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Service Manual Energy Storage Unit - 64860066-000
Service Manual Energy Storage Unit - 64860066-000
This manual contains descriptive information of the equipment identified by the type number stated above.
For information on specific applications refer to the System Manual of the Surgical Stand.
PMSN Best
2 (10.0)
3 (10.0)
4 (10.0)
5 (10.0)
6 (10.0)
7 (10.0)
8 (10.0)
9 (10.0)
10 (10.0)
11 (10.0)
12 (10.0)
13 (10.0)
14 (10.0)
15 (10.0)
16 (10.0)
17 (10.0)
18 (10.0)
19 (10.0)
20 (10.0)
21 (10.0)
22 (10.0)
23 (10.0)
Z1-1 (10.0)
Z1-2 (10.0)
Z2-1 (10.0)
Z2-2 (10.0)
Z3-1 (10.0)
Contents
1. INTRODUCTION .............................................................................................................5
4. INSTALLATION.............................................................................................................17
4.1. Setting to work ............................................................................................................17
4.2. Functional description .................................................................................................17
4.2.1. Overcharge ..............................................................................................................17
4.2.2. Overcharge time ......................................................................................................17
4.2.3. Battery voltage %.....................................................................................................18
4.2.4. Charger current %....................................................................................................18
4.2.5. Lamp circuit..............................................................................................................18
6. REPLACEMENT............................................................................................................20
6.1. Replacing mains fuses (F1, F2) ..................................................................................20
6.2. 55 A Fuse (F3) ............................................................................................................20
7. ADJUSTMENTS ............................................................................................................21
7.1. checking Battery V max. and frequency calibration ...................................................21
1. INTRODUCTION
The Energy Storage Unit is a rechargeable battery assembly consisting of a battery pack and battery charger .
The Energy Storage unit is intended for use with the HF Generator in the BV300 plus, BV Pulsera series and
Veradius system of Mobile Surgical stands.
WARNINGS
The warning label on the battery charger box means that HIGH VOLTAGE is present
inside the box. Once the box is opened, it is necessary to proceed very carefully
because high voltage leads are exposed. Touching these leads could cause injury.
The Energy Storage Unit (ESU) has the function, within the IXION system, to provide the continuous power
supply to the HF generator, in the correct voltage range (240 ÷366 Vdc ± 2.5 Vdc). The lower threshold voltage
(240 V) is not controlled by the ESU, while the upper limit is controlled.
The input voltage (230 Vac) must be provided by the Host system via a medical double insulated transformer.
The power coming from the mains (230V) is rectified and supplied through an high frequency power converter to
a battery pack where it is stored waiting to be supplied to the HF Generator.
Battery Charger - power supply for battery and interface with Host system.
Battery Pack - series of 26 battery, core of sub subsystem where Energy is storage.
Interconnecting cables - Power cable, Lamp cable and signal/interface cable
The battery pack usable output voltage is within 240(±2.5) - 366(±2.5) Vdc, with a maximum peak current < 90 A
.
To restore the energy losses of the battery pack during the operations, two different charging modes,
controlled by the battery charger are implemented: the floating mode, that can be operated in every
conditions of use (i.e. during operations and in standby), and the overcharge mode that can take place
only when the system is switched off.
For the overcharge mode the system control shall be master and the ESU the slave.
NOTE
The Energy Storage Unit must be powered by medical insulating transformer as required for
C-UL Certification
Notes
Mains voltage 230 ±10 % Vac, 50/60 Hz
Mains current 1,5 Arms
Output voltage 240 - 366 Vdc ( ± 2.5 Vdc)
Charge current 500mA
Overcharge voltage 403V±5V
Overvoltage protection 440V
Iout max ≤ 90 A max
Battery Charger 87%
Efficiency
Clearance for air flow ≥ 12 mm
Size 360 x 261 x 299 mm max. (width x length x height)
Mass ≈ 36 kg
Cooling internal fan
Operational temperature 10° C < T < 50° C
Overcharge mode
500mA
NOTE
The life of the battery is shortened when the temperatures exceed those given above.
Incorrect charging/discharging can also result in a shortened life.
350
voltage (V)
340
ON charge
OPEN circuit
330
320
310
300
0% 20% 40% 60% 80% 100%
charge (%)
Fig 1 Battery charge function of the voltage during the normal battery charge
The battery charger groups has the functions to control the battery pack energy delivery to the HF generator and
the charge mode of the battery pack, according to commands received by the system control, and to provide the
system control with status information.
To implement these functions the battery group is composed by one board with components on both sides.
The method used to control the battery charge are two different high frequency power stadium:
• Buck converter
• DC/AC converter full bridge.
The control (microcontroller) uses the load current and the battery charge voltage, sensed by the resistors, to set
the load current within the current range from typically <20mA till 500mA maximum.
The charging current is a function of the battery voltage, when the battery voltage approaches the maximum
voltage the charge current begins to reduce.
Figure 1 shows the battery voltage as function of the battery charge percentage.
On the control board are placed the command inputs for the Z1 and Z2 relays and the output signalling that the
charge voltage is not present.
The maximum charge current is 500 mA in normal mode and in overcharge mode; the full charge is maintained
by a float voltage of 366 V with a current typically < 20 mA.
The selection of the charging mode is performed, by the system control, by means of the generation of a
"overcharge enable" pulse command (active LOW); the ESU answers to this command using the overcharge
acknowledge (enable OK) signal (active low).
Variable frequency output signals are given to the system control to inform it about the battery voltage and
charger output current, when the system is ON, those signal are derived by a proper micrcocontroller used like
Voltage to Frequency converter.
The charger has also an output for a led lamp to indicate that the battery charger mains supply is ON, and it is
used also to indicate, when the system is switched OFF but plugged into the mains, the battery voltage status
during the battery charge phase.
There is present a fan to move the air within the charger box.
Fuses
Mains feeding fuse F1 3.5 A (5x20 Type T High Breaking Capacity)
Mains feeding fuse F2 3.5 A (5x20 Type T High Breaking Capacity)
Energy storage output fuse F3 55 A (19.4x78.3 Type FF)
Capacitor Bank output fuse F4 55 A (19.4x78.3 Type FF)
Test points
TP0 Reference
TP1 VBUS (+385V) refer to TP2 [Normally 385Vdc]
TP2 O Vbus
TP3 VCO timer refer to TP0 From 0KHZ to 10KHz
TP4 Voltage +12V refer to TP0 [Normally 12Vdc]
TP5 +5V refer to TP2
TP6 Vcharger refer to TP0
TP7 Icharger refer to TP0 [1V=244mA]
TP8 +5V refer to TP0
TP9 VBattery refer to TP0
TP10 Spare
VF timer refer to TP0
TP11 From 0KHZ to 10KHz
(VCO Battery Voltage)
CF timer refer to TP0
TP12 From 0KHZ to 10KHz
(VCO Charge current)
Adjustments
R215 Used to set the no load charger voltage at 366 ± 1 V (factory set)
J2
Molex Lamp Cable Pin Direction Description
22-27-2021 connector 1 Output
2 Output
J5
Molex Pin Direction Description
Fan Cable connector
22-27-2021 1 Output
2 Output
Environmental
Temperature: -25° C to 40° C long term
-25° C to 50° C short term ( 5 weeks )
Pressure: 70 - 110 kPa
Humidity: 5 - 95%
Vibration
Frequency: 10 - 150 Hz
g value: 0 - 2
Amplitude: 0 - 0.15 mmt
Shocks
g value: 0 - 10 g
Pulse duration: 6 - 10 msec.
3.6. STANDARDS
The Energy Storage Unit is developed and manufactured with observance of a number of directives, regulations
and standards ( e.g. IEC, UL, CSA). Information regarding the compliance status with standards and product
approvals can be obtained from:
Gilardoni S.p.A.
Quality Assurance Department
Via Arturo Gilardoni 1
23826 Mandello del Lario (LC)
Italy
Type
HARTING - 09185166813
Pin Description
1 Lamp +
2 Lamp -
Pin Description
1 power line
2 power line
3 Ground
Pin Description
1 + Battery Blu 230mm
Charge 500mA
370
540
520
500
480 360
460
440
420 350
400
380
360 340
340
320
300 330
Volt
mA
280
260
240 320
220
200
180 310
160
140
120 300
100
80
60 290
40
20
0 280
0 100 200 300 400 500 600 700 800 900 1000
minutes
I Batt V Batt
OverCharge 500mA
420
540
520
500
480 400
460
440
420
400 380
380
360
340
320 360
300
Volt
mA
280
260
240 340
220
200
180
160 320
140
120
100
80 300
60
40
20
0 280
0 50 100 150 200 250 300 350 400
minutes
I Batt V Batt
4. INSTALLATION
For the installation procedure of the ESU see the procedure for the ESU in the replacement section of the
Service Manual Corrective Maintenance of the X-ray system
After a replacement, make sure that all the Energy Storage Unit cables are reconnected.
The OVERCHARGE MODE is set on the base of the discharges of the battery pack.
4.2.1. OVERCHARGE
The battery overcharge starts after the reception of the overcharge command from the system control, via the
specific cable, and the system is switched OFF. When the system is switched ON the overcharge mode is
suspended and the floating mode is resumed.
The CHARGER sets active the “ENABLED OVERCHARGE” signal and, via the electrical interface, send it back
to the system control as soon as the overcharge command has been received.
To sense if the system is switched ON / OFF is used the 5 V and the 0 V lines at the electrical interface coming
from the system control.
The ENABLE signal is stored into the CHARGER because the system control send it as a pulse signal and to
overcome the case when the CHARGER mains supply is disconnected.
The overcharge voltage is applied only when the battery voltage crosses the threshold of 350 V± 5V; As soon
as the 350 V threshold is crossed the overcharge timer starts; the timer switches the charger to the normal mode
after a fixed time (approx. 180 min) in the case the overcharge current has not crossed the lower current
threshold (100 ± 5 mA).
The timer is required to prevent damages to the battery pack in case of a too long overcharge.
If the overcharge is stopped, by switching ON the system, the overcharge time is transmitted to the system
control using the “OVERCHARGE TIME” line in the form of a variable frequency signal.
Once the overcharge is completed the CHARGER comes back to the normal floating mode and a “overcharge
completed” signal is made active via the electrical interface.
Via the electrical interface a RESET signal is sent, by the system control, to the CHARGER to reset all the
stored signals.
The signals stored are the overcharge enable and overcharge timer value.
curr. mA 25±10 50±10 100±10 150±10 250±10 350±10 450±5 > 515±5
lim. 0.44/0.66 0.88/1.32 1.95/2.65 2.90/4.00 5.15/6.35 7.80/8.60 9.950/10.05 10.2/10.7
Freq.kHz
The lamp has three main different functionalities: 1) during the normal operation the led is lit indicating that the
ESU is powered, 2) while the batteries are charging the led is flashing, at different frequency, indicating different
charge status, and it stops the flashing when the charge status is around 100 % of charge, 3) led switched off
when the system is plugged into the mains but some faults are in the charger.
Floating mode
Overcharge mode
In case of fault detected in the charger the led is always switched OFF.
5. CORRECTIVE MAINTENANCE
Alarm 3 is automatically restore after fault condition is solved. Alarm 1 is automatically restore after fault
condition is solved only if Battery Charger OFF is drive from Host system.
Alarm 1,2,4, stops battery charger an ON/OFF at mains level is need for reset.
Switch charger OFF by mains connector, wait about one minutes and then restart charger; If the problem
remains check replace the Energy Storage Unit
Measure with a scope the frequency between Tp11 and Tp0 and between Tp12 and Tp0.
Check the charge current and voltage. See current % and voltage % specification during the battery charge’.
Replace the Energy Storage Unit if not according to the charge curve.
C1
V1
Check the Charge lamp +12 V power supply between Tp0 and Tp4. If the +12 V power supply is OK but the
charge lamp is off replace the Energy Storage Unit.
6. REPLACEMENT
The only field replaceable items are the fuses.
7. ADJUSTMENTS
No adjustments are required, but the following sections show how the factory calibrations can be checked.
NOTE
This gives a max voltage of 366 ± 2.5 V (when the batteries are connected with charger on)
9. BATTERY CONNECTION
Before to use the batteries is necessary to restore the circuit configuration, as the batteries have been shipped
disconnected from the battery charger in order to preserve their power charge.
Take off the plastic cover of the last battery Negative side
Z1-1
J13 Power
cable connector
J2 lamp cable
connector J5 Fan
connector
J1 mains
connector
J9 control cable
connector
Z1-2
4598 000 3119.x/10405600 (10.0)
(Gil document code 64860066) Energy Storage Unit
Z2-1
Z2-2
4598 000 3119.x/10405600 (10.0)
(Gil document code 64860066) Energy Storage Unit
To Battery
EMI
Filter
Rectifier Power
Insulation
bridge relay
transforme
PFC Buck DC/AC
r
Converter converter
Stand by
Low voltage supply
Feedback
Optocoupler Loop control and µContorller
VtoF
µContorller
Optocoupler
Lamp cable
Signal cable
Z3-1
4598 000 3119.x/10405600 (10.0)