. 6600-1186-101Controller label set (Spanish - black background) ................................... 6600-1228-100Controller label set (Spanish - light grey background) ............................. 6600-1228-101Controller label set (French - black background) ..................................... 6600-1227-100Controller label set (French - light grey background) ............................... 6600-1227-101Controller label set (Swedish - black background) .................................. 6600-1092-100Controller label set (Swedish - light grey background) ............................ 6600-1092-101Controller label set (Italian - black background) ...................................... 6600-1095-100Controller label set (Italian - light grey background) ................................ 6600-1095-101Controller label set (Japanese - black background) ................................ 6600-1690-100Controller label set (Japanese - light grey background) .......................... 6600-1690-101Controller label set (Russian - light grey background) ............................. 6600-1186-108Controller label set (Greek - light grey background) ................................ 6600-1186-109Controller label set (Dutch - light grey background) ................................ 6600-1186-110Controller label set (Portuguese - light grey background) ....................... 6600-1186-111

Figure 6-40Cover assembly controllers with HBJ and HCE serial numbers

CI.0

2.12

5

1 4 5 6

7

32

Cont

rolle

rs w

ith H

BJ a

nd H

CE S

eria

l No .

6/Illustrated Parts

6-41 6-41


Item Stock Number1. Screw, 6-32 x 3/8 .............................................................................. 0140-6624-1062. Split lock washer, #6 ......................................................................... 6600-0345-4003 Spacer ............................................................................................... 0402-0233-3004. ThermaLink service board* ............................................................... 6600-0074-8505. Keps nut, 6-32 ................................................................................... 6600-0382-4006. Ribbon cable ..................................................................................... 6600-0240-7007. Anti-static cover ................................................................................. 6600-0387-4008. ThermaLink wire harness (fits only boards without test switch) ........ 6600-0530-7009. Retainer clip ...................................................................................... 6600-0672-40010. Screw lock ......................................................................................... 6600-0673-400

* PC board without test switch on board. To replace boards with on board test switch, order Upgrade kit listed below.

Parts not shownThermaLink upgrade kit (includes items 1-10) ......................................... 6600-0399-800

Figure 6-41ThermaLink assembly controllers with HBJ and HCE serial numbers

654321

98

CI.0

2.29

3

10 7

Controllers with HBJ and HCE Serial Num

bers

6/Illustrated Parts

6-42 6-42

Controllers with HBJ serial numbers

Item Stock Number1. Front cover, controller (beige) ........................................................... 6600-0064-5002. Switch panel replacement kit(includes display panel,

switch panel, and alarm LED gasket), English .................................. 6600-0136-800Switch panel replacement kit, Spanish.............................................. 6600-0136-802Switch panel replacement kit, French ............................................... 6600-0136-803Switch panel replacement kit, Swedish ............................................. 6600-0136-804Switch panel replacement kit, Italian ................................................. 6600-0136-805Switch panel replacement kit, Japanese ........................................... 6600-0136-806

3. Gasket, alarm LED *. ......................................................................... 6600-0210-5004. Support panel, display board............................................................. 6600-0147-5005. Washer, #6 int. lock ........................................................................... 0144-1106-1316. Screw, 6-32 x 3/8, TRS, PH .............................................................. 0140-6624-1067. Display board (tested) ....................................................................... 6600-0105-7108. Display board ESD shield .................................................................. 6600-0515-5009. Nut, 6-32 keps w/ ext ......................................................................... 6600-0382-40010. Intermediate harness (display/control board cable) .......................... 6600-0211-70011. Spacer, 6-32 x 1/2, 1/4 hex ............................................................... 6600-0242-60012. Washer,lock, split ring #6 .................................................................. 6600-0345-40013. Washer, flat .156 x .312 nylon ........................................................... 0402-1127-30014. Washer, #6, .375 OD......................................................................... 6600-0016-40015. Washer, lock .156 x .035 int tooth ..................................................... 0202-4510-34016. Ohmeda logo, label set ..................................................................... 6600-0142-100

* Press adhesive against side against the LED bar.

Cont

rolle

rs w

ith H

BJ S

eria

l No .

6/Illustrated Parts

6-43 6-43

Figure 6-42Control panel assembly controllers with HBJ serial numbers

16

2

1

34

5

7

8

612

14

1310

1511

CI.0

2.12

7

Note: EMI shield is pro-vided flat. Fold as shownbefore installation.

Ends fold 90° over the endsof the board.

9

Controllers with HBJ Serial No.

6/Illustrated Parts

6-44 6-44

Controllers with HCE serial numbers

Item Stock Number1. Front cover, controller (light grey) ..................................................... 6600-0064-5012. Washer .............................................................................................. 6600-0399-4003. Screw, 6-32 x 3/8, TRS, PH .............................................................. 0140-6624-1064. Nut ..................................................................................................... 6600-0382-4005. Display board ESD shield .................................................................. 6600-0515-5006. Display board kit ................................................................................ 6600-0080-8507. Spacer ............................................................................................... 6600-0768-4008. Spacer, nylon .................................................................................... 6600-0544-4009. Washer, #6, .3750 ............................................................................. 6600-0016-40010. Switch panel assembly kit

English ............................................................................................... 6600-0441-701French ............................................................................................... 6600-0441-702Spanish ............................................................................................. 6600-0441-703German ............................................................................................. 6600-0441-704Italian ................................................................................................. 6600-0441-705Swedish ............................................................................................. 6600-0441-706Japanese ........................................................................................... 6600-0441-707Russian ............................................................................................. 6600-0441-708Greek................................................................................................. 6600-0441-709Dutch ................................................................................................. 6600-0441-710Portuguese ........................................................................................ 6600-0441-711

Cont

rolle

rs w

ith H

CE S

eria

l No .

6/Illustrated Parts

6-45 6-45

Figure 6-43Control panel assembly, controllers with HCE serial numbers

CI.0

2.19

7

2 31

458710 96

Controllers with HCE Serial No.

6/Illustrated Parts

6-46 6-46

6.6 Board Components

Display Board

Controllers with HAG and HBJ serial numbers

Tested and Packaged, Stock No. 6600-0105-710

CI.0

2.12

8

Cont

rolle

rs w

ith H

AG a

nd H

BJ S

eria

l No .

6/Illustrated Parts

6-47 6-47

CI.0

2.14

6

Figure 6-44Display board controllers with HAG and HBJ serial numbers

Controllers with HAG and HBJ Serial No.

6/Illustrated Parts

6-48 6-48

Display Board

Controllers with HCE serial numbers

6600-0420-700

CI.0

2.19

9

Cont

rolle

rs w

ith H

CE S

eria

l No .

6/Illustrated Parts

6-49 6-49

Figure 6-45Display Board controllers with HCE serial numbers

CI.0

2.20

0


6/Illustrated Parts

6-50 6-50

Display Board

Controllers with HCE serial number

6600-0512-700

CI.0

2.31

2

6/Illustrated Parts

6-51 6-51

Controllers with HCE Serial No.C

I.23.

070

Figure 6-46Display Board, Surface Mount

6/Illustrated Parts

6-52 6-52

Control Board

Controllers with software revision 02.00

100/120V Stock No. 6600-0106-710220/240V Stock No. 6600-0126-710

CI.0

2.12

9

Softw

are

revi

sion

02.

00

6/Illustrated Parts

6-53 6-53

Figure 6-47Control Board (tested and packaged) controllerswith software revision 02.00

CI.0

2.15

3

Software revision 02.00

6/Illustrated Parts

6-54 6-54

Control Board


100/120/220/240V Stock No. 6600-0204-702

CI.0

2.13

0

* R37 = 500 ohm when LS1 is 1" tall* R37 = 2000 ohm when LS1 is 1⁄2" tall

On Control boards with a A/DModule daughter board, the A/Dmodule is installed at U14.The following components are notinstalled: C36, C37, C39, CR7, CR8,CR12, R10, R11, R45, R67, R73, R75,and R101.

Softw

are

revi

sion

03.

00

6/Illustrated Parts

6-55 6-55

Figure 6-48Control Board controllers with Software revision 03.00

CI.0

2.13

1

C3

C4 R3 C6

R2

C9

U4R1

Y1U2

C8 U3

C7

U1

C1

C2

1 1

1

1J1

+

+ CI.0

2.26

4

A/D Module Board Component Location(as seen from the solder side of the board)


6/Illustrated Parts

6-56 6-56

Softw

are

revi

sion

04.

00 a

nd h

ighe

r

Control Board

Controllers with software revisions 04.00 and higher

Stock No. 6600-0515-700

CI.0

2.30

9,31

1

6/Illustrated Parts

6-57 6-57

Software revision 04.00 and higher

Figure 6-49Control Board, Surface Mount

CI.0

2.31

0

6/Illustrated Parts

6-58 6-58

CI.0

2.20

5

6.7 Label Sets

W CAUTION: Use onlyWhite Fan. Air CirculationAlarm will sound if WhiteFan is not installed.

•U

tiliser laSonde de Température Cutanée

Ohmed

a

Use Ohm

eda Skin Temperature Probe•

Stock Number Serial Number

OhmedaColumbia MD 21046 1801 Made in USA

W CAUTION: Federal law in the USA and Canada restricts thisdevice to sale by or on the order of a licensed medical practitioner. m

W WARNING: Air Heater may be hot.

W CAUTIONS: Electrical shock hazard. Do not remove cover. Refer servicing to qualified service personnel.

Do not force Controller Unit into Incubator. If resistance is encountered, have the Controller Unit inspected by qualified service personnel.

NOTE: Unit has internal circuitbreakers that can only be reset byservice personnel.

Power

Label Set, ControllerCare Plus6600-1186-1XX

Ohio Care Plus Incubator®

Ohio Care Plus Incubator Controller®

RS-232 SerialPort / Nurse Call

W WARNING: Air Heater may be hot.

W CAUTION: Do not force Controller Unit into Incubator. If resistance is encountered, have the Controller Unit inspected by qualified service personnel.

This product complieswith the requirementsof the standard forMedical and DentalEquipment, UL544,2nd Edition.

OhmedaColumbia MD 21046 1801 USA

LR87400Certified to the requirements of the Canadian Electrical Code. CSAhas not investigated other physiological effects.

Certifié selon les exigences du code Canadien de l'electricité.L'ACNOR n'a pas etudié les autres effets physiologiques possibles.

W DANGER: Risque d'explosion. Ne pas employer en présence d'anesthésiques inflammables.

Risk Class 2CSA Standard C22.2 No.125

®

7.2V Ni CdRechargeable0690-1000-310

P/N 6600-1186-108P/N 6600-1186-109P/N 6600-1186-110P/N 6600-1186-111

RussianGreekDutchPortuguese

P/N 6600-0308-108P/N 6600-0308-109P/N 6600-0308-110P/N 6600-0308-111


English P/N 6600-1186-101French P/N 6600-1227-101German P/N 6600-1229-101Spanish P/N 6600-1228-101Italian P/N 6600-1095-101Swedish P/N 6600-1092-101Japanese P/N 6600-1690-101

Do not place itemson this surface


English P/N 0205-4740-300French P/N 0205-4740-300German P/N 0205-4740-300Spanish P/N 0205-4740-300Italian P/N 0205-4740-300Swedish P/N 0205-4740-300


English P/N 6600-0622-101

English P/N 6600-0638-101French P/N 6600-0638-101

English P/N 6600-0586-101

Skin Temperature ProbeSonde de Température CutanéeSonda de Temperatura CutáneaHauttemperatursondeModel/Modele

Modelo/Model

Lot Number/No de Lot

Numero de Lote/CH-B:

LA003 THA

Mfd for: OhmedaColumbia MD 21046 1801

For use withPara usar con

Utiliser avecFur den Gebrauch

OhmedaIncubators.........................IC & Care PlusInfant Warmer Systems.....2001 ,3000, 4000 & 5000 Series

W Use with other equipment could causepatient injury.W Toute utilisation avec d'autres equipementsrisque de blesser le patient.W Si se usa junto con otro aparato, podrialesioner al paciente.W Gebrauch mit anderen geräten könnteverletzung des patienten verursachen.

Contact technicalsupport to orderthis label

Contact technical supportto order this label

Contact technical supportto order this label


6/Illustrated Parts

6-59 6-59

CI.0

2.20

6

W WARNINGS: Fire hazard. Keep matches, lighted cigarettes and all other sources of ignition out of the room in which the incubator is located. Textiles, oils, and other combustibles

are easily ignited and burn with great intensity in air enriched with oxygen.

Oxygen concentrations higher than 40% can increase the risk of retrolental fibroplasia.It is possible that even concentrations of 40% or less (formerly considered safe) couldbe dangerous for some infants. Therefore, arterial blood gas measurements areextremely important for regulation of the concentration of inspired oxygen when in anoxygen enriched environment.

Oxygen Concentration Chart

Oxygen input 5L/min 10L/min 15L/min

Average oxygenconcentration range 25-45% 35-55% 45-75%

NOTE: Oxygen concentration levels in this chart are intendedas a reference only. Actual concentrations should be checkedwith an oxygen analyzer.

W CAUTION: Federal law inUSA and Canada restrictsthis device to sale by or onthe order of a licensedmedical practitioner.

OhmedaColumbia MD 21046 1801

Made in USA

Stock NumberSerialNumbee

m

Ohio Care Plus Incubator®

CAUTIONPRECAUTIONATTENTIONVORSICHTVARNING

ATTENZIONE

W DANGER: Possible explosion hazard. Do not use in the presence of flammable anesthetics.

W WARNING: The front door inner wall must be in place while a patient occupies the incubator.

Use only hospital gradegrounded power receptacle.

Air Temperature Control Probe.Use only Ohmeda Part No.6600-0086-700.

Refresher Instructions

Replace filter every three (3)months.Replaced:

Oxygen Inlet

W WARNINGS: Power must be disconnected prior to removing bed platform.

Air Heater may be hot.

Label Set, Incubator, Care Plus6600-0305-1XX

English

P/N 6600-0305-108

French

P/N 6600-0305-109

German

P/N 6600-0305-110

SpanishItalianSwedishJapanese



EnglishFrenchGermanSpanishItalianSwedishJapanese

P/N 6600-0305-101P/N 6600-0317-101P/N 6600-0321-101P/N 6600-0319-101P/N 6600-1096-101P/N 6600-1093-101P/N 6600-1688-101

P/N 6600-0136-108P/N 6600-0136-109P/N 6600-0136-110P/N 6600-0136-111

Grey

P/N 6600-0135-108P/N 6600-0135-109P/N 6600-0135-110P/N 6600-0135-111

P/N 6600-0913-100P/N 6600-0913-100P/N 6600-0913-100P/N 6600-0913-100P/N 6600-0913-100P/N 6600-0913-100P/N 6600-0913-100


RussianGreekDutch

P/N 6600-0305-111Portuguese



6/Illustrated Parts

6-60 6-60

6.8 Replacement controllers

Systems without the ThermaLink Option

Language, Replacementvoltage, Controllerfrequency Light Grey/new display

English

100 Vac 60 Hz 6600-0243-969100 Vac 50 Hz 6600-0243-968120 Vac 60 Hz 6600-0243-900120 Vac 50 Hz 6600-0243-901220 Vac 60 Hz 6600-0243-902220 Vac 50 Hz 6600-0243-903240 Vac 60 Hz 6600-0243-906240 Vac 50 Hz 6600-0243-907

Spanish

120 Vac 60 Hz 6600-0243-920120 Vac 50 Hz 6600-0243-921220 Vac 60 Hz 6600-0243-922220 Vac 50 Hz 6600-0243-923

French

220 Vac 60 Hz 6600-0243-912220 Vac 50 Hz 6600-0243-913Swedish220 Vac 50 Hz 6600-0243-955

Italian

220 Vac 50 Hz 6600-0243-945

Japanese

100 Vac 60 Hz 6600-0243-996100 Vac 50 Hz 6600-0243-968

6/Illustrated Parts

6-61 6-61

Systems with the ThermaLink Option

Language, Replacementvoltage, Controllerfrequency Light Grey/new display

English

100 Vac 60 Hz 6600-0244-969100 Vac 50 Hz 6600-0244-968120 Vac 60 Hz 6600-0244-900120 Vac 50 Hz 6600-0244-901220 Vac 60 Hz 6600-0244-902220 Vac 50 Hz 6600-0244-903240 Vac 60 Hz 6600-0244-906240 Vac 50 Hz 6600-0244-907

Spanish

120 Vac 60 Hz 6600-0244-920120 Vac 50 Hz 6600-0244-921220 Vac 60 Hz 6600-0244-922220 Vac 50 Hz 6600-0244-923

French

220 Vac 60 Hz 6600-0244-912220 Vac 50 Hz 6600-0244-913

Swedish

220 Vac 50 Hz 6600-0244-955

Italian

220 Vac 50 Hz 6600-0244-945

Japanese

100 Vac 60 Hz 6600-0244-969100 Vac 50 Hz 6600-0244-968

6.9 Servo-controlled Humidifier Upgrade KitsHumidifier, 120 Volt, English (light grey) .................................................. 6600-0506-803Humidifier, 120 Volt, French (light grey) .................................................. 6600-0506-804Humidifier, 120 Volt, Spanish (light grey) ................................................ 6600-0506-805Humidifier, 100 Volt, Japanese (light grey) .............................................. 6600-0506-806Humidifier, 220-240 Volt, English (light grey) .......................................... 6600-0506-807Humidifier, 220-240 Volt, French (light grey) ........................................... 6600-0506-808Humidifier, 220-240 Volt, Spanish (light grey) ......................................... 6600-0506-809Humidifier, 220-240 Volt, German (light grey) ......................................... 6600-0506-810Humidifier, 220-240 Volt, Italian (light grey) ............................................. 6600-0506-811Humidifier, 220-240 Volt, Swedish (light grey) ......................................... 6600-0506-812

6/Illustrated Parts

6-62 6-62

Notes

7/Schematics 7/Schematics

7-1 6600-0017-000 03/12/98 7-1

Figure 7-1Wiring DiagramControllers with HAG serial numbers

CI.0

2.29

1


Controllers with software revision 03.00 or higher



7-2 6600-0017-000 03/12/98 7-2

Figure 7-2Controller Plate WiringControllers with HAG serial numbers

GND From Rear

0140-6627-110

Note: For customer convenience,Ohmeda stock numbers have beenretained on the wiring diagrams.

The 6600-0313-700 wire harnessincludes J2, J1, the AC entrancewires and the relay wires.

Top View

Orange 240VOrange 240VOrange 120VOrange 100VYellow

YellowBlue

WhiteOrange

Yellow

Orange

Install .125 x 1.00 LongHeat Shrink TubingTo Cover ExposedSolder Connections

0140-6517-104 (4)

GND FromDisplay Board

6600-0262-400 (2)

0202-1131-300 (2)

Detail A

GND FromPower Receptacle(Grn/Yel)

6600-0015-600

Notice: Wires Should BePulled Back Tight OverSwitch to Prevent TouchingDC Board

0208-0335-300 (2)

6600-0261-400

0208-0446-300Brown

0202-1131-300 (6)BlueGreen/Yellow

0208-0446-300

See Detail A0205-4737-300

0208-0335-300

Note: Sleving Must ExtendBeyond Motor Bracket

Red

Black

0144-1108-131 (2)

0144-1106-131

BlueBrownOrangeYellow

Red

Black

OrangeRed

Green/Yellow

Yellow

Install .125 x 1.00 Long Heat ShrinkTubing to Cover Exposed SolderConection and Transformer Terminal(4 Places)

BlueWhiteOrange

CI.0

2.20

1

6600-0157-700Attach to Switch withDouble Back Tape

Cont

rolle

rs w

ith H

AG S

eria

l No.


7-3 6600-0017-000 03/12/98 7-3

6600-0122-700Wire Harness includes J4, the Air temperature sensorconnector and the patient probe jack.

6600-0051-600

0202-1131-3006600-0261-400

0202-3415-340

0140-6624-106

0202-1131-300Do Not Tighten UntilBattery Wires Are Installed

6600-0109-400Discard Nut Supplied With Jack

6600-0122-700

Blue

BlackWhite

Red

Figure 7-3Detail, Air Temp. and Patient Temp. WiringControllers with HAG serial numbers

0202-1131-300Do Not Tighten UntilBattery Wires Are Installed

6600-0261-400

0208-0335-300

CI.0

2.29

2

6600-0017-000 08/28/96



7-4 6600-0017-000 03/12/98 7-4

R20+9.8 V Adj.

I/O Expander 3

Micro-Controller

I/O Expander 2

EPROM

ADC

Board Layout(Identifies calibration adj.and socketed chips)

Figure 7-4aControl Board Schematic (page 1 of 2)Controllers with Software Revision 02.00

Controllers without HBJ Serial Numbers

CI.0

2.15

4

R38High Air Temp.Alarm Limit

R362 KHzAdj.

R37AlarmVol.

R25ADCCal.

R19LineVoltCal.

CI.0

2.27

2

CI.0

2.27

1

Notes: (Unless otherwise specified)

1. All resistors are 5%. 1/4 Watt2. Square denotes refer to other page ∫3. GND symbol with line denotes GNDS tied together4. Componants drawn with dotted lines are not installed

Softw

are

Revi

sion

02.

00


7-5 6600-0017-000 03/12/98 7-5

R20+9.8 V Adj.

I/O Expander 3

Micro-Controller

I/O Expander 2

EPROM

R38High Air Temp.Alarm Limit

CI.0

2.15

4

Figure 7-4bControl Board Schematic (page 2 of 2)Controllers with Software Revision 02.00

R19LineVoltCal.

R25ADCCal.

R37AlarmVol.

R362 KHzAdj.

ADC

CI.0

2.27

8

CI.0

2.27

7

Software Revision 02.00


7-6 6600-0017-000 03/12/98 7-6

Figure 7-5Display Board SchematicControllers with HAG and HBJ serial numbers

CI.0

2.27

8

CI.0

2.28

0



Cont

rolle

rs w

ith H

AG a

nd H

BJ S

eria

l No.


7-7 6600-0017-000 03/12/98 7-7

Figure 7-6Display Board Schematic - through mount boardControllers with HCE serial numbers

CI.0

2.20

3


1. All resistors are 5%. 1/4 Watt2. GND symbol with line denotes GNDS tied together



7-8 6600-0017-000 03/12/98 7-8

Figure 7-7Wiring Diagram - Software Revision 03.10Controllers with HBJ and HCE serial numbers

CI.0

2.20

4

Cont

rolle

rs w

ith H

BJ a

nd H

CE S

eria

l No.

ThermaLink Boards with test switch

ThermaLink Boardswithout test switch


7-9 6600-0017-000 03/12/98 7-9

Figure 7-8aControl Board Schematic-Surface Mount Board (page 1 of 7)Software Revision 04.00

CI.2

3.05

3


NI = not installed= output signal= input signal


7-10 6600-0017-000 03/12/98 7-10

Figure 7-8bControl Board Schematic-Surface Mount Board (page 2 of 7)Software Revision 04.00

CI.2

3.05

4

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r



7-11 6600-0017-000 03/12/98 7-11

Figure 7-8cControl Board Schematic-Surface Mount Board (page 3 of 7)Software Revision 04.00Figure 7-1d

CI.2

3.05

5




7-12 6600-0017-000 03/12/98 7-12

Figure 7-8dControl Board Schematic-Surface Mount Board (page 4 of 7)Software Revision 04.00

CI.2

3.05

6

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r



7-13 6600-0017-000 03/12/98 7-13

Figure 7-8eControl Board Schematic-Surface Mount Board (page 5 of 7)Software Revision 04.00

CI.2

3.05

7




7-14 6600-0017-000 03/12/98 7-14

Figure 7-8fControl Board Schematic-Surface Mount Board (page 6 of 7)Software Revision 04.00

CI.2

3.05

8

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r



7-15 6600-0017-000 03/12/98 7-15

Figure 7-8gControl Board Schematic-Surface Mount Board (page 7 of 7)Software Revision 04.00

CI.2

3.05

9




7-16 6600-0017-000 03/12/98 7-16

Figure 7-9aDisplay Board Schematic (page 1 of 2)Surface Mount Board (6600-0512-700)

CI.2

3.07

1


7-17 6600-0017-000 03/12/98 7-17

Figure 7-9bDisplay Board Schematic (page 2 of 2)Surface Mount Board (6600-0512-700)

CI.2

3.07

2


7-18 6600-0017-000 03/12/98 7-18

Figure 7-10Wiring DiagramSoftware Revision 04.00

CI.2

3.07

3

Softw

are

Revi

sion

04.

00 a

nd H

ighe

r


7-19 6600-0017-000 03/12/98 7-19

Figure 7-11Controller Plate DiagramControllers with HBJ and HCE serial numbers

OrangeYellow

GND FromPower Receptacle

GND FromGrounding Post

0202-3205-300

0202-1131-300 (2)

Detail A

GND FromRear Controller

GND FromMotor

For all transformer conections install.125" x 1" long heat shrink tubing tocover exposed solder connections.

For transformer and motorconnections see Figure 7-6.

Note: Sleevingmust extendbeyond themotor bracket.

6600-0125-400 (4)

Blue

Green/Yellow

Brown

Blue

0208-0335-300(all cable clamps)

OrangeYellowBrown

0205-4737-300

See Detail A

Blue

6600-0404-800

Black

For red and black wires install.125" x 1" heat shrink tubing tocover exposed solder connectionsand switch terminal.

Red

Green/Yellow

CI.0

2.20

2



7-20 6600-0017-000 03/12/98 7-20

Board Layout(identifies calibrationadj. and socketed chips)

EPROM

Micro-controller

Figure 7-12aControl Board Schematic (page 1 of 2) - units with 3711 chip at U14Controllers with Software Revision 03.00 or higher


R12Section 3.3 I(Fan Sensor Adj.)


R38Section 3.3 H(High AirTemp.Limit Adj.)

R107Section 3.3 G(ADC Hi)


CI.0

2.13

1

R19Section 3.3 F(Line VoltageSignal . Adj.

TP1-1 to 1-8TP2-1 to 2-8

R20Section 3.3 B(+9.8V adj.)



Heater Block Diagram

PhaseGroundNeutral

LineFilter

PowerSwitch

K 1Safety Relay

HeaterControl

CR 13

Heater

SolidStateRelay

ControlLogic

HeaterControlSignal

Thermostat

R 21

U 3

MonitoringCircuit

CI.0

2.13

7

CI.0

2.25

6

Softw

are

Revi

sion

03.

00


7-21 6600-0017-000 03/12/98 7-21

Figure 7-12bControl Board Schematic (page 2 of 2) - units with 3711 chip at U14Controllers with Software Revision 03.00 or higher

TP1-1 to 1-8TP2-1 to 2-8



CI.0

2.13

1







EPROM

Micro-controller


CI.0

2.26

0

CI.0

2.27

3



7-22 6600-0017-000 03/12/98 7-22


EPROM

Micro-controller







CI.0

2.13

1


TP1-1 to 1-8TP2-1 to 2-8


PhaseGroundNeutral

LineFilter

PowerSwitch

K 1Safety Relay

HeaterControl

CR 13

Heater

SolidStateRelay

ControlLogic

HeaterControlSignal

Thermostat

R 21

U 3

MonitoringCircuit

CI.0

2.13

7

Figure 7-13aControl Board Schematic - units with ADC daughter boardControllers with Software Revision 03.00



See sheet 3

CI.0

2.25

7

*

*Replaced by A/D Module

Note: U15 is the same U15 shownon sheet 3

Softw

are

Revi

sion

03.

00


7-23 6600-0017-000 03/12/98 7-23

TP1-1 to 1-8TP2-1 to 2-8



CI.0

2.13

1







EPROM

Micro-controller


Figure 7-13bControl Board Schematic - units with ADC daughter boardControllers with Software Revision 03.00

*

*Replaced by A/D Module

CI.0

2.26

0

CI.0

2.25

9



7-24 6600-0017-000 03/12/98 7-24

Figure 7-13cControl Board Schematic - units with ADC daughter boardControllers with Software Revision 03.00

CI.0

2.25

8

J1 is the header connecting the A/D module to the control board at U14

Note: U15 is the same as shown on sheet 1

Softw

are

Revi

sion

03.

00


7-25 6600-0017-000 03/12/98 7-25

Figure 7-14ThermaLink Board Schematic - boards with test switchControllers with HBJ and HCE serial numbers

Board ComponentsThermaLink Board

CI.0

2.27

4

CI.0

2.27

6

CI.0

2.27

5


7-26 6600-0017-000 03/12/98 7-26

Board ComponentsThermaLink Board (6600-0074-850)

CI.1

4.16

6

CI.1

4.16

7

CI.1

4.16

9

Figure 7-15ThermaLink Board Schematic - boards without test switchControllers with HBJ and HCE serial numbers

Appendix

A-1 A-16600-0017-000 03/12/98

Appendix

Patient Temperature Probe and Air Temperature SensorCharacteristics

Temp Resistance Temp Resistance Temp Resistance Temp Resistance (°C) (Ohms) ( °C) (Ohms) ( °C) (Ohms) ( °C) (Ohms)

1.0 31483.82.0 29909.83.0 28423.74.0 27020.25.0 25694.16.0 24440.87.0 23255.98.0 22135.49.0 21075.3

10.0 20072.111.0 19122.412.0 18223.113.0 17371.314.0 16564.215.0 15799.116.0 15073.817.0 14385.918.0 13733.219.0 13113.920.0 12526.021.0 11967.822.0 11437.623.0 10933.824.0 10455.125.0 10000.026.0 9567.327.0 9155.628.0 8764.0

29.0 8391.329.1 8355.129.2 8319.029.3 8283.029.4 8247.329.5 8211.729.6 8176.429.7 8141.129.8 8106.129.9 8071.230.0 8036.530.1 8002.030.2 7967.630.3 7933.430.4 7899.430.5 7865.630.6 7831.930.7 7798.330.8 7765.030.9 7731.731.0 7698.731.1 7665.831.2 7633.131.3 7600.531.4 7568.131.5 7535.9

31.6 7503.831.7 7471.831.8 7440.031.9 7408.432.0 7376.932.1 7345.632.2 7314.432.3 7283.432.4 7252.532.5 7221.832.6 7191.232.7 7160.832.8 7130.532.9 7100.433.0 7070.433.1 7040.533.2 7010.833.3 6981.333.4 6951.833.5 6922.633.6 6893.433.7 6864.433.8 6835.533.9 6806.834.0 6778.234.1 6749.834.2 6721.534.3 6693.334.4 6665.334.5 6637.334.6 6609.634.7 6581.934.8 6554.434.9 6527.035.0 6499.835.1 6472.635.2 6445.735.3 6418.835.4 6392.135.5 6365.435.6 6339.035.7 6312.635.8 6286.435.9 6260.336.0 6234.336.1 6208.436.2 6182.736.3 6157.036.4 6131.536.5 6106.236.6 6080.936.7 6055.836.8 6030.736.9 6005.837.0 5981.1

37.1 5956.437.2 5931.837.3 5907.437.4 5883.137.5 5858.937.6 5834.837.7 5810.837.8 5786.937.9 5763.138.0 5739.538.1 5716.038.2 5692.538.3 5669.238.4 5646.038.5 5622.938.6 5599.938.7 5577.038.8 5554.338.9 5531.639.0 5509.039.1 5486.639.2 5464.239.3 5441.939.4 5419.839.5 5397.739.6 5375.839.7 5354.039.8 5332.239.9 5310.640.0 5289.040.1 5267.640.2 5246.240.3 5225.040.4 5203.940.5 5182.840.6 5161.940.7 5141.040.8 5120.240.9 5099.641.0 5079.041.1 5058.541.2 5038.241.3 5017.941.4 4997.741.5 4977.641.6 4957.641.7 4937.741.8 4917.941.9 4898.142.0 4878.542.1 4858.942.2 4839.542.3 4820.142.4 4800.842.5 4781.6

42.6 4762.542.7 4743.542.8 4724.542.9 4705.743.0 4686.943.1 4668.343.2 4649.743.3 4631.243.4 4612.743.5 4594.443.6 4576.143.7 4558.043.8 4539.943.9 4521.944.0 4503.944.1 4486.144.2 4468.344.3 4450.644.4 4433.044.5 4415.544.6 4398.144.7 4380.744.8 4363.444.9 4346.245.0 4329.1

46.0 4161.947.0 4002.148.0 3849.349.0 3703.150.0 3563.351.0 3429.552.0 3301.453.0 3178.854.0 3061.355.0 2948.956.0 2841.157.0 2737.858.0 2638.959.0 2544.060.0 2453.0

Appendix

A-2 A-26600-0017-000 03/12/98

Temperature Conversion Chart

°C °F °C °F °C °F

20.0 68.0 34.5 94.1 37.6 99.721.5 70.7 35.0 95.0 37.7 99.922.0 71.6 35.1 95.2 37.8 100.022.5 72.5 35.2 95.4 37.9 100.223.0 73.4 35.3 95.4 38.0 100.423.5 74.3 35.4 95.7 38.1 100.624.0 75.2 35.5 95.9 38.2 100.824.5 76.1 35.6 96.1 38.3 100.925.0 77.0 35.7 96.3 38.4 101.125.5 77.9 35.8 96.4 38.5 101.326.0 78.8 35.9 96.6 38.6 101.526.5 79.7 36.0 96.8 38.7 101.727.0 80.6 36.1 97.0 38.8 101.827.5 81.5 36.2 97.2 38.9 102.028.0 82.4 36.3 97.3 39.0 102.228.5 83.3 36.4 97.5 39.5 103.129.0 84.2 36.5 97.7 40.0 104.029.5 85.1 36.6 97.9 40.5 104.930.0 86.0 36.7 98.1 41.0 105.830.5 86.9 36.8 98.2 41.5 106.731.0 87.8 36.9 98.4 42.0 107.631.5 88.7 37.0 98.6 42.5 108.532.0 89.6 37.1 98.8 43.0 109.432.5 90.5 37.2 99.0 43.5 110.333.0 91.4 37.3 99.1 44.0 111.233.5 92.3 37.4 99.3 44.5 112.134.0 93.2 37.5 99.5 45.0 113.0

CarePlus Specifications

Electrical specifications

Power requirements

Domestic (Designed to UL 2601-1 and CSA 601-1 specifications)120 Vac 50/60 Hz Models (115 Vac ± 10%, 5.7 Amps)

Export (Designed to IEC 601-1 and IEC 601-2-19 specifications)220 Vac 60 Hz Models (220 Vac ± 10%, 3.0 Amps)220-230 Vac 50 Hz Models (220 Vac - 10%, 230 Vac + 10%, 3.0 Amps)240 Vac 50/60 Hz Models (240 Vac ± 10%, 2.7 Amps)100 Vac 50/60 Hz Models (100 Vac ± 10%, 6.4 Amps)

Nominal power consumption

450 watts at maximum heater output

Line voltage compensation

Heat output compensated for line voltage fluctuations up to 10% of nominal line voltage.

Appendix

A-3 A-36600-0017-000 03/12/98

Circuit breakers controllers with HBJ and HCE serial numbers

Rated Current: 7 AmpsTrip Point: 9.8 Amps MinimumType: Manual ResettingModel: ETA 41-06-P10 7 Amps

Circuit breaker on all other controllers

Rated Current: 7 AmpsTrip Point: 9.45 Amps MinimumType: Manual ResettingModel: Airpax Snapak

B. Performance specifications

Patient temperature measurement

Range Displayed: +22 to 42°C (71.6 to 107.6°F)Accuracy*: ± 0.3°C (± 0.5°F) within a range of 30-42°CResolution: ± 0.1°C or °F

Probe Model Numbers: LA003, LA005 (disposable)Probe Interchangeability: ± 0.1°C (± 0.2°F)

Air temperature measurement

Range Displayed: 5 to 50°C (41.0 to 122.0°F)Resolution: ± 0.1°C or °FAccuracy*: Varies over temperature range

Temperature Range Accuracy

5 to 22°C (41-71.6°F) ± 0.5°C (0.9°F)22.0 to 42.0°C (71.6-107.6°F) ± 0.3°C (0.5°F)42.0 to 50.0°C (107.6-122.0°F) ± 0.5°C (0.9°F)

Control temperature ranges

Patient Control Mode: 35.0 to 37.0°C (95.0 to 98.6°F), up to 37.5°C (99.5°F) withinternal adjustment

Air Control Mode: 20.0 to 37.0°C (68.0 to 98.6°F), up to 39.0°C (102.2°F) with controlpanel Override switch.

Thermal performance

Temperature Rise Time*: Less than or equal to 20 minTemperature Variability*: 0.2°C (0.4°F)Temperature Overshoot*: Less than or equal to 0.8°C (1.4°F)

Note: * These terms are defined in the Definitions in the front of the manual.

Appendix

A-4 A-46600-0017-000 03/12/98

Alarms

Indicator and Nonsilenceable Audio AlarmPower Failure

Indicator and Silenceable Single Tone AlarmDifference between patient temperature and patient control temperature exceeds 1.0°Cpatient control mode (can be adjusted to 0.5°C).

Air temperature is 1.5°C above or 3.0°C below air control temperature (air controlmode; Disabled for 15 minutes after control temperature change and for 30 minutes onpower up).

Indicator, Silenceable Two Tone Alarm and Heater ShutdownAir temperature sensor disconnected (both modes)Patient probe disconnected or malfunctioning (patient control mode)Air circulation system failurePatient temperature > 42.0°C or < 30.0°CAir temperature > 38.0°C (air control mode w/o Override)Air temperature > 40.0°C (patient control mode or air control mode with Override)

Indicator, Nonsilenceable Two Tone Alarm, Heater Shutdown and Possible Error CodeSystem failure

Operator prompt tone

Intermittent audio tone sounds when the unit is first switched On and when the patientcontrol mode is first selected. Tone is silenced when control temperature is entered.The heater will not operate until a control temperature has been entered. On controllerswith serial numbers beginning with HBJ, this 30 second tone also precedes allsilenceable alarms.

Proportional heat control

Features zero voltage switching to minimize radiated and conducted EMI. Heaterpower compensated for line voltage fluctuations of up to 10% of the nominal voltage.

Air velocity over mattress

Less than 10 cm/sec. (Double Walled Units)Less than 35 cm/sec. (Single Walled Units)

Noise level within unit

Less than 60 Decibels, A weighted

Note: These are approximate values and are for references only. Actual values mayvary depending on incubator configuration.

Incubator Temperature (°C)

%RH(Incubator)

100

75

50

70 6052

2012

30

0

35 39

High Setting

Low Setting

Empty Reservoir

35

25

CI.0

2.06

7

Appendix

A-5 A-56600-0017-000 03/12/98

Humidifier specifications*

High setting: 65 ± 10% RHLow setting: 45 ± 10% RHEmpty humidifier: 15 ± 10% RH

Specification test conditions used to collect data:Room temperature: 25°CRoom humidity: 50% RHReadings taken two hours after reaching temperature equilibrium without an infant inthe incubator.

*For optional servo-controlled humidifier specifications, see manual 6600-0223-000.

Oxygen concentration within unit

Note: These are approximate values and are for references only. Actual values mayvary depending on incubator configuration.

25 to 45% with 5 l/min. oxygen input35 to 65% with 10 l/min. oxygen input45 to 75% with 15 l/min. oxygen input

Carbon dioxide concentration within unit

Less than 0.5% when a 4% carbon dioxide, 96% air mixture is fed into the infantcompartment at rate of 0.75 l/min (simulated infant occupancy).

C. Safety specifications

Isolation voltage

2500 Vrms 60 Hz from the patient probe to the ac phase and neutral lines for one minute.

IEC 601-1 Class I Equipment

m IEC 601-1 Type B Isolation

Mode of Operation: Designed for continuous operation.Protection against ingress of water: Not protected.

WARNING w The patient probe is not isolated from earth ground. Any additional equip-ment used with the Care Plus must comply with UL 2601, CSA 601-1, IEC601-1, and VDE 750.

Leakage current

For all ground wire configurations with UL, CSA, or AAMI test load attached:

Power supply: 120V 50/60 HzLeakage current: less than 300 µA

Power supply: 220/240 V 50/60 HzLeakage current: less than 500 µA

Self test

The microprocessor performs self test and software verification functions when thepower is first switched On.

Appendix

A-6 A-66600-0017-000 03/12/98

D. Environmental specificationsOperating Temperature Range: 20 to 30°C (68 to 86°F)Storage Temperature Range: -25 to 60°C (-13 to 140°F)Operating and Storage Pressure Range: 500 to 1060 hPaOperating and Storage Relative Humidity Range: 0 to 95%

E. Electromagnetic Compatibility (EMC) SpecificationsAll models meet the requirements as specified in IEC 601-1-2Collateral Standard Electromagnetic Compatibility - Requirements and Tests.

F. Mechanical specificationsIncubator with cabinet

Height: 135.9 cm (53.5 in)Depth: 64.8 cm (25.5 in)Width: 88.9 cm (35.0 in)Weight: 84.04 kg (185 lbs)Casters: 5 inch diameter, 2 locking, 2 non-locking

Incubator only

Height: 62.2 cm (24.5 in)Depth: 61.5 cm (24.2 in)Width: 83.1 cm (32.7 in)Mattress: 34.8 x 65.0 cm (13.7 x 25.6 in)

Maximum Load:30 lbs. (13.6 kg)Tilt Positions:

Two Position: 3 degrees or 6 degreesContinuous Tilt: 0 to 12 degrees

Cabinet rail systems

Maximum total weight: 23 kg (50 lbs), including any items on overhead or rail mountedshelves.

G. ThermaLink Option Specifications

(Applies to controllers with serial numbers beginning with HBJ and HCE)

Hewlett Packard CMS Monitor (Vuelink)

The incubator may be connected to a Hewlett Packard CMS Monitor via a Vuelink openinterface module (HP P/N M1032A Option A05) and HP Ohmeda option cable. The param-eters passed to the HP monitor are: patient temperature, air temperature, set temperature,incubator power, and D.E.T. (Desired Environmental Temperature); the first three param-eters are displayed by default on power-up. The user can select to display any or all of the 5parameters. All alarms are also passed to the monitor. See the Hewlett Packard CMS andVuelink manuals for features and functions of the HP system.

SpaceLabs Monitor (Flexport)

The Incubator may be connected to a SpaceLabs Bedside Monitor via a Flexport (SL P/N90444A). The parameters passed to the SpaceLabs Bedside Monitor are: patient tem-perature, air temperature, set temperature, and P-A (Patient minus Air). All alarms arealso passed to the monitor. See the SpaceLabs Monitor and Flexport manuals for fea-tures and functions of the SL system.

Appendix

A-7 A-76600-0017-000 03/12/98

Serial data

WARNING w The computer or RS-232 monitor’s user program must continuously checkthe data link. The program should constantly verify connection to the incu-bator and check for updated data.

Note: In the event of a power failure, all serial communication will cease until power isrestored.

RS-232 Connector

The Nurse Call and the serial data output share the same female, nine pin, d-type connector.

Pin 2: Receive Data (incubator input)

Pin 3: Transmit Data (incubator output)

Pin 5: Gnd (Signal Ground)

Cable requirements

The user interface cable must have capacitance less than 1500 pF. It should be ashielded cable such as Belden 9611 with AMP connector shielding kit 748046-1 andferrule 747579-8

Data transmission

The incubator continuously sends data from the time that it is first powered up. Note that theincubator cannot be controlled through the serial port. Data output stops when the incubatorreceives a <cntrl>S (XOFF) and resumes when it receives a <cntrl>Q (XON).

Data format

1 start bit, 7 data bits (ASCII), 1 parity bit (odd), 1 stop bit, 1200 baud, full duplex

Serial data has the format: start text character, “<stx>”; Care Plus header, “CP”; softwareversion; data string; checksum characters; carriage return, “<cr>”; line feed, “<lf>”; end oftext character, “<etx>”. Data elements are separated by spaces, “_”. Each String contains53 characters:

Sample data:

<stx>CP0300_36.52_34.20_P_34.80_36.50_00001000_E014_11<cr><lf><etx>

Data for discussion (use the following table):

<stx>CPxxxx_pt.pt_at.at_m_ac.ac_pc.pc_alrmleds_code_ck<cr><lf><etx>

<stx>

Start of text character (ASCII 2); indicates a string of data will follow.

CPxxxx

CP means the data is from the Care Plus; xxxx is the software version in the unit, e.g.0300 for version 3.00.

pt.pt

This is the patient temperature in degrees centigrade. The patient temperature will alwaysbe sent even if it is outside the normal display range. Temperatures less than or equal to1.00°C indicate an open or a disconnected probe. Any temperature greater than or equalto 50°C is a shorted probe.

at.at

This is the air temperature in degrees centigrade. The air temperature will always be senteven if it is outside the normal display range. Temperatures less than or equal to 1.00°Cindicate an open or a disconnected probe. Any temperature greater than or equal to 50°Cis a shorted probe.

Appendix

A-8 A-86600-0017-000 03/12/98

m

This is the mode of operation. P means patient control mode. A means air control mode.Always check the mode of operation before evaluating the air and patient control temperatures.

ac.ac

In the air control mode, this is the air control temperature set with the M and ? switches. Inthe patient control mode this is the air temperature that will maintain the patient controltemperature (or DET). The DET is calculated by the software and changes in response toinfant condition, incubator heat loss, etc. Both readings are in degrees centigrade.

pt.pt

In the patient control mode, this is the patient control temperature set with the M and ?switches in degrees centigrade. It has no significance in the air control mode.

alrmleds

This series of bits represents the alarm LEDs. If an LED is illuminated, the correspond-ing bit is set to 1 (alarm active). If there is no alarm, the bit is set to 0. Audible alarmstatus bit is 1 if an alarm condition exists and if the alarm is not silenced. Audible alarmstatus bit is 0 if there are no active alarms, or if the active alarms are silenced.

00000100

Patient Temperature Alarm

Control Temperature Alarm

High Air Temperature Alarm

Air Circulation Alarm

Probe Failure Alarm

System Failure Alarm

Not Used

Audible Alarm Status Bit

code

This is the error code that appears in the control temperature display during a systemfailure alarm (e.g. E014). If the system is operating normally (no system failure), zeroesreplace the error code (e.g. E000).

ck

This is the two byte ASCII representation of the byte that when added to the sum of allthe ASCII data bytes in the string equals zero. Note that all over flows are dropped andthe sum of the data bytes DOES NOT INCLUDE the <stx>, checksum, <etx>, <cr>, or<lf> characters or the parity bit of each byte.

<cr>

Carriage return character.

<lf>

Line feed character.

<etx>

End of transmission character (ASCII 3).

Appendix

A-9 A-96600-0017-000 03/12/98


Alarms

100%75%50%25%

Patient Temp

Control Temp

High Air Temp

Air Circulation

Probe Failure

System Failure

Power Failure

Heater

AirControl

Mode

Controls

PatientControl

AirControl

AirOverride

> 37° C

Enable°F / °C

PatientControl

CI.0

2.20

7

<stx>CP0300_36.52_34.20_P_34.80_36.50_00001000_E014_11<cr><lf><etx>

Figure A-1Serial data

Nurse Call

Contact ratings

Maximum resistive load: 4 VAMaximum DC switching voltage: 100 VdcMaximum switching current: 0.25 AMaximum carrying current: 0.50 A.

Connector

The Nurse Call contacts and the serial data output share the same female, nine pin, d-type connector.

Pin 6: Closed contact under normal conditions, i.e. poweron, no alarm (recommended configuration)

Pin 1: Common contactPin 9: Open contact under normal conditions, power on, no alarm

These contacts are not powered. They only provide closure.

Table A-1 Nurse Call signals

Incubator Nurse Call SignalStatus Pins 1&6 Pins 1&9

Normal Closed OpenAlarm Open ClosedPower switch off Open Closedor power failsNurse Call cable Open Opendisconnected

WARNING w If you use the normally open Nurse call connection (pins 1 & 9), a discon-nected Nurse Call cable will not trigger an alarm.

Note: Any interruption of incubator power (deliberately switching off the incubator,accidentally unplugging the power cord, etc.) triggers a Nurse Call alarm.

Appendix

A-10 A-106600-0017-000 03/12/98

External Humidifier

WARNING w The external humidifier must be installed for proper incubator operation,even if you do not plan to use the humidifier.

The Care Plus offers three levels of humidification: none, low, and high. If you do notwant humidification, do not put water in the humidifier.

Even at high humidification levels, the humidifier reservoir holds more than enoughwater to last for 24 hours.

1. Gently slide the humidifier out of the base. You will feel an initial resistance. Pullsteadily to avoid spilling the contents of the sump.

2. Set the humidifier down on a level surface and add water to the filllevel indicated on the label (1000 ml maximum).

Note: Do not fill the humidifier past the fill level. Filling past the fill level actuallyDECREASES humidification.

3. Slide the humidifier back into the base.

4. Adjust the slide on the side of the humidifier to set thehumidification level:

• For high humidification move the slide completely back.

• For low humidification move the slide completely forward.

Figure A-2Using the external humidifier

CI.0

2.15

2

Lid

Slide

Humidifier

Appendix

A-11 A-116600-0017-000 03/12/98

Upgrading Existing Units

To upgrade incubator with an internal humidifier, order the Care Plus base replace-ment/upgrade kit (Stock Number 6600-0107-800).

Parts Compatibility

The only difference between the external humidifier model and internal humidifiermodel is the incubator base and the humidifier. All other hood, infant compartment,mounting devices, and electrical components are identical.

Internal humidifier

Units with the old style internal humidifier have a fill port on the left side of the incuba-tor.

To fill the reservoir:

1. Pull the fill port to the open position (Figure A-3)

2. Slowly fill the reservoir with distilled water until the water reaches the fill mark(approximately 700 ml).

3. Close fill port.

To empty the reservoir:

1. Place a catch basin under the fill port and pull the port out, into theopen position.

2. Rotate the fill port counterclockwise and drain the water.

3. Rotate the fill port back to an upright position and push it back into the incubatorbase.

Figure A-3Using the internal humidifier

CI.0

2.01

3

Rotate to Empty

HumidifierFill Port

PullTo Open

Appendix

A-12 A-126600-0017-000 03/12/98

Notes

Ohmeda IncOhmeda DrivePO Box 7550Madison WI 53707-7550USATel 608 221 1551Fax 608 222 9147http://www.ohmeda.com

Cvr Chg03 98

Ohio Care Plus IncubatorS Manual6600 0017 00003 99 I 13 10 06Printed in USA

© Ohmeda Inc

North America

United States

USA Customer ServiceOhmeda IncOhmeda DrivePO Box 7550Madison WI 53707-7550Tel 800 345 2700Fax 608 221 4384

USA Technical SupportOhmeda IncOhmeda DrivePO Box 7550Madison WI 53707-7550Tel 800 345 2755Fax 608 223 2474

USA Service andDistribution CenterOhmeda Inc7750 The Bluffs NWAustell GA 30001Tel 800 345 2755Tel 770 739 4774Fax 770 739 4770

Canada

Customer Service andService CenterOhmeda5975 Falbourne Street Unit 2Mississauga OntarioCanadaL5R 3W6Tel 905 568 9533Fax 905 568 9799Telex 06989362

Asia/Pacific

IndiaOhmedaB.O.C. India LtdOxygen HouseP43 Taratala RoadCalcutta 700 088IndiaTel 91 33 478 4342Fax 91 33 478 4410

JapanOhmeda Ltd.No. 21 Maru Ya Bldg.2-6-11 Kaname-cho Toshima-kuTokyo 171 JapanTel: 81-3-3973-4055Fax: 81-3-3973-9102

MalaysiaOhmedaMalaysian Oxygen Berhad13 Jalan 22246100 Petaling JayaSelangorMalaysiaTel 60 3 755 4233Fax 60 3 756 6389

SingaporeOhmeda Pte Ltd198 Yishun Avenue 7Singapore 768926Tel 65 753 6311Fax 65 753 1817

AustraliaOhmedaUnits 1 & 2149 Arthur StreetP O Box 356HomebushNSW 2140AustraliaTel 61 132 229Fax 61 297 461796

Europe

AustriaOhmeda Austria GmbHAm Concorde Park E1 / 7A - 2320 SchwechatAustriaTel 43 1 706 36 60Fax 43 1 706 36 60 - 11

BelgiumOhmedaDivisie van BOC NVMaaltecenter Blok GDerbystraat 2519051 GentTel 32 9 220 4757Fax 32 9 221 8541

DenmarkBOC Ohmeda A/SCarl Gustavs Gade 3Høje-TaastrupDK-2630 TaastrupDenmarkTel 45 43 71 43 72Fax 45 43 71 72 71

FinlandBOC Ohmeda OyPL 78 Kuunkehrä 2 B02211 EspooFinlandTel 358 9 803 73 44Fax 358 9 803 05 69

FranceOhmedaParc De Pissaloup8 Avenue Jean D’Alembert78191 Trappes-CedexFranceTel 33 1 30 68 60 00Fax 33 1 30 68 60 01

GermanyOhmeda GmbH & co.KGLangemarckplatz 3D 91054 ErlangenGermanyTel 49 91 31 81 01 10Fax 49 91 31 81 01 77

ItalyOhmedaVia Carpaccio 3320090 Trezzano sul NaviglioMilanItalyTel 39 2 445761Fax 39 2 48403233Telex 314479 I

NetherlandsOhmeda BVRembrandtlaan la3723 BG BilthovenNetherlandsTel 31 30 2289 289Fax 31 30 2288 366

SpainOhmedaC/Manuel Tovar 2628034 MadridSpainTel 34 1 334 26 00Fax 34 1 358 12 84

SwedenBOC Ohmeda ABNordicPO Box 631Östra Sandgatan 12S 251 06 HelsingborgSwedenTel 46 42 17 87 40Fax 46 42 17 87 47

United KingdomOhmedaOhmeda House71 Great North RoadHatfield HertfordshireAL9 5EN EnglandTel 44 1707 263570Fax 44 1707 260191Telex 915128

Latin America,Caribbean

Latin AmericaOhmeda9200 Dadeland BoulevardSuite 610Miami FL 33156USATel 305 670 9938Fax 305 670 4834

Middle East

DubaiOhmedaMiddle East OperationsP O Box 5527DubaiUnited Arab EmiratesTel 97 14 822653Fax 97 14 822659

Documents

1-FC - Care Plus 3/98 - Diagramas Electrónicos Para Reparararchivos.diagramas.mx/otros/CarePlus Service Manual[1].pdf · Care Plus® Access Incubator Service Manual. ... 2.3 Mounting