Ohio® Care Plus®

Series 1000/2000
Incubator
Service Manual
User Responsibility
This Product will perform in conformity with the description thereof contained in this
operating manual and accompanying labels and/or inserts, when assembled, operated,
maintained and repaired in accordance with the instructions provided. This Product
must be checked periodically. A defective Product should not be used. Parts that are
broken, missing, plainly worn, distorted or contaminated should be replaced immedi-
ately. Should such repair or replacement become necessary, Ohmeda recommends
that a telephone or written request for service advice be made to the nearest Ohmeda
Regional Service Center. This Product or any of its parts should not be repaired other
than in accordance with written instructions provided by Ohmeda and by Ohmeda
trained personnel. The Product must not be altered without Ohmeda’s prior written
approval. The user of this Product shall have the sole responsibility for any malfunction
which results from improper use, faulty maintenance, improper repair, damage or
alteration by anyone other than Ohmeda.

CAUTION w Federal law in the USA and Canada restricts this device to sale by or on the
order of a licensed medical practitioner.

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

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

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

s This static control precaution symbol appears throughout this manual. When
this 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 ground
and not through static sensitive devices.

Technical Competence
The procedures described in this service manual should be performed by trained and
authorized personnel only. Maintenance should only be undertaken by competent
individuals who have a general knowledge of and experience with devices of this
nature. No repairs should ever be undertaken or attempted by anyone not having such
qualifications.

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

Read completely through each step in every procedure before starting the procedure;
any exceptions may result in a failure to properly and safely complete the attempted
procedure.

i 6600-0292-000 2/2/99 i
Table of Contents
Definitions
Note: A note provides additional information to clarify a point in the text.

Important: An Important statement is similar to a note, but is used for greater empha-
sis.

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

equipment exists.

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

Accuracy: As stated in the performance specifications, the assigned accuracy of the

equipment; including all the system components from the sensors to the display.

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

Desired Environmental Temperature (DET): The air temperature required to maintain

the infant’s temperature at the patient control temperature (patient control mode).

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

mattress.

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

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

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

Temperature Equilibrium: The condition where the average incubator temperature

does not vary by more than 0.2°C in a one hour period.

Temperature Variability: The maximum difference between the incubator temperature

and the average incubator temperature at equilibrium.

Temperature Overshoot: The number of degrees by which the maximum incubator

temperature exceeds the average incubator temperature at temperature equilibrium
following 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

ii 6600-0292-000 2/2/99 ii
Table of Contents
Important
Technical Competence .................................................................................................... i

Precautions
Warnings ........................................................................................................................ ix
Cautions .......................................................................................................................... x

1/Functional Description
1.1 Control Board ......................................................................................................... 1-1
A. Microprocessor ...............................................................................................1-3
B. SRAM & EPROM ............................................................................................ 1-6
C. Over temperature & Air_Display Sensor ........................................................ 1-6
D. Power Supply Circuitry ................................................................................... 1-7
E. Heater Control ................................................................................................1-8
F. Analog Inputs ................................................................................................1-10
G. Watchdog Timer ...........................................................................................1-10
H. Audible Alarm ...............................................................................................1-11
I. A/D Converter ................................................................................................1-11
1.2 Display Board ......................................................................................................1-13

2/Set Up and Checkout

2.1 Mounting the Care Plus on the cabinet .................................................................. 2-1
2.2 Checkout Procedure .............................................................................................. 2-2
A. Mechanical checks .........................................................................................2-2
B. Accessory checks ........................................................................................... 2-4
C. Controller checks ............................................................................................ 2-6
D. Operational checks .......................................................................................2-10

iii 6600-0292-000 2/2/99 iii

Table of Contents
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 Calibration Procedures .......................................................................................... 3-3
A. Preparation .....................................................................................................3-3
B. Check Voltage Supplies .................................................................................. 3-5
C. Display Brightness .......................................................................................... 3-5
D. Alarm Frequency ............................................................................................ 3-6
E. Line Voltage Compensation ............................................................................ 3-7
F. Analog to Digital Converter (ADC) .................................................................. 3-7
G. Alarm Volume .................................................................................................3-8
H. Air Safety Circuit Calibration (High Air Temperature Alarm) .......................... 3-9
I. Fan Sensor Adjustment .................................................................................... 3-9
J. Thermal Switch Operation .............................................................................3-10
K. Setting the Patient Temperature Alarm Threshold ....................................... 3-10
L. Setting the Maximum Patient Control Temperature ...................................... 3-10
M. Closure .........................................................................................................3-10
3.5 Electrical Safety Check ........................................................................................ 3-11
A. Leakage Current ...........................................................................................3-11
B. Ground Resistance Check ............................................................................ 3-11

4/Troubleshooting
4.1 Alarms and Error Codes ........................................................................................ 4-1
A. Front Panel Alarms .........................................................................................4-2
B. Error Codes .................................................................................................... 4-5
4.2 Power Up Tests ...................................................................................................4-10
4.3 On Line Testing ...................................................................................................4-10
4.4 On Demand Testing .............................................................................................4-11
A. RAM Memory Display Loop .......................................................................... 4-11
B. Switch Activated Displays .............................................................................4-12
4.5 Test Points ...........................................................................................................4-13

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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
s5.6 Control Board Replacement ................................................................................. 5-8
s5.7 Display Board Replacement ..............................................................................5-10
5.8 Solid State Relay Replacement ........................................................................... 5-13
5.9 Heater and/or Heater Gasket Replacement ........................................................ 5-14
5.10 Thermal Switch Replacement ............................................................................ 5-16
5.11 Fan Sensor Replacement .................................................................................. 5-16
5.12 Fan Motor Replacement ....................................................................................5-18
5.13 Battery Replacement .........................................................................................5-20
5.14 Cabinet Caster Replacement .............................................................................5-20

6/Illustrated Parts
6.1 Hood Components .................................................................................................6-1
6.2 Hood Latch Assembly, Compartment Probe and Related Items ........................... 6-5
6.3 Base Platform Components ................................................................................... 6-6
6.4 Cabinet Components ...........................................................................................6-10
6.5 Controller Components ........................................................................................ 6-14
6.6 Board Components ..............................................................................................6-23
6.7 Label Sets ............................................................................................................6-25

7/Schematics

Appendix
Patient Temperature Probe and Air Temperature Sensor Characteristics ................. A-1
Temperature Conversion Chart .................................................................................. A-2
CarePlus Specifications ............................................................................................. A-2
A. Electrical specifications ................................................................................. A-2
B. Performance specifications ............................................................................ A-3
C. Safety specifications ...................................................................................... A-5
D. Environmental specifications ......................................................................... A-6
E. Electromagnetic Compatibility (EMC) Specifications ..................................... A-6
F. Mechanical specifications .............................................................................. A-6

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TableofofIllustrations
List Contents
1/Functional Description
Figure 1-1 Control Circuitry Block Diagram ........................................................... 1-2
Figure 1-2 Power Supply Circuitry ......................................................................... 1-7
Figure 1-3 Heater Control and Monitoring Circuits ................................................ 1-9
Figure 1-4 Display Board Block Diagram ............................................................1-14

2/Set Up and Checkout

Figure 2-1 Mounting the CarePlus Incubator on a cabinet .................................... 2-1
Figure 2-2 Operating Controls, Indicators and Connectors ................................... 2-5
Figure 2-3 Control Panel ....................................................................................... 2-7

3/Calibration and Adjustments

Figure 3-1 Cable for Variable Resistance Box ...................................................... 3-2
Figure 3-2 Control Board Test Points and Potentiometers .................................... 3-4
Figure 3-3 Display Brightness Adjustment ............................................................ 3-6

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

5/Repair Procedures
Figure 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 .................................................... 5-11
Figure 5-9 Display Panel Controllers ................................................................... 5-12
Figure 5-10 Heater, Thermal Switch and Fan Sensor Replacement ..................... 5-15
Figure 5-11 Fan Motor Replacement ....................................................................5-18

vi 6600-0292-000 2/2/99 vi
List
TableofofIllustrations
Contents
6/Illustrated Parts
Figure 6-1 Hood Frame and Hardware ................................................................. 6-1
Figure 6-2 Hand Hole Assembly ........................................................................... 6-2
Figure 6-3 Iris Porthole Assembly ......................................................................... 6-3
Figure 6-4 Front Door and Inner Wall Assembly ................................................... 6-4
Figure 6-5 Incubator Assembly, Filter and Hood Latch ......................................... 6-5
Figure 6-6 Base Platform, Humidifier and Cover Assembly .................................. 6-7
Figure 6-7 Base Platform Assembly ...................................................................... 6-8
Figure 6-8 Casters and Base ..............................................................................6-11
Figure 6-9 Cabinet Parts .....................................................................................6-12
Figure 6-10 I.V. Pole and Bumpers .......................................................................6-13
Figure 6-11 Motor, Fan Sensor, Circuit Breaker and Transformer Assembly ....... 6-15
Figure 6-12 Back Panel .........................................................................................6-17
Figure 6-13 Controller Chassis and Fan Assembly ...............................................6-19
Figure 6-14 Cover Assembly ................................................................................. 6-21
Figure 6-15 Control Panel Assembly ..................................................................... 6-23
Figure 6-16 Display Board .....................................................................................6-25
Figure 6-17 Control Board .....................................................................................6-26

7/Schematics
Figure 7-1a Control Board Schematic (page 1 of 7) ................................................ 7-1
Figure 7-1b Control Board Schematic (page 2 of 7) ................................................ 7-2
Figure 7-1c Control Board Schematic (page 3 of 7) ................................................ 7-3
Figure 7-1d Control Board Schematic (page 4 of 7) ................................................ 7-4
Figure 7-1e Control Board Schematic (page 5 of 7) ................................................ 7-5
Figure 7-1f Control Board Schematic (page 6 of 7) ................................................ 7-6
Figure 7-1g Control Board Schematic (page 7 of 7) ................................................ 7-7
Figure 7-2a Display Board Schematic (page 1 of 2) ............................................... 7-8
Figure 7-2b Display Board Schematic (page 2 of 2) ............................................... 7-9
Figure 7-3 Wiring Diagram .................................................................................. 7-10
Figure 7-4 Controller Plate Diagram ....................................................................7-11

vii 6600-0292-000 2/2/99 vii

Table of Contents
Notes

viii 6600-0292-000 2/2/99 viii

Precautions
Table of Contents
wWarnings
Two people are required to lift the Care Plus Incubator. Follow safe lifting techniques to
avoid injury.

After completing a repair, the appropriate calibration procedure must be performed.

After completing any portion of the calibration and adjustment procedures, perform the
Checkout Procedure to make sure that the Care Plus Incubator is operating correctly.
In addition, a final Electrical Safety Check , section 3.5, must be performed. Record the
information for future reference.

Disconnect the power to the incubator for the mechanical portion of the Checkout
Procedure.

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

Before any disassembly or repair, disconnect the electrical supply and any gas supply
connections. Also remove any accessories. Do not perform any service or maintenance
with 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 been
serviced.

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

Never oil or grease oxygen equipment unless a lubricant that is made and approved 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 oxygen service lubricant recommended
(Stock No. 6700-0092-200).

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

The humidifier plugs must be installed for proper incubator operation, if you do not plan
to use the humidifier.

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

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

The patient probe is not isolated from the earth ground. Any additional equipment used
with the Care Plus must comply with UL 544, CSA 22.2, IEC 601 and VDE 750

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

ix 6600-0292-000 2/2/99 ix
Precautions
Table of Contents
wCautions
Servicing of this product in accordance with this service manual should never be
undertaken in the absence of proper tools, test equipment and the most recent revision
of this service manual which is clearly and thoroughly understood.

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

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

When handling the controller, avoid bumping the fan or the heater. If these items are
knocked 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 the
Checkout Procedure, check for brittle or deteriorated insulation on the power cord.

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

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

x 6600-0292-000 2/2/99 x
1/Functional Description
The incubator control circuitry is located inside the removable controller. The controller
interfaces 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.

Two external thermister assemblies supply temperature signals to the control board.

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

The air temperature sensor mounts on the hood inside the infant compartment and
attaches with the air temperature sensor connector, located on the left side of the
controller. It contains two separate thermistor circuits: the air control thermistor signal is
used by the control circuitry to adjust heater output and to trigger alarms; the air display
thermistor 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.

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

1.1 Control Board

The control board contains the incubator logic circuitry, diagrammed in Figure 1-1, as
well as the power supply and distribution circuitry, diagrammed in Figure 1-2. Please
refer 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 analog
to 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 to
drive the alarm in case of power outages.

1-1 6600-0292-000 2/2/99 1-1

1/Functional Description

CI.23.067

* Circuit produces feedback signal to microcontroller.

Figure 1-1
Control Circuitry Block Diagram

1-2 6600-0292-000 2/2/99 1-2

1/Functional Description
A. Microprocessor
Memory Allocation and Peripherals
The processor accesses the digital I/O ports via two different methods: Port 1 of the
microcontroller (pins 2-9) interface to the display board, while all of the other ports are
external memory mapped. Memory mapping the ports simplifies both the hardware and
software, and allows for the use of common off the shelf parts to minimize the chance
of obsolescence. The external data space is 64K bytes, and is divided up as indicated
in 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 the
same value. For an output port, any address in this range can be written to. As an
example, to write to Output Port #1, writing to address 4000h is the same as writing to
address 4FFFh - only one write is needed to latch the data.

1-3 6600-0292-000 2/2/99 1-3

1/Functional Description
Address decoding is accomplished by decoding the upper address lines with a
74HC138 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 3
address lines A12 through A14. The outputs are further qualified by /RD and /WR using
OR gates U1 and U2. This prevents programming errors from writing to a read only
port. It also prevents activating a port when accessing program memory, since only one
of the signals /PSEN, /RD or /WR will be active for any given bus cycle. The table
below defines the bits of the Input #1 port (U4).

Bit Signal Name Function

0 HEATER_STATUS High when AC is applied

to heater.

1 /OT (OverTemp) From Air Overtemp circuit

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

AIR_DISPLAY sensor

3 Frequency From U23, square wave with

frequency the same as AC line

4 2KHz 556 timer - audible alarm

frequency

5 DATA_OUT Read data from the

EEPROM (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).

Bit Signal Name Function

0 HIGH_PRIORTY_ALARM See Table 1-4

1 LOW_PRIORTY_ALARM See Table 1-4

2 WATCHDOG_TIMER Pulsed on a regular basis

by firmware to keep the
watch dog timer reset

3 -MUX_CAL Used by the Air Overtemp

circuit mux (U26)

}
4 MUX_A

5 MUX_B Selects the analog channel

to convert at the ADC

6 MUX_C

7 RUN/HOLD Enables/disables the ADC

conversions.

Table 1-3 — Output #1 bit definitions

1-4 6600-0292-000 2/2/99 1-4

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

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)

Bit Signal Name Function

0 HEAT Controls external heater

solid state relay

1 CALL Signals the external Nurse

Call board

2 SBR1

}
3 SBR2 Bank select for SRAM.
Allows 64K of storage

4 SBR3 space to be used.

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

1-5 6600-0292-000 2/2/99 1-5

1/Functional Description
B. SRAM & EPROM

The SRAM (U7) on the board is 128K x 8 in size. Only 4K of the device is available to
the processor (via the /CS1 chip select). A bank select scheme was implemented using
the 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 output
port 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). The EPROM
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, allowing for
firmware expansion.

An electrically erasable PROM (EEPROM) is located at U28. This is the common

93C46 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 an
over 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 dip
switch SWI and the -MUX_CAL signal from the processor) and presents it to U10. If the
input 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 U10
act as a window comparator: When the input voltage is between the voltages set at
pins 4 and 7 of the comparators, the open collector outputs stay high. When the input
goes outside this range (for example, the AIR_DISPLAY sensor is missing or shorted to
ground), 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.

1-6 6600-0292-000 2/2/99 1-6

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

Logic power is supplied by a dual linear regulator design. Voltage regulator VR3 is a
7805 5 volt regulator, with the GND pin raised up from ground to generate the 10V
signal (+9V_STDBY) from the input rectified voltage (+11_UNREG). This is used to
trickle charge an off board NiCd backup battery through R34. Schottky diode D1
presents a low impedance path for powering the board during loss of AC power. Diode
D4 isolates VR3 from the battery backup power.

VR1 drops the 10 volts down to the 5V supply needed by the logic. VR1 is an LM2937
low dropout (LDO) regulator. C64 is the output capacitor for the regulator, and must be
present to guarantee that the LDO regulator remains stable. The regulator was chosen
to be footprint compatible with the 7805, but allows for longer battery life by presenting
a lower voltage drop between input and output pins.

Line Frequency
Pulsed DC Signal +8 V Unregulated
(Power Failure (To Heater Control
Detection) Circuit)
8 Vac

+5 V Display
Rectifier +5V (To Display
Regulator Board)

8 Vac

Line Voltage +9 V Standby

CI.02.136
Signal (Approx. 7 Volts;
(Adjustable) from Battery
11 Vac during Power
+9.8 V (To Failure
Battery and
Air Flow
Sensor)
Regulator
Rectifier +5 V Standby
(Adjustable Regulator
(Control
Bias)
Board Logic)

11 Vac

Figure 1-2
Power Supply Circuitry

1-7 6600-0292-000 2/2/99 1-7

1/Functional Description
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 low
pass filter that eliminates the AC line ripple on the unregulated bus. Diode D2 prevents
momentary 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 the
ADC for conversion.

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

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

E. Heater Control
The heater control algorithm ensures that line voltage variations will not affect the
heater output as long as the voltage remains between 90 and 110% of the nominal
voltage (115 volts for 120 volt units). For voltages outside this range, the line voltage is
assumed 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 output
necessary to maintain the required temperature, between 0 and 60 cycles will be
delivered to the heater every second. When the line voltage is within 10% (90% to
110%) 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 of
cycles is calculated by multiplying the percentage of the maximum heater output
required by 60. For example, at 90% of the nominal voltage, the heater would be on for
60 cycles out of 60 when 100% of the maximum heater output was required. Above
110% 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 state
relay, and a thermal switch wired in series. The heater is normally switched ON and
OFF by closing or opening the solid state relay.

The heater is switched by two relays, and its voltage status is sensed by an electrically
isolated circuit. Darlington transistor Q2 and resistors R41 and R45 control an off board
solid state relay (SSR). This is controlled by the HEAT signal, from output port of chip
U19. The onboard relay, K1, is controlled by Darlington transistor Q1 and associated
components by the RELAY signal, from the Air Overtemp circuitry.

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1/Functional Description

CI.02.133
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 inputs
attached across the heater terminals. Resistors R29, R35, R37 and R38 limit the
maximum current through the bridge circuit, and provide a level of redundancy. The
output 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 an
inverter, so HEATER_STATUS is high when heater power is applied. Inverter gate U8
lights 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.

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1/Functional Description
Safety Relay

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

Under normal conditions, the Relay signal is high ( +2.4 Vdc minimum). This switches
on 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 goes
low (0.5 Vdc Maximum), switching OFF the transistor and opening the safety relay
contacts.

Solid State Relay

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

The microcontroller switches ON the heater by setting the Heat signal high. This
switches ON Q2, turning on the solid state relay and activating the zero crossing
detection circuit inside the relay. Because this circuit switches ON or OFF only at zero
voltage 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 self
resets (closes) when it has cooled.

F. Analog Inputs
The analog input to the system is through U27, a 74HC4051 analog multiplexer. All the
thermistor inputs are from the input to ground, with a 5.76K, 0.1% pull-up resistor
completing the sensor circuit. External patient inputs are filtered with pi filters consisting
of two caps and an inductor.

G. Watchdog Timer
U12 and related circuitry is the watchdog timer. The processor firmware generates
regular pulses to the WATCHDOG_TIMER signal (via output port U20). This keeps the
device constantly triggered. If the software should stop re-triggering the timer (due to
hardware or software failure, for example), the device times out. This causes a number
of things to occur:
• An interrupt is generated to the processor -INT1 pin. If the fault is in software, this
may bring the software back on track and correct the problem.
• The high priority alarm is enabled. For a software error, this signal will be asserted
so 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 fan
speed 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 and
supplied 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 the
threshold of the circuit.

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1/Functional Description
H. Audible Alarm
The alarm tones are generated by a 556 dual timer. The leftmost timer generates a 1
Hz 50% duty cycle square wave, which is used to generate the two tone high priority
alarm. The second timer generates the signal that goes to the transducers.

The output of the second slot of the LM556C timer is used to generate both a 2 kHz
and 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 / -49
Hertz) for a period of 0.50 seconds (+/- 0.05 seconds) and then 1745 Hertz (+36 / -34
Hertz) for a period of 0.51 seconds (+0.06 / - 0.07 seconds). When the low priority
alarm is sounding, the tone emitted will be 2049 Hertz (+34 / -49 Hertz) for a period of
time which is determined by software.

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

As the voltage is varied, the volume varies accordingly. VR4 is an LM317L adjustable
voltage regulator. Its output voltage is controlled by RP4, a multiturn potentiometer, or
U30, a Xicor nonvolatile EEPot under software control. Resistors R100 and R102 are
added 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 threshold
and trigger pins on the second timer of the LM556C timer to +5V_STDBY, which stops
the multivibrator from toggling. This also allows the processor to detect the disabled
timer, preventing field service or manufacturing from releasing a board into service with
the alarm disabled.

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

Vref is generated by U15, an LM385 1.2V band gap reference. This voltage is sent
through 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. This
signal is then sent into an RC low pass filter consisting of R69 and C27, and is then
sent 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 supply
rail. This voltage is needed by the ADC and the op-amps. L6, C32 and C53 create a
separate analog Vcc plane and electrically isolate the plane from any noise on the
digital Vcc plane of U14.

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1/Functional Description
The ICL7109 generates an output based upon the difference in voltage between the
IN_HI and IN_LO inputs. By raising the IN_LO pin above ground, this voltage is effec-
tively subtracted from the input voltage, achieving the input scaling without external
components. This DC offset voltage is controlled by RP5 (DC_OFFSET). The full scale
value of the ADC is set by RP6, the SPAN_ADJUST potentiometer. This adjusts the
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

J10 Expansion bus interface

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

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1/Functional Description
1.2 Display Board
The display board is the interface between the operator and the control system. It
informs the operator about the incubator and patient status. The operator controls the
system by depressing the various switches on the front display. The control board uses
P2 bank as bi-directional data lines, plus several timer and control lines for the display
unit.

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 to
low transition of the PROG line and decoded to set a high impedance on the selected
port 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 to
the micro controller depending on which address is selected by the decoder, U4 and
the 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 bits
follow. After the 35th bit is loaded, data is latched to provide direct output. Because the
output is inverted, a logical 1 input 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 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 display
channel. The large gain of the Darlington allows a small current to sustain the load
current from the LEDs.

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

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

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Notes
1/Functional Description

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2/Set Up and Checkout
2.1 Mounting the Care Plus on the cabinet

WARNING: w Safely mounting or dismounting the Care Plus Incubator

requires two people.

1. Install the four mounting knobs.

WARNING w If mounting hardware is not securely fastened, the incubator could tip off
the stand.

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

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

3. Refer to 2.2 in this section to perform preoperative checkout procedures.

Controller
CI.23.002

Controller
Lever
Mounting
Knob

Figure 2-1
Mounting the Care Plus Incubator

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2/Set Up and Checkout
2.2 Checkout Procedure

WARNING w After completing a repair the appropriate calibration procedure must be

performed. After completing any portion of the calibration and adjustment
procedures, perform the Checkout Procedure to make sure that the Care
Plus Incubator is operating correctly. In addition, a final Electrical Safety
Check, section 3.5, must be performed. Record the information for future
reference.

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

A. Mechanical checks

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

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

2. Examine the power cord for damage. Replace the power cord 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 the
locks and verify the unit moves smoothly.

5. On the cabinet, open the cabinet front doors (if present) and verify that the four
incubator mounting knobs that attach the Care Plus to the cabinet are secured
tightly in place.

6. Rotate both front door latches toward the center of the incubator, verify the red flag
is visible on both latches, and lower the door. Make sure that the inner wall is
securely fastened to the door.

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

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2/Set Up and Checkout
7. Make sure that the front door is securely fastened to the incubator.

8. Check that the mattress and the mattress tray are properly installed. Verify that you
must lift the tray slightly to slide it out of the hood. This prevents the tray from
sliding out accidentally. Slide the mattress tray back into the hood.

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

10. If the optional inner wall is installed, check that it is securely attached to the outer
wall. To attach the inner wall, insert the two outside inner wall fasteners in the key
holes in the inner wall and slide them along the slots until the wall is in position.
Lock the wall in place by snapping the two inside fasteners into the holes in the
middle of the inner wall.

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

12. Check the hood tilt latch. Open the front door. Rotate the hood back approximately
30 degrees, until it locks into position. Push against the hood and make sure that it
is held in place. To close the hood, support the hood and release the hood latch by
pushing back on the release tab. Gently lower the hood.

13. Close the front door and rotate the latches upward. Verify that the red flag on the
latch is masked by the opaque patch on the hood.

14. Check the operation of the tilt mechanism. Rotate the tilt handles down to raise the
bed until it locks in position, then rotate the handles up to return the bed to its
original position.

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

16. Locate the humidifier fill tray (if present) on the underside of the base. Slide the fill
tray out. Verify that the seals are in good condition and that there is no obvious
damage to any of the humidifier components. Slide the humidifier back in and push
until it locks in position. Push it back until you feel slight resistance, then push
harder till it snaps into position. Otherwise, verify that the plugs are in place.

17. Unscrew the two filter mounting knobs on the rear of the incubator, lift off the
vented filter cover panel and check the condition of the filter. If the filter is dirty, has
been used with an infectious patient, or has been in use for three months, it must
be replaced. When you replace the filter, mark the date on the label supplied with
the replacement filter. Affix the label to the side of the incubator.

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2/Set Up and Checkout
Item (Figure 2-6) Function

Hood tilt latch Secures hood in the tilted position; You must press and hold the
hood tilt release tab to raise or lower the hood.

Tilt handles Rotate handle for Trendelenburg and Fowler positioning.

Portholes Press the latch to open the porthole.

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

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

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

Patient probe Push probe connector (Model 2000 only) firmly into socket until it
clicks. Grasp the
connection connector and pull to disconnect.

Air temperature Keyed connector for air temperature sensor; to connect the air
sensor connection temperature sensor, align the connectors and push them together.
Disconnect the sensor by pressing in the back of the connector
while pulling back on the “T” handle.

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

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

Power switch Turns incubator on and off.

Inner wall Used to secure inner walls.

fastener

B. Accessory checks
1. Check that all accessories are securely mounted.

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

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

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2/Set Up and Checkout

Portholes

CI.23.004
Air Temp. Sensor

Front Door Latch

Tilt Handle

MAX 1000 mL
MIN

Front View

Left Side View Right Side View

CI.23.005

CI.23.006
Tubing Access Covers

Hood Tilt Latch

W WARNINGS: Fire hazard. Keep matches, lighted cigarettes Power must be disconnected prior to removing bed platform. Oxygen Concentration Chart Replace filter every three (3)
and all other sources of ignition out of the room in which the Air Heater may be hot. months.
Average oxygen

?
incubator is located. Textiles, oils, and other combustibles are
easily ignited and burn with great intensity in air enriched with The front door inner wall must be in place while a patient Oxygen input concentration range
oxygen. occupies the incubator.
Use only Ohmeda skin temperature probe. 5L/min 25-45%
Possible explosion hazard. Do not use in the presence of
flammable anesthetics. The humidity reservoir, or humidity reservoir plugs, must be
fully inserted for correct incubator operation, even if the
10L/min 35-55% m
Oxygen concentrations higher than 40% can increase the risk 15L/min 45-75%
of retrolental fibroplasia. It is possible that even concentrations humidifier feature is not used.
Ohmeda
of 40% or less (formerly considered safe) could be dangerous Use only hospital grade grounded power receptacle. NOTE: Oxygen concentration levels in this Columbia MD 21046 1801
for some infants. Therefore, arterial blood gas measurements W CAUTION: U.S. Federal and Canadian law restrcts this chart are intended as a reference only. Made in USA Oxygen Inlet: Ensure the Controller
are extremely important for regulation of the concentration of U.S. Pat. No. 4,936,824 is sealed and latched prior to
device to sale by or on the order of a licensed medical Actual concentrations should be checked
inspired oxygen when in an oxygen enriched environment. practitioner. with an oxygen analyzer.
administering oxygen.
?

Controller Latches
Oxygen Inlet

Patient Probe
Connector
Power Switch
Power Input

Air Temperature
Sensor Connector (Model 2000 Only)

Oxygen Inlet
Filter Mounting Knobs
(Cord Wrap)

Figure 2-2
Operating Controls, Indicators and Connectors

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2/Set Up and Checkout
C. Controller checks

WARNING w Do not use the Care Plus in the Presence of flammable anesthetics; an
explosion hazard exists under these conditions.

Patient Control Mode and Patient Probe

(available on Care Plus 2000 only)
Note: The Enable switch must be pressed to activate the temperature adjustment, the
Override or the control mode switches. These switches remain active as long as the
enable indicator is illuminated (approximately 12 seconds after the last time one of
these switches is pressed).

Note: If the patient probe reading is below 22.0°C (71.6°F), LLLL appears in place of
the patient temperature.

Note: All silenceable alarms are preceded by a 30 second operator prompt tone.

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

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

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

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

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

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

a. An alternating two tone audible alarm sounds for approximately five seconds, all
the indicators illuminate and “188.88” appears in the three temperature dis-
plays.
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:
Patient Air Control
Temperature Temperature Temperature
XX.XX (software 60H (AC frequency; 39.0°C (maximum
version, for ex:01.01) 50H for 50 Hz units) air control temperature)
c. An operator prompt tone sounds, and the control temperature display flashes
“33.0°C”. The operator prompt tone will sound every two seconds until a control
temperature is entered by pressing one of the temperature switches (? or M).
d. If the system failure alarm sounds, note the error code and switch off the unit.
Wait ten seconds and switch the unit back on. If the system failure alarm recurs,
remove the incubator from use. Then, call for service.

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2/Set Up and Checkout
Air Control
Temperature Temperature
Display Display

CI.23.014
188.8 8 188.8 8

Alarm 100% >37°C

75% Control
LEDs 50% Temperature
25%
Switches

Enable Indicator
Alarm
Silence °F / °C Enable Switch
Switch

Heater Power LEDs (% of Override Switch

max power: minute average) Override Indicator
°F/°C Switch
Series 1000

Patient Air Air Control Control

Temperature Temperature Mode Temperature
Display Display Indicator Display

CI.23.003
188.8 8 188.8 8 188.8 8 Patient Control
Mode Indicator
Alarm 100% >37°C Control
LEDs 75%
50% Temperature
25% Switches

Enable Indicator
Alarm
Silence °F / °C Enable Switch
Switch

Heater Power LEDs (% of Override Switch

max power: minute average) Override Indicator

°F/°C Switch
Patient Control Mode Switch
Air Control Mode Switch
Series 2000

Figure 2-3
Control Panels

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2/Set Up and Checkout
7. Adjust the control temperature to silence the prompt tone.

8. Check display illumination and the audible alarm by depressing the Alarm Silence
switch until all the indicator LEDs illuminate and “188.8” appears in the three
temperature displays (approximately five seconds). An audible alarm will sound.

9. Check the Enable switch. Press the Enable switch. The enable indicator should
illuminate and go out after approximately 12 seconds. Verify that pressing the tem-
perature switches (? and M) has no effect when the enable indicator is extinguished.

10. Check the analog to digital calibration and the line voltage. Depress the Enable
switch until the temperature displays show, from left to right (approximately five
seconds):

Patient Air Control

Temperature Temperature Temperature

25.05°C (±0.2°C) 37.95°C (±0.2°C) From 09.00 to 11.00

(low calibration point) (high calibration point) (Service use only)

Note: An audible alarm will sound to indicate that the actual temperatures are not
displayed.

11. Check the patient probe. Warm the patient probe by placing it between your
fingers. Verify that the displayed patient temperature increases. If you have an
ASTM approved thermometer, accurate to ±0.1°C, place the thermometer and the
patient probe in a glass of warm water. Stir the water and wait several minutes until
the thermometer reading stabilizes. Verify that the patient temperature shown on
the control panel is within 1°C of that shown on the thermometer. Replace the
probe if the difference exceeds 1°C.

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

13. Check the extended range of air control temperatures. With the control temperature
set to 37.0°C, sequentially press the Enable and Override switches. The enable
indicator should illuminate and the override indicator should blink. Depress the M
switch and verify that the maximum air control temperature is now 39.0°C. The
override indicator will blink as long as the control temperature 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/°C switch. Verify that the control temperature is now displayed as 96.8°F. Press
the switch a second time to return to a Celsius display.

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2/Set Up and Checkout
15. Switch to the patient control mode of operation. Press the Enable and the Patient
Control switches and 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 tone
sounds every two seconds. Adjust the control temperature to silence the prompt
tone. The enable indicator will be extinguished approximately 12 seconds after
the last time one of the temperature switches (? and M) is pressed.

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

16. Check the range of patient control temperatures. Press the Enable switch to
activate the temperature switches (? and M). The enable indicator will illuminate.
Press and hold the ? switch. Verify that the lowest control temperature attainable
is 35.0°C. If the enable indicator has gone out, press the Enable switch again.
Depress the M switch. Verify that the patient control temperature cannot be set
above 37.0°C.

Note: The maximum patient control temperature can be raised to 37.5°C by

internal adjustments specified in the service manual.

17. Check the patient temperature alarm. Press the Enable switch and adjust the
patient control temperature until it exceeds the patient temperature by more than
1.0°C. An alarm should sound, the patient temperature should flash and the patient
temperature alarm indicator should illuminate. Press the Enable switch and adjust
the patient control temperature until it is within 0.8°C of the patient temperature.
The alarm should cancel.

Note: Service personnel can configure the alarm to trigger if the difference ex-
ceeds 0.5°C and to reset when the difference is less than 0.3°C.

18. Check the probe failure alarm.

a. Unplug the patient probe from the controller. Verify that an alternating two tone
alarm sounds, the probe failure LED illuminates, HHHH flashes in the patient
temperature display and the heater power LEDs are extinguished. Plug the
probe back in and verify that the alarm cancels.
b. Unplug the air temperature sensor from the controller by pushing in the back of
connector while pulling back on the “T” handles. Verify that an alternating two
tone alarm sounds, 00.0°C flashes in the air temperature display, the probe
failure LED illuminates, and the heater power LEDs are extinguished. Align the
connectors and plug the air temperature sensor back into the controller. Verify
that the alarm cancels.

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2/Set Up and Checkout
19. Check the power failure alarm and the battery backed memory. Verify that you are
still in the patient control mode. Adjust the patient control temperature to 36.0°C.
Switch to the air control mode and adjust the control temperature to 35.0°C. Unplug
the incubator. An intermittent, nonsilenceable alarm should sound and the power
failure LED should illuminate. All other displays and indicators will be extinguished.
Wait two minutes and plug the incubator back in. Verify that the alarm cancels and
the unit returns to the air control mode of operation with a control temperature of
35.0°C. Switch to the patient control mode and verify a control 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 must
be 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 the
Alarm Silence switch. Verify that the alarm is silenced for one minute. Reconnect
the air temperature sensor.

Note: The functionality of the remainder of the alarms is continually checked by the
microprocessor software during normal operation. If a fault occurs in any of this cir-
cuitry, an indicator lights and a tone is sounded.

Computer independent circuitry continuously measures and compares the incubator

temperature with a factory set level. Visual and audible alarms are activated and the
heater is shut-off if the incubator temperature exceeds this pre-set level, independent of
the software.

Additionally, a computer independent “watchdog” circuit will reset the computer, turn off
the heater, and activate the alarms in the event of a microprocessor failure or software
error.

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 the
air temperature reading to stabilize. Verify that the air temperature remains within
0.5°C of the control temperature for five minutes after stabilization.

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WARNING 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 standard
safety precautions.

3.1 Maintenance schedule

The unit should be maintained in accordance with the procedures detailed in the
Service 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 after
use with infectious patients.

Quarterly

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

Note: This is the minimum replacement frequency. The filter must also be replaced
whenever 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. If
possible verify an acceptable sound level within the infant compartment. Every other
quarterly 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 memory
circuits during a power failure.

Note: Whenever performing service on the incubator, check the female end of the
power 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.

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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 be
ordered 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
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 be
used as substitute)

Optional items include:

Description Stock Number

Oscilloscope, 15 MHz, dual trace ............................................................ 0175-2302-000
Ohmeda Temperature Simulator Box (variable resistance box with
switches 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 the
jacks, because there is no one connector that will accommodate all types of variable
resistance boxes.
CI.02.139

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

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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, the
line 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 temperature
display.

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

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

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

3.4 Calibration Procedures

WARNINGS w After completing a repair of the Care Plus, the appropriate calibration
procedure must be performed. After completing any portion of the cali-
bration and adjustment procedures for the Care Plus Incubator, perform
the 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 and

any 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 ensure
that static charges are safely conducted to ground. The Velostat material is
conductive. 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.

A. Preparation
1. Remove the controller from the incubator. First unplug the patient probe, the air
temperature sensor, the power supply cord, from the controller. Then lift up the
controller latches and slide it forward, out of the incubator. Place the controller on
the anti-static mat.

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CAUTION w When handling the controller, avoid bumping the fan or the heater. If these
items are knocked out of alignment, the fan can grate against either the heater
or 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, 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 patient
temperature alarm, in its original position.

Note: Leave switch 3, which selects a maximum patient control temperature

(patient control mode), in its original position.

Note: Set switch 5 to the ON (right) position for series 1000 controllers, and to the
OFF (left) postion for all other controllers.

CI.23.066

Switches 1-8

Figure 3-2
Control Board Test Points and Potentiometers

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B. Check Voltage Supplies
1. Switch ON the incubator. It will proceed through the normal power up tests. Enter a
control temperature to silence the prompt tone.

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

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

Test Point Voltage

TP1-28 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 replaced
when they are not within the specified range.

C. Display Brightness
Note: Because display brightness is factory calibrated for both replacement boards and
complete controllers, brightness adjustments are only required if the LEDs appear to be
dim.

1. Hold down the Alarm Silence switch until all the displays illuminate (approximately
five seconds). Check that all displays are illuminated and of uniform brightness. If
the displays are acceptable, proceed to Section D. Otherwise, continue with this
adjustment 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 mounting
screws, shown in Figure 3-3.

3. Remove ESD shield.

4. Connect meter leads to terminals 10 and 11 of display board connector J8.

5. Reconnect the power cord.

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

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Lockwasher
Screw
Front Panel
ESD Shield

Display Board
RP1

CI.02.111
Screw

Figure 3-3
Display Brightness Adjustment

7. Monitor the voltage at connector J8 pins 10 to 11 or across R11 on the display

board. Adjust display board potentiometer RP1 (accessible from the edge of the
board) to obtain a reading of 3.30 ± 0.2 Vdc.

Important The brightness 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 reverse
order.

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 the
control board as required.

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E. Line Voltage Compensation
1. Verify that the incubator is in the calibration loop. In this loop the control temperature
display continuously shows the percent of nominal input voltage at which the unit 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 on the
back of the base platform.

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

Rated Input
Voltage (from serial Nominal Input Measure
number sticker) Voltage Between Pins
240 volts 240 volts 6 and 2
220 volts 220 volts 5 and 2
120 volts 115 volts 4 and 2
100 volts 95 volts 3 and 2

4. Calculate the percent of the nominal input voltage by dividing the measured voltage
by 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 shows
the percentage calculated in the previous step ± 2%.

Note: The control temperature reading appears in the format XX.XX, which must be
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 Enable
switch until the proper calibration readings appear in the patient and air temperature
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 box is
available, proceed to F.b for simpler procedure, otherwise go to step 3.

3. The Ohmeda temperature simulator box (Stock No. 0217-2788-800) is a variable

resistance 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 Patient
Temperature display.

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Note: Although the tolerance is ± 0.02, the readings should be adjusted as closely
as 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 setting

I1) 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 control
temperature to silence the prompt tone.

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

Resistance Temp. Patient Temperature

Input 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 the
Enable switch until the proper calibration readings appear in the patient
and air temperature displays (approximately five seconds):
Patient Temperature 25.5 ± 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. 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 toggles

between 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 toggles

between F9E and F9F.

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

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G. Alarm Volume

WARNING w Lowering the volume excessively may prevent caregivers from hearing
alarms. The alarm volume and frequency are precalibrated at the factory
for 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 1000
watts), 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 display
panel and the heater status LED on the control board are both illuminated. The
heater 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 the
hood. 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 of
temperature 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. If
necessary, reposition the heat gun (dryer) so that the rate of increase does not
exceed 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 safety
relay opens (audible click; heater status LED extinguished).

7. Press the alarm silence switch and remove the air temperature sensor from the
glass 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 RP1
on the control board and repeat this procedure.

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

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I. Fan Sensor Adjustment
Adjust RP3 for 2.70 to 2.90 VDC between TP1-24 and TP1-8 using a DC Voltmeter
such as a Fluke 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 the
power cord.

b. Switch the incubator ON.

c. Depress the F/C switch approximately 5 seconds until different numbers appear in
the control temperature display (approximately five seconds). This number will be
the 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 switch
on the rear of the controller.

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

Note: An open thermal switch makes it appear as if the heater is continuously

enabled. This may trigger error code E13. Switch the unit OFF and continue with
step 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 thermal
switch closes, the heater indicator LED may flicker depending on the status of the
heater.

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 between
the 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 set
at 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 are
disconnected 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 the
maximum patient control temperature and the tolerance selected for the patient
temperature alarm.

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

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

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

5. With the controller release latches in the release position (perpendicular to the
controller 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 rubbing
against the base platform.

10. Complete the Electrical Safety Check in Section 3.5.

11. Perform the Checkout Procedure in Section 2.6.

3.5 Electrical Safety Check

A. Leakage Current
Use approved equipment and techniques to test the unit’s leakage current and ground
continuity. Follow the directions supplied by the test equipment manufacturer to verify
the following:

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

Less than 500 microamperes measured at any exposed metal surface for equip-
ment rated at 220/240 Vac, 50/60 Hz.

B. Ground Resistance Check

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

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Notes

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4/Troubleshooting
WARNING 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 standard
safety precautions.

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

s Use the Static Control Work Station (Stock No. 0175-2311-00) to help ensure
that static charges are safely conducted to ground. The Velostat material is
conductive. Do not place electrically powered circuit boards on it.

Note: Self test programs stop when a system error code is detected. Therefore a
second error code will not be displayed for another failure. The same failure can trigger
more than one error code. The actual code that appears is determined by the point in
the test loop where the fault occurs.

The Care Plus features three levels of testing for maximum reliability and ease of
troubleshooting. Self tests are performed on power up to check microcontroller,
EPROM, and RAM function. They are performed continuously during operation to verify
proper ADC, heater control, safety circuit, temperature sensor, alarm, RAM, and
software 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 ADC
channels; monitor the occurrence of any software upsets, and check the line voltage. You
can check the fan RPM. A separate RAM memory test loop continuously repeats the
power up tests.

When required, you can operate the controller outside the incubator to directly measure
control board signals. During controller testing, it is important to remember that the
alarm criteria discussed in this section apply regardless of whether or not the controller
is installed in the unit. Failure to connect the patient probe (or an equivalent load) in
patient control mode, or the air temperature sensor in either operational mode will
trigger the probe failure alarm. Air or patient temperature readings outside the alarm
limits will still activate the corresponding alarms. In patient control mode the heater will
not switch ON unless the patient temperature reading is within the 30 to 42°C range.

4.1 Alarms and Error Codes

There are two types of alarms on the Care Plus incubator. The first group of alarms are
indicated by the alarm LEDs on the control panel. When one of these alarms is active
the corresponding LED illuminates and an audible alarm sounds.

Error codes are a subset of the system failure alarm. When the system failure alarm
illuminates for anything other than a gross microcontroller failure, the corresponding
error code appears in the control temperature display.

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A. Front Panel Alarms
Note: All alarms, with the exception of the system failure and power failure alarms, are
preceded 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 the
difference between the patient temperature and the control temperature exceeds
1°C. The alarm self resets when the patient temperature returns to within 0.8°C of
the control temperature.

Note: The patient temperature alarm can be adjusted to trigger if the temperature
difference exceeds 0.5°C and reset when the difference is less than 0.3°C (Refer to
Section 3.3.K.).

Note: If the patient temperature is outside the 22 to 42°C range, either HHHH or
LLLL, respectively, will appear in the patient temperature display.

Audio Signal: Intermittent single tone if patient temperature within the 30 to

42°C range. Outside this range, an alternating two tone alarm
sounds.

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 not
between 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 each
mode or control temperature change. The alarm is triggered when the reading from
the air control thermistor exceeds the control temperature by more than 1.5°C or
falls more than 3°C below the control temperature. The alarm self resets with a
hysteresis of 0.2°C.

Audio Signal: Intermittent single tone

Alarm Silence: 15 minutes

Heater Status: Normal heater operation, dependent on selected control

temperature and air temperature.

3. High Air Temperature Alarm

This alarm is triggered if the air display temperature exceeds the alarm limit in the
table. This alarm is not self resetting; you must press the alarm silence switch
before the alarm will reset.

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A transient alarm may be triggered if you change from a mode with a 40°C alarm limit
to a mode that has a 38°C alarm limit.

Control Temp.
Mode Range Alarm Limit

Patient 35.0 to 37.0° C 40.0°C

Control (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

Alarm Silence: 5 minutes
Heater Status: Heater is automatically shut off.

4. Air Circulation Alarm

This alarm triggers when the fan sensor detects that the fan has stopped spinning
or is not installed. The fan sensor is mounted facing the hub. The fan is designed
with 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 the
microcontroller as an interrupt. The microcontroller counts the interrupts for 10
second intervals to determine the fan’s RPM. If the RPM drops below 800 for 2
consecutive intervals, the air circulation alarm 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 seconds
until the fan RPM appears in the control temperature display.

The air circulation alarm can trigger for several reasons. Check the following:
Blower motor is turning
White 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 be
recalibrated before the unit is put back in service.

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4/Troubleshooting
The air circulation alarm is most commonly triggered by a blower motor failure or a
missing fan.

Audio Signal: Alternating two tone

Alarm Silence: 5 minutes

Heater Status: Heater is automatically shut off

5. Probe Failure Alarm

In the air control mode, the probe failure alarm is triggered by a disconnected air
temperature sensor. In the patient control mode, the probe failure alarm is triggered
by either a disconnected or faulty patient temperature probe (short or open) or a
disconnected air temperature sensor. The alarm self resets when the condition is
remedied.

The patient temperature probe is judged to be disconnected or faulty if its signal is

outside 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 display
signals are outside this range. This means that the probe failure alarm will be
triggered instead of error codes 10 or 11 if both circuits in the air temperature
sensor 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 control
mode only) by observing the patient temperature display and verifying that it is
consistent with the temperature of the probe. If LLLL or HHHH appear in the
display, check the actual probe reading by depressing and holding the Air Control
switch until a value appears in the patient temperature display (approximately five
seconds). If the temperature is outside the 5 to 50°C range, replace the patient
temperature probe.

Check the air temperature sensor by depressing and holding the Override switch
until the air control thermistor reading appears in the patient temperature display
and 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.

Audio Signal: Alternating two tone

Alarm Silence: 1 minute

Heater Status: Heater is automatically shut off

6. System Failure Alarm

The system failure alarm is triggered if one or more of the system parameters
monitored by the microcontroller self tests fail. This section describes the actual
tests and gives a list of probable causes for each code.

If the microcontroller fails, there may be some cases where the only indication is a
continuous, nonsilenceable audio alarm (i.e. no alarm indicator illuminates and no
error code appears). This occurs because the microcontroller controls the display
indicators. To ensure patient safety, a microcontroller independent safety relay will
switch 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 until
it has been serviced.

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4/Troubleshooting
Audio Signal: Alternating two tone

Alarm Silence: Cannot be silenced

Heater Status: Heater is automatically shut off

7. Power Failure Alarm

The power failure alarm is triggered when the line frequency signal pulse is absent
on I/O expander U15 pin 15. (On controllers with serial numbers that begin with
HAF, the line frequency pulse is absent on the microcontroller U19, Pin 12.) During a
power failure alarm the NI-CAD battery powers the control logic and RAM circuits for
up to 10 minutes. If power is restored within this time, the unit will return to the mode
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, a
faulty transformer, or, on controllers with serial numbers beginning with HBJ and
HCE, an open circuit breaker.

Audio Signal: Intermittent single tone

Alarm Silence: Cannot be silenced

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 board
replacement, or in some cases the replacement of socketed integrated circuits.
Additional information is provided for the purpose of identifying the faulty assembly.

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 normal
incubator 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 triggering
conditions, 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 cycles repeat-
edly through this test. To begin the loop, switch off the unit. Then turn it back on
while depressing the Override switch until a continuous alarm sounds (approximately
five seconds). If the error recurs, replace the microcontroller (U19) and repeat 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 exceeded the
limits of 37.96 ±0.3°C. This corresponds to a voltage of approximately 540 mV at the
ADC input (U1 pin 14).

To see if the ADC requires calibration, depress the Enable switch until the low
calibration reading (25.05 ±0.3°C) appears in the patient temperature display, and

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4/Troubleshooting
the 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
of tolerance. If the problem persists, replace the control board.

3. E03, ADC Low Calibration Failure

The reading from the ADC calibrate low resistor (R8, 10 kOhm), has exceeded the
limits of 25.05 ± 0.3°C. This corresponds to a voltage of approximately 690 mV at
the ADC input (U1 pin 13).

To see if the ADC requires calibration, depress the Enable switch until the low
calibration reading (25.05 ± 0.3°C) appears in the patient temperature display and
the 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
of tolerance. 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 stored
at memory locations 3FFE and 3FFF on U16.

There are no related test points, however the RAM memory test loop cycles
repeatedly through this test. To begin the loop, switch off the unit. Then turn it back
on while depressing the Override switch until a continuous alarm sounds. If the
error recurs, replace the EPROM (U16), and repeat the RAM test loop. If the error
still 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 cycles
repeatedly through this test. To begin the loop, switch off the unit. Then turn it back
on while depressing the Override switch. If the error recurs replace the control
board.

6. E07, ADC Converter Failure

This alarm is triggered if the Conversion Complete Signal from the ADC does not
occur 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 Conversion
Complete 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 air
temperature sensor or the patient temperature probe and observing that the
temperature 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 that
would 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 E10
would be triggered.

The most probable cause is a faulty comparator circuit (U5) in the S/O circuit. Since
this is not a socketed chip, control board replacement is recommended.

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4/Troubleshooting
8. E09, Incorrect Dip Switch Setting

The signals from dipswitches 1 and 2 are logic high (corresponds to logic low inputs
at U17 for the inverted signals). The most probable cause is that dipswitches 1 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 (U11B
or U11C) may be faulty. Board replacement is recommended, since these circuits are
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 less
than 410 mV at TP2-7) while the air control signal remains within the 5 to 50°C
range.

Red Dot
1
5 2

CI.02.138
4 3

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

Observe the displayed air temperature. If it is outside the 5 to 50°C range, replace
the air temperature sensor. Alternatively, perform a continuity check on the sensor
by measuring the resistance between pins 4 and 5 on the sensor connector (Figure
4-1), or between pins 10 and 11 on the control board J4 connector. Replace the
sensor if you 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 problem
persists, 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 less
than 410 mV at TP2-7) while the air display signal remains within the 5 to 50°C
range.

Depress and hold the Override switch until the air control temperature appears in
the air temperature display (approximately five seconds). If the displayed air control
temperature is outside the 5 to 50°C range, replace the air temperature sensor.
Alternatively, perform a continuity check on the sensor by measuring the resistance
between pins 1 and 2 (Figure 4-1) on the sensor connector or between pins 6 and
7 on the control board J4 connector. Replace the sensor if you 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 problem
persists replace the control board.

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4/Troubleshooting
11. E12, Heater Not Switching On

The microcontroller has commanded the heater to switch on (Heat TP2-2 low), but
the heater status signal from U7A pin 11 remains low indicating that the heater is
off.

This is a difficult code to troubleshoot, since the control signals and the continuity
across the solid state relay change from those required to power the heater to
those 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 problem
persists after relay replacement, replace the control board.

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 indicating that the
heater is on.

This error code can be triggered without an actual failure having occurred, because
of 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 (logic
low on controllers that have Software Revision 02.00), which illuminates the heater
status LED and signals the microprocessor that the heater is on.

The thermal switch normally opens for a few minutes when a hot incubator is
switched off because of residual radiant heat and the lack of a cooling air flow. If
the incubator is restarted before the thermal switch has cooled, E13 may appear as
soon as this alarm is enabled (approximately three and a half minutes after power
up; 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, before
it has had time to cool down. The thermal switch opens at a temperature of 76.7°C
and is located on the back of the controller. Because the decimal point is not
illuminated, 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 of
the thermal switch. The resistance should be less than 1 Ohm.

The third possibility is a shorted solid state relay. Replace the relay. If the problem
persists, replace the control board.

13. E14, Alarm Oscillator Failure

An alternating two tone alarm signal has been activated, but the 2 kHz signal at
TP2-1 is not toggling.

To troubleshoot this failure, an alternating two tone alarm must be active. If there is
no error code displayed, trigger an alarm by disconnecting the patient temperature
probe while in the patient control mode.

If you hear the alarm (i.e. the 2 kHz signal is present), replace the microcontroller
(U19). If the problem persists, the I/O expander (U15) may be faulty. Since this is
not a socketed chip, control board replacement is recommended.

If you do not hear the alarm (i.e. the 2 kHz signal is missing), the timing circuit
(U6B) or one of the circuits that gate the timing circuit inputs may be faulty. Since
these chips are not socketed, control board replacement is recommended.

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4/Troubleshooting
14. E15, Software Upset

A software upset has caused the watchdog timer to time out and the system is
unable to recover because critical parameters (e.g. control temperature) stored in
the 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 the
number of recoverable software upsets that have occurred by depressing and
holding the Override switch until a new value appears in the control temperature
display (approximately five seconds). If FF appears in the control temperature
display, no software upsets have occurred. Complete the Checkout Procedure and
return 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 the
power, waiting approximately 5 minutes, and turning the power back on.

If the failure recurs, replace the control board.

16. E17, Software Upset

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 an
hour. Then check the number of recoverable software upsets that have occurred by
depressing and holding the Override switch until a new value appears in the control
temperature display (approximately five seconds). If FF appears in the control
temperature display, no software upsets have occurred. Complete the Checkout
Procedure and return the unit to service.

If another value appears in the control display, replace the control board .

17. E18, Air Temperature Sensor Out of Tolerance

This failure is normally caused by a faulty air temperature sensor. Power the unit
up 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 readings
by pressing and holding the Override switch until the air control temperature
appears in the patient temperature display (approximately five seconds). Compare
this 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, replace
the control board.

18. E19, Software Upset

The watchdog timer has timed out 256 times since power up. This error can be
caused by a software upset and 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 the number of recoverable software upsets that have occurred by
depressing and holding the Override switch until a new value appears in the control
temperature display (approximately five seconds). If FF appears in the control
temperature display, no software upsets have occurred. Complete the Checkout
Procedure and return the unit to service.

If another value appears in the control display, replace the control board.

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4/Troubleshooting
4.2 Power Up Tests
When 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, all
the 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:

Patient Temperature Air Temperature Control Temperature

XX.XX 60.H 39.0°C
(software revision (AC frequency (max. manual
01.01 etc.) 50.H for 50 Hz control temp.)
models)

3. An operator prompt tone sounds and the control temperature display flashes
33.0°C. The operator prompt tone will sound every two seconds until a control
temperature is entered.

4.3 On Line Testing

The incubator continuously performs the following tests during normal operation. An
error in any of the tests triggers the system failure alarm. The corresponding error code
will 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)

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4/Troubleshooting
4.4 On Demand Testing
There are two types of on demand testing: a combination RAM Memory display loop
that cycles through the power up tests and checks display board functions; and special
switch activated displays, which display various parameters to aid in diagnosing
problems. The specific troubleshooting applications of individual on demand tests are
discussed 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 tests

Instruction Test (E01)
EPROM Checksum Test (E04)
RAM Test (E05)

The following on line self tests

ADC 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)

Important Unless you specifically want to repeat the power up tests, troubleshooting should
be performed in the normal operational modes.

2. Displays

The display loop runs simultaneously with the self tests, displaying frames of data
and 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 ———

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4/Troubleshooting
B. Switch Activated Displays
In normal operation, the Alarm Silence, the Enable, the Override, the F/C, the Patient
Control, and the Air Control switches activate service displays when held down for
more than five seconds. An alarm also sounds to indicate that actual patient and air
temperatures are not displayed. The normal display reappears when you release the
switch.

The following table summarizes the data that will be displayed when each switch is
depressed and held for at least five seconds. It is intended as a quick reference. Switch
applications for troubleshooting are discussed in Section 4.1.B under the individual
error codes.

Important Continue to hold down the switch for as long as you wish to view the special
service display. The normal display reappears when you release the switch.

Patient Air Control

Switch Temperature Temperature Temperature

Alarm* 188.88 188.88 188.88

Silence

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 temp

Control (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 00.00 Fan RAM

XX.XX C Format;
includes temps
outside normal
range)
Patient ADC counts for Blank ADC counts for
Control patient temperature line voltage
thermistor.

* All display board LEDs illuminate to test proper operation.

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4/Troubleshooting
4.5 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 Section
4.1.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. Hence
thermistor resistance rather than signal voltage should be used to check temperature
measurements.

Reference the appendix tables for summaries of the resistance versus temperature or
percent of nominal voltage for the various ADC inputs.

Test Point Description & Reading

TP1-20 9.8 ± 0.05 Vdc*

TP1-28 + 5 Volts Disp (5 ± 0.3 Vdc)
TP1-1 + 5 Volts Stby (5 ± 0.3 Vdc)
TP1-21 + 8 Volts Unregulated (8 ± 1.5 Vdc)
TP1-8 Fan Sensor (3.0 Vdc)*
TP1-4 2 kHz Frequency (2 kHz ± 100 Hz)*
(measure during calibration loop)
TP1-17 Heater Control Signal (Low = Heater ON)
TP1-6 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)
TP1-5 Air Display Signal
TP1-2 Alarm signal, when jumped with TP1-1 will short audio transducer
to temporarily silence alarm (FOR USE DURING SERVICE ONLY!)
TP1-24 Ground
TP1-25 Battery Voltage (+9 Volts STBY (9 ± 0.3 Vdc)

* Refer to calibration section for adjustment procedure.

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Notes
4/Troubleshooting

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5/Repair Procedures
WARNINGS w Before any disassembly or repair, disconnect the electrical supply and
any 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 and
approved 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 oxygen
service lubricant recommended (Stock No. 6700-0092-200).

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

s Use the Static Control Work Station (Stock No. 0175-2311-00) to help ensure
that static charges are safely conducted to ground. The Velostat material is
conductive. 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 for
example, perform only the necessary steps.

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. To remove front door, remove the "E" type retaining rings from the pins on both
sides of the door hinge. To release the door pull either hinge pin out of the hinge.

4 Remove the inner wall as shown in Figure 5-1. Press up on the center of the wall
until it flexes enough to free the two inside inner wall fasteners from their holes,
then slide the wall torward the incubator so that the two outside fastners slide along
their keyhole slots and out the large holes at the slots end. If the rear inner wall is
installed, it can be removed in a way similar to the front inner wall.

5-1 6600-0292-000 2/2/99 5-1

5/Repair Procedures

CI.23.038
100
75% %
50%
25%

>37
°C

°F /
°C

Figure 5-1
Remove 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 and
screw that anchors the sensor cable; removing the two Phillips head screws
that hold the sensor mounting blocks and spacers in position; and then sliding
the air temperature sensor out of the hood.
c. Remove the nut and screw that attach the hood to the hood tilt latch (rear, right
hand corner of the incubator).
d. Remove the two cap head shoulder bolts used to secure the back of the hood
to the base hinges.

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5/Repair Procedures

Mounting Block

Air
Temperature
Shims

Hinge Screw
Mounting Block
Screws

Cable Anchor
Hinge

CI.02.150
Nut

Filter Cover

Filter
Mounting
Knobs

Figure 5-2
Remove the Outer Hood

6. Remove hood hardware as follows (Figure 5-3):

a. To remove the portholes, unscrew the mounting posts on either side. On
double-walled units this means you may have to remove the inner wall.
b. To remove the hood frame, first remove the outer hood. Then remove the hinge
covers, the nut and screw that secure the hood tilt latch, and the caphead
shoulder bolts that hold the hood frame and corner brackets in position.

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5/Repair Procedures

Rear
Acorn Nut Hoodframe
Lockwasher
Washer

CI.23.046
Screw

Left Hood Acoustic Right

Hoodframe Support Baffle Hoodframe
Bracket

Figure 5-3
Remove hood hardware

c. To remove the porthole cuff, open the porthole and slip the larger cuff band out
from under the outer ring on the porthole housing.
d. To remove the porthole seal (present on units equipped with the humidifier
only), open the porthole and slip the seal over the outer ring of the porthole
housing.
e. To remove the iris porthole, remove the iris gasket and the frame can slide out
of the hood.

Reverse the steps for assembly. Slip the seal over the outer ring on the porthole
housing. To install new porthole cuffs, slip the larger cuff band over the outer ring of the
porthole housing. To reattach the inner wall insert the two outside fasteners in their
keyhole slots and slide the wall untill the two inside fasteners pop into their holes.

Note: Be sure that the hood is aligned with the base platform before tightening the cap
head shoulder bolts that secure the hood and corner brackets.

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5/Repair Procedures
5.2 Front Door Repair
1. Remove the "E" type retaining rings from the pins on both sides of the door hinge.
To remove the door pull either hinge pin out of the door hinge.

2. To remove the inner wall press up on the center of the wall until it flexes enough to
free the two inside inner wall fasteners from their holes, then slide the wall toward
the incubator so that the two outside fasteners slide along the key hole slots and
out the large holes at the slots end.

3. To remove the hinge pin, hinge pin bracket, and deflector remove the three cap
head screws that secure it to the front door.

4. To remove a front door latch, remove the retaining washer that secures the latch.
See Figure 5-4. Once the door latches have been removed, they can not be
reassembled. Replacement latches must be ordered.

5. To remove the portholes, unscrew the mounting posts on either side of the port.

Spring Retaining Outside Inside

Washer Washer Inner Wall Inner Wall
Mounting Mounting
Post Post

Flat
Washer Keyhole
Slot
Inner
Wall

Front Door
Latch

Door
Hinge
Front Door Latch
Assembly
Front
Spring Door
Washer Porthole

Flat
CI.23.047, 078

Washer Retainer
Washer

Inner Inner Wall

Wall Deflector
Acorn Deflector
Latch Nut Mount

Door

Figure 5-4
Front Door Disassembly

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5/Repair Procedures
5.3 Air Temperature Sensor Replacement

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

Note: The air temperature sensor is located inside the infant compartment and should
not be confused with the fan sensor or the air flow sensor located on the rear of the
controller.

1. Remove the rear inner wall 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.

4. Remove the two Phillips head screws and shims that attach the air temperature
sensor mounting blocks to the outer hood. Then slide the air temperature sensor
out 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.

10. Route the cable out the rear of the base, through the hole near the air filter, and
around 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 on
the 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 the
symmetrical mounting block, backed by the two shims, over the sensor from the
inside of the hood. Align the cable guard on the other block with the sensor cable
on the outside of the hood. Secure the blocks with the two remaining Phillips head
screws.

14. Anchor the sensor cable to the outer hood.

15. On double walled units, replace the rear inner wall.

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5/Repair Procedures

Mattress

Tilt
Assemblies

Mattress Base
Tray Platform
Cover

Filter
Cover

Filter

Base Platform
Lid

Slide

CI.23.012
100%
75%
50%
25%

>37
°C

°F /
°C

Humidifier Controller

Figure 5-5
Base Platform Cover Removal

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5/Repair Procedures
5.4 Base Platform Cover Replacement
1. Remove the "E" type retaining rings from the pins on both sides of the door hinge.
To remove the door pull either hinge pin out of the door hinge.

2. Rotate the hood back into the locked position.

3. Remove the mattress and the mattress tray.

4. To remove the tilt assemblies lift the tilt handle out of its slot, then pull the tilt rod
just a little up out of its hole. Turn the handle down 90°, then tilt the assemble all
the way back while turning it another 90°. Grasp the rod where it enters the hole
and pull it straight out.

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.

2. Lift up the controller latches and slide the controller forward, out of the incubator.

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

3. Remove the Phillips head screws and lock washers used to attach the controller
cover.

4. Lift off the controller cover.

s5.6 Control Board Replacement

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

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.

5-8 6600-0292-000 2/2/99 5-8

5/Repair Procedures
5. Position the new control board so that J3 is at the front of the controller. Replace
the 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 numbered
for proper alignment.

7. Make sure that switches 1, 2, 7 and 8 are set to OFF (open position). This selects a
maximum control temperature of 39°C and disables the calibration and service
loops. Make sure that dipswitches 3 and 4 are in the same position as on the
previous board.

8. Perform the Calibration Procedure in Section 3.4.

9. Replace the controller cover, using the Phillips head screws and lock washers
previously 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 2.2. Listen for any grating sound
caused by the fan rubbing against the base platform. Adjust the fan position if
rubbing is present.

12. Perform the Electrical Safety Check in Section 3.5.

Orange
Yellow

Relay Mounting Nuts

Solid State Relay

CI.02.116
Black
Red

J2
J5
J4 J1

Lock Nuts
Control (Control
Board Board)
J3

Screws
(Solid State
Relay)

Figure 5-6
Controller Interior

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5/Repair Procedures
s5.7 Display Board Replacement

Front Panel Mounting Screws (2)

Lock Washer

CI.02.117
Board Mounting
Nuts (5)

Front Panel
Display Board ESD Shield Mounting Screw (3)

Figure 5-7
Replace the Display Board

5-10 6600-0292-000 2/2/99 5-10

5/Repair Procedures
1. Access the controller as described in Section 5.5.

2. Turn the controller upside down and remove the lower three front panel mounting
screws, shown in Figure 5-7.

3. Turn the controller right side up and remove the remaining front panel mounting
screws, 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 the
ESD 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 pointing
toward 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 power
cord 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. To replace the ESD shield:

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 J8
through 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.

5-11 6600-0292-000 2/2/99 5-11

5/Repair Procedures
Control
Panel
Assembly
Display
Board ESD
Shield

CI.02.197
Figure 5-9
Display Panel

16. Replace the 5 mounting screws to reattach the front panel as in Figure 5-7.

17. Replace the controller cover, using the Phillips head screws and lock washers
previously removed.

18. Pull up on the controller latches. Carefully slide the controller back into the incuba-
tor. Push down on the latches to secure the controller.

19. Perform the Checkout Procedure in Section 2.2. Listen for any grating sound
caused by the fan rubbing against the base platform. Adjust the fan position if
rubbing is present.

20. Perform the Electrical Safety Check in Section 3.5.

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5/Repair Procedures
5.8 Solid State Relay Replacement
(Figure 5-6)

Note: There are several manufacturers for the solid state relay. The replacement relay
may 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.

1. Access the controller as described in Section 5.5.

2. Remove the two screws used to mount the relay and the metal oxide varister (if
present).

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 and
connect 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 the
side of the controller. Pins 3 and 4 should be toward the front of the controller.

7. Replace the controller cover, using the Phillips head screws and lock washers
previously removed.

8. Pull up on the controller latches. Carefully slide the controller back into the incuba-
tor. Push down on the latches to secure the controller.

9. Perform the Checkout Procedure in Section 2.6. Listen for any grating sound
caused by the fan rubbing against the base platform. Adjust the fan position if
rubbing is present.

10. Perform the Electrical Safety Check in Section 3.5.

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5/Repair Procedures
5.9 Heater and/or Heater Gasket Replacement

CAUTION w If gaskets are not installed properly, water can leak in during cleaning and
damage the electronics.

1. Access the controller as described in Section 5.5.

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 the
chassis.

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 of
the 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 mounting
screws 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 flat
surface with the holes faces toward the heater.

14. Replace and tighten the fan mounting knob to secure the fan.

15. Replace the controller cover, using the Phillips head screws and lock washers
previously removed.

16. Pull up on the controller latches. Carefully slide the controller back into the incuba-
tor. Push down on the latches to secure the controller.

17. Perform the Checkout Procedure in Section 2.2. Listen for any grating sound
caused by the fan rubbing against the base platform. Adjust the fan position if
rubbing is present.

18. Perform the Electrical Safety Check in Section 3.5.

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5/Repair Procedures

Thermal Switch Screws

Fan Knob
Thermal Switch
Thermal Switch Gasket
Fan

Heater
Studs

Heater Gasket

Fan Sensor

CI.02.112
Assembly Rear Controller Seal

Rear Controller
Rear Controller Air Seal
Motor Shaft Seal
Fan Motor Fan Motor Shaft

Ferrel

Fan Motor Bracket

Motor Mount

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

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5/Repair Procedures
5.10 Thermal Switch Replacement

CAUTION w If gaskets are not installed properly, water can leak in during cleaning and
damage the electronics.

Note: It is not necessary to remove the heater.

1. Access the controller as described in Section 5.5.

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 of
the controller as shown in Figure 5-10. Position your hand inside the controller to
catch the mounting nuts and lock washers when you remove the screws. Retain
the gasket for use with the new thermal switch.

5. Align the gasket with the new thermal switch and replace the mounting hardware
as shown in Figure 5-10.

6. Reconnect the thermal switch to the wires from J1 pin 2 and the heater. Make sure
that there is clearance between the thermal switch wires and the motor.

7. Perform Section 3.4.J of the calibration procedures.

8. Replace the controller cover, using the Phillips head screws and lock washers
previously removed.

9. Pull up on the controller latches. Carefully slide the controller back into the incuba-
tor. Push down on the latches to secure the controller.

10. Perform the Checkout Procedure in Section 2.2. Listen for any grating sound
caused by the fan rubbing against the base platform. Adjust the heater and fan
position if rubbing is present.

11. Perform the Electrical Safety Check in Section 3.5.

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 and
damage the electronics.

Note: It is not necessary to remove the heater.

1. Access the controller as described in Section 5.5.

2. Remove the fan from the motor shaft, by removing the knob and sliding the fan off
the shaft.

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5/Repair Procedures
3. Disconnect the heater wires and the thermal switch wires and the harness ground
wire. Then remove the back of the controller from the chassis by removing the four
mounting screws.

4 Disconnect the fan sensor cable from the control board (J5) and remove the cable
from 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 and
washers from the existing assembly.

7. Route the replacement fan sensor cable through the two p-clips and connect it to
J5 on the control board.

8. Attach the back of the controller to the chassis with the four mounting screws. Then
reconnect 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 lockwashers
previously removed.

12. Perform the Checkout Procedure in Section 2.6 Controller Check. Listen for any
grating sound caused by the fan rubbing against the base platform. Adjust the
heater and fan position if rubbing is present.

13. Perform Electrical Safety Check in Section 3.5.

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5/Repair Procedures
5.12 Fan Motor Replacement
1. Access the controller as described in Section 5.5.

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. Then
remove the back of the controller from the chassis by removing the four mounting
screws.

4. Remove the old air seal. Use isopropyl alcohol to remove any adhesive residue on
the 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 the
controller chassis.

7. Remove the four motor mounting screws and slide the motor out of the bracket and
the 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.

Sensor Assembly
Mounting Hardware

Fan Sensor Assembly

Shaft Air Seal
Motor Shaft

Fan Motor

Screw
Washer
Fan Motor Shock Mount
Mounting Ferrule
Bracket
CI.02.113

Figure 5-11
Fan Motor Replacement

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5/Repair Procedures
10. Install the new shock mounts in the motor bracket. Then install the ferrules in the
shock 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 the
controller. 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 the
flat 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 wire
to the controller chassis.

20. Calibrate the fan sensor as described in Section 3.4 I.

21. Replace the controller cover, using the Phillips head screws and lock washers
previously removed.

22. Pull up on the controller latches. Carefully slide the controller back into the incuba-
tor. Push down on the latches to secure the controller.

23. Perform the Checkout Procedure in Section 2.2. Listen for any grating sound
caused by the fan rubbing against the base platform. If rubbing is present, adjust
the motor and fan position by loosening the motor bracket mounting screws and
moving the motor and bracket.

24. Complete the Electrical Safety Check in Section 3.5.

5-19 6600-0292-000 2/2/99 5-19

5/Repair Procedures
5.13 Battery Replacement
1. 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 the
battery into the bracket.

4. Reattach the controller cover, using the Phillips head screws and lock washers
previously 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 caused
by the fan rubbing against the base platform. Adjust the heater and fan position if
rubbing is present.

7. Perform the Electrical Safety Check in Section 3.5.

5.14 Cabinet Caster Replacement

WARNING w Two people are required to safely replace a caster. Remove the incubator
and 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 attach the
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.

5-20 6600-0292-000 2/2/99 5-20

6/Illustrated Parts
6.1 Hood Components

1 2

4
9 11 9
5
6
13 12 10 9 8 7

CI.23.046
Item Stock Number
1. Hood frame, left ................................................................................. 6600-0965-500
2. Hood .................................................................................................. 6600-0961-500
3. Hood frame, rear ............................................................................... 6600-0967-500
4. Polyethylene tape .............................................................................. 6600-0110-300
5. Hood frame, right ............................................................................... 6600-0966-500
6. Acorn nut 10-32 ................................................................................. 6600-0736-400
7. Lock washer, split ring #10 ................................................................ 6600-0745-400
8. Washer #10 ....................................................................................... 6600-0744-400
9. Screw, 10-32 x .62 Phillips ................................................................ 6600-0735-400
10. Acoustic baffle ................................................................................... 6600-0983-500
11. Screw, 10-32 x .75 Phillips ................................................................ 6600-0089-400
12. Hood support bracket ........................................................................ 6600-0964-500
13. Screw, 10 - 32 x .875 Phillips ............................................................ 6600-0757-400

Figure 6-1
Hood frame and hardware

6-1 6600-0292-000 10/15/97 6-1

6/Illustrated Parts

CI.23.048
1 5

Item Stock Number

1. Hinge pin ‘E’ clip ................................................................................ 6600-0300-400
2. Hand hole hinge pin .......................................................................... 6600-0205-400
3. Hand hole cover ................................................................................ 6600-0498-500
4. Hand hole frame ................................................................................ 6600-0274-500
5. Hinge spring ...................................................................................... 6600-0242-400

Figure 6-2
Hand hole assembly (6600-0561-700)

6-2 6600-0292-000 10/15/97 6-2

6/Illustrated Parts

9
7
9

CI.23.049
8

5 6

Item Stock Number

1. Tightening ring ................................................................................... 6600-0794-500
2. Iris cuff kit (10) ................................................................................... 6600-0499-800
3. Iris gasket .......................................................................................... 6600-0699-500
4. Iris frame ........................................................................................... 6600-0696-500
5. Hand hole assembly .......................................................................... 6600-0561-700
6. Hand hole latch ................................................................................. 6600-0202-700
7. Hand hole post (small) ...................................................................... 6600-0969-500
8. Hand hole post (large) ....................................................................... 6600-0968-500
9. Screw 10-24 x .375, Skt Hd cap ........................................................ 6600-0081-500

Figure 6-3
Iris porthole assembly

6-3 6600-0292-000 10/15/97 6-3

 6/Illustrated Parts
2 3 4 5

CI.23.047,.078
1
Item 19
Door Latch Kit Detail

17 Spring
Washer
6 Flat
7 Washer Retainer
16 18 8 Clip

Inner
9 Wall
10
15 11
Latch
14
Door
13 12
Item Stock Number
1. Front door* ........................................................................................ 6600-0970-500
2. Hand hole post (large) ....................................................................... 6600-0968-500
3. Screw, 10-24 x .375, Skt Hd Cap ...................................................... 6600-0081-400
4. Hand hole post (small) ...................................................................... 6600-0969-500
5. Inner wall, front .................................................................................. 6600-0976-500
6. Retaining washer (included with item 18)
7. Spring washer ................................................................................... 6600-0218-400
8. Washer, .81 OD .41 ID ...................................................................... 6600-0173-400
9. Screw, 1/4 - 28 x 1.5, Phillips ............................................................ 6600-0739-400
10. Lock washer, split ring, 1/4 ................................................................ 6600-0751-400
11. Washer, 1/4 ....................................................................................... 6600-0750-400
12. Deflector mount ................................................................................. 6600-0985-500
13. Inner wall deflector ............................................................................ 6600-0971-500
14. Acorn nut 1/4 -28 ............................................................................... 6600-0762-400
15. Front door hinge ................................................................................ 6600-0972-500
16. Hand hole latch ................................................................................. 6600-0202-700
17. Hand hole .......................................................................................... 6600-0561-700
18. Door latch (includes item 6) ............................................................... 6600-0974-500
19. Door latch kit (includes 2 latches and all hardware) .......................... 6600-0616-800

*Must order door latch kit when replacing door

Figure 6-4
Front door and inner wall assembly

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6/Illustrated Parts
6.2 Hood Latch Assembly,
Compartment Probe and Related Items
1 2 3

5
6
18 7
17
8
16
15
14

CI.23.045
13 12 11 10
Item Stock Number
1. Sensor assembly ............................................................................... 6600-0495-701
2. Sensor shim ...................................................................................... 6600-0222-500
3. Hood assembly .................................................................................. 6600-0083-850
4. Screw, 1/4 - 20 x .44 Skt Hd Shldr .................................................... 6600-0737-400
5. Screw, #8 x 1.00 Truss Hd ................................................................ 6600-0083-400
6. Lock washer, split ring 1/4 ................................................................. 6600-0473-400
7. ‘P’ clip cable clamp ............................................................................ 6600-0144-400
8. Nut, elastic lock 8-32 ......................................................................... 0202-1008-300
9. Knob, filter cover ............................................................................... 6600-0982-500
10. Filter cover ......................................................................................... 6600-0981-500
11. Filter assembly .................................................................................. 6600-0105-300
12. Screw, 8-32 x 1/2 Phillips .................................................................. 0140-6627-108
13. Hood latch gravity lock ...................................................................... 6600-0963-500
14. Acorn nut 10-32 ................................................................................. 6600-0736-400
15. Lock washer, split ring #10 ................................................................ 6600-0745-400
16. Hood latch spacer ............................................................................. 6600-1009-500
17. Screw, 10-32 x .875 Phillips .............................................................. 6600-0757-400
18. Hood latch locking bracket ................................................................ 6600-0962-500

Figure 6-5
Incubator assembly, filter and hood latch

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6/Illustrated Parts
6.3 Base Platform Components
Item Stock Number
1. Tubing access cover ......................................................................... 6600-0330-501
2. Door latch masking patch .................................................................. 6600-1837-100
3. Platform cover ................................................................................... 6600-0345-501
4. Tilt rod, left ......................................................................................... 6600-0978-500
5. Tilt rod holder .................................................................................... 6600-0979-500
6. Tilt rod, right ...................................................................................... 6600-0977-500
7. Humidifier hole plug ........................................................................... 6600-0762-500
8. Humidifier sump ................................................................................ 6600-1012-500
9. Humidifier slide .................................................................................. 6600-1013-500
10. Humidifier lid ...................................................................................... 6600-1011-500
11. Humidifier gasket ............................................................................... 6600-0433-500
12. Mattress tray ...................................................................................... 6600-0980-500
13. Mattress ............................................................................................. 6600-0984-500

Humidifier upgrade kit

(includes items 8-11 above plus mounting rails) ............................... 6600-0574-800

6-6 6600-0292-000 10/15/97 6-6

6/Illustrated Parts

4
13

5
6
12
7

11

10

9
CI.23.051

Figure 6-6
Base platform, humidifier and cover assembly

6-7 6600-0292-000 10/15/97 6-7

6/Illustrated Parts
Item Stock Number
1. Base platform Kit ............................................................................... 6600-0100-850
2. Humidifier slide, right ......................................................................... 6600-0676-500
3. Humidifier slide, left ........................................................................... 6600-0677-500
4. Screw, locking 8-32 x 5/8 Phillips ...................................................... 6600-0523-400
5. Lock washer, #8 int tooth .................................................................. 6600-0262-400
6. Screw, #8-32 x 1/4 Phillips ................................................................ 6600-0248-400
7. ‘P’ clip cable clamp ............................................................................ 6600-0144-400
8. Controller latch, left ........................................................................... 6600-0225-500
9. Screw, 8-32 x 3/8 Phillips .................................................................. 0140-6127-106
10. Controller latch, right ......................................................................... 6600-0226-500
11. Screw, 8-32 x .38 Phillips .................................................................. 6600-0261-400
12. Washer, .188 ID x .438 OD ............................................................... 6600-0080-400
13. Cable tie 1/4 ...................................................................................... 6600-0585-400
14. Screw, 8 x 3/8 Phillips ....................................................................... 6600-0767-400
15. Cap and chain ................................................................................... 0217-3785-700
16. Nipple 1/8 NPT x 3/16 ....................................................................... 6600-0102-400
17. Nut 1/8 NPT x .125† .......................................................................... 6600-0176-500
18. Power cord (North America) .............................................................. 0208-0950-300
19. Sensor assembly ............................................................................... 6600-0495-701

† Apply Loctite 242

6-8 6600-0292-000 10/15/97 6-8

6/Illustrated Parts
4 5 6

9
3
8 10
2 11
12

1
13

CI.23.052
14

19 15
16
18
17

Figure 6-7
Base platform assembly

6-9 6600-0292-000 10/15/97 6-9

6/Illustrated Parts
6.4 Cabinet Components
Item
1. Bottom panel
2. Caster, locking
3. Caster, non-locking
4. Nut, 5/16-24
5. Lock washer, 5/16 helical
6. Flat washer, 5/16
7. Cap screw, 5/16 - 24 x .75
8. Side panel
9. Nut, #10 - 32
10. Lock washer, #10 helical
11. Flat washer, #10
12. Cap screw, #10-32 x .50

6-10 6600-0292-000 10/15/97 6-10

6/Illustrated Parts

2
1
3

4
5
6

12

9 10 11 CI.23.060,061

12

Figure 6-8
Casters and base

6-11 6600-0292-000 10/15/97 6-11

6/Illustrated Parts

1
2
3

6 4
5
7

10

CI.23.062,063
Item Stock Number
1. Top panel
2. Cap screw, #10-32 x .50
3. Nut, #10 - 32
4. Lock washer, #10 helical
5. Flat washer, #10
6. Rear panel (optional)
7. Shelf (optional)
8. Front panel with doors (optional)
9. Handle
10. Door Magnet

Parts Not Shown

Cabinet Upgrade Kit (includes optional items above) ....................... 6600-0577-800
Basic Cabinet Kit ............................................................................... 6600-0589-800

Figure 6-9
Cabinet parts

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6/Illustrated Parts

2 6
5
4

10
1
11

7
13
8 9
12

CI.23.064,065
Item Stock Number
1. I.V. pole telescoping (1) ..................................................................... 6600-0556-700
2. I.V. pole hanger(1)
3. U-bolt with plate and nuts (1)
4. Screw, #10-32 x 1.00 skt btn hd cap (1)
5. Acorn nut, #10-32 lock (1)
6. Tubing (1)
7. Screw, #10-24 hex sch shlder(1)
8. Washer .200 ID, .440 OD (2)
9. Nut, #10-24 hex (1)
10. Split lock washer, 1/4" (2)
11. I.V. pole label
12. Bumper (optional) (2)
13. Cap screw, #10 - 32 x 5/8 (4)

I.V. pole kit (includes items 1-11) ...................................................... 6600-0576-800

Bumper Kit (includes items 12 & 13) ................................................. 6600-0578-800

Figure 6-10
I.V. pole and bumpers

6-13 6600-0292-000 10/15/97 6-13

6/Illustrated Parts
6.5 Controller Components
Item Stock Number
1. Screw, 6-32 x 7/8 TRS PH ................................................................ 6600-0150-400
2. Washer, flat #6 .................................................................................. 0202-4510-340
3. Shock mount ..................................................................................... 6600-0105-400
4. Bushing, shock mount ....................................................................... 6600-0341-500
5. Motor bracket, 60 Hz ......................................................................... 6600-0517-500
Motor bracket, 50 Hz ......................................................................... 6600-0518-500
6. Motor kit, 100/120/220/240V, 60Hz† ................................................. 6600-0054-800
Motor kit, 100/120V, 50 Hz† .............................................................. 6600-0054-802
Motor kit, 220/240V, 50 Hz† .............................................................. 6600-0054-801
7. Bracket edge protector (3" long) ....................................................... 6600-0123-400
8. Airseal, motor shaft* .......................................................................... 6600-0471-500
9. Washer, lock, #6 split ring ................................................................. 6600-0345-400
10. Screw, 6-32 x 1/2, RD, PH ................................................................ 0140-6124-108
11. Fan sensor kit (includes item 8). ....................................................... 6600-0403-800
12. Washer, lock , #8 int tooth ................................................................. 6600-0262-400
13. Nut, 8-32, ext tooth lock .................................................................... 0202-1131-300
14. Transformer, 100/120V ..................................................................... 0208-7580-300
Transformer kit, 220/240V ................................................................. 6600-0145-800
15. Controller Latch Kit (1/pkg) ................................................................ 6600-0108-800
16. Spacer, 6-32 ...................................................................................... 6600-0376-400
17. Washer, lock, # 6 int tooth , ............................................................... 6600-0399-400
18. Nut, 8-32, ext lock ............................................................................. 0202-1131-300
19. Circuit breaker bracket ...................................................................... 6600-0864-500
20. Screw, 6-32 x 1/4 TRS, PH ............................................................... 0140-6624-104
21. Circuit breaker (5 amp)ˆ .................................................................... 6600-0562-604
22. Spacer, threaded, 6-32 x 1/4 ............................................................. 6600-0377-400
23. Slide rail ............................................................................................. 6600-0167-500
24 Controller chassis (beige) .................................................................. 6600-0469-500
Controller chassis (light grey) ............................................................ 6600-0469-501
25. 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.

6-14 6600-0292-000 10/15/97 6-14

6/Illustrated Parts

9 10 11

4
3
2 7
1

14
13

12

15

24

16 22
17
18 CI.02.122

19 23

25

20 21 20

Figure 6-11
Motor, fan sensor, circuit breaker and transformer assembly

6-15 6600-0292-000 10/15/97 6-15

6/Illustrated Parts
Item Stock Number
1. Rear controller airseal* ...................................................................... 6600-0472-500
2. Nut, 10-32 keps w/ ext ....................................................................... 6600-0066-400
3. Washer flat .219 ID .50 OD ............................................................... 6600-0067-400
4. Nut, 6-32 keps w/ ext ......................................................................... 6600-0400-400
5. Washer, #6 ........................................................................................ 6600-0016-400
6. Gasket, thermal switch ...................................................................... 6600-0209-500
7. Thermal switch .................................................................................. 6600-0073-600
8. Screw, 6-32 x 1/2 RD PH .................................................................. 0140-6124-108
9. Controller rear seal (external)* .......................................................... 6600-0067-500
10. Heater, 120V † .................................................................................. 6600-0199-500
Heater, 100V † .................................................................................. 6600-0231-500
Heater, 220/230V † ........................................................................... 6600-0177-500
Heater, 240V † .................................................................................. 6600-0198-500
11. Gasket, heater ................................................................................... 6600-0142-500
12. Rear controller (beige) ....................................................................... 6600-0470-500
Rear controller (light grey) ................................................................. 6600-0470-501

† Always replace gasket (item 11) when replacing heater

* Press adhesive side against the rear of the controller.

6-16 6600-0292-000 10/15/97 6-16

6/Illustrated Parts

6 7 8

10

CI.02.123
5
4
11
3
2

9
1

12

Figure 6-12
Back panel

6-17 6600-0292-000 10/15/97 6-17

6/Illustrated Parts
Item Stock Number
1. Nut, precision, 1/4 -32 NEF (series 2000 only) ................................. 6600-0109-400
2. Bezel, patient temp probe connector (series 2000 only) ................... 6600-0071-500
3. Hairpin clip (series 2000 only) ........................................................... 6600-0104-400
4. Cable tie ............................................................................................ 6600-0364-400
5. ON/OFF switch with bezel (DPST)* (includes nut) ............................ 6600-0229-600
6. Switch guard kit (includes label & washer) ........................................ 6600-0046-850
7. Capacitor assy kit .............................................................................. 6600-0404-800
8. Line filter, 6A (AC entrance) .............................................................. 6600-0094-700
9. Screw, 6-32 x 3/8 .............................................................................. 0400-3135-300
10. Keps nut, #6 32 ................................................................................. 6600-0400-400
11. Connector cover plate ....................................................................... 6600-0473-500
12. Screw, 8-32 x 3/8 .............................................................................. 0140-6127-106
13. External tooth lock nut, 8-32 .............................................................. 0202-1131-300
14. Solid state relay kit (includes item 15) ............................................... 6600-0457-800
15. Metal oxide varistor assy ................................................................... 6600-0458-800
16. Washer .............................................................................................. 0202-0095-300
17. Washer, #6 ........................................................................................ 6600-0016-400
18. Split lock washer, #6 ......................................................................... 6600-0345-400
19. Screw, 6-32 x 7/8 .............................................................................. 6600-0150-400
20. Fan knob ........................................................................................... 6600-0448-400
21. Blower fan, 5 blade (white) ................................................................ 6600-0008-850
22. Hex nut .............................................................................................. 0144-3127-113
23. Washer, lock , #10, split ring ............................................................. 6600-0322-400
24. Cooling fan (CCW rotation) ............................................................... 6600-0056-400
25. 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 ......................................................................... 6600-0400-400
27. Washer, lock int tooth , 1/4 ................................................................ 6600-0396-400
28. Grounding post kit (series 2000 only) ................................................ 6600-0260-800
29. Washer .............................................................................................. 6600-0399-400
30. Patient probe jack .............................................................................. 6600-0067-700
31. Screw, 1/2-13 x 1.0 Skt BTN Cap (series 1000 only) ........................ 6600-0769-400
32. Washer, .53 ID x 1.06 OD (series 1000 only) .................................... 6600-0770-400
33. Washer, lock ext tooth .5 (series 1000 only) ..................................... 6600-0776-400
34. Washer, lock split ring 1/2 (series 1000 only) .................................... 6600-0771-400
35. Nut, 1/2-13 hex (series 1000 only) .................................................... 6600-0424-400

* This toggle switch does not contain circuit breakers, and should only be used on controllers that
have external circuit breakers.

6-18 6600-0292-000 10/15/97 6-18

 6/Illustrated Parts

Open
20
Blue 21
Black
Red
White

30 23 22

25
29
26
27 24
3 19
2 18
1 17
16

CI.02.198
13
10

28

15
14
4 12
32 5 11
7 6
35 32
34 9
33

31

Figure 6-13
Controller chassis and fan assembly

6-19 6600-0292-000 10/15/97 6-19

6/Illustrated Parts
Item Stock Number
1. Control board (tested) ....................................................................... 6600-0079-850
2 Internal tooth lock washer ................................................................. 6600-0399-400
3. Screw, 6-32 ....................................................................................... 6600-0389-400
4. Screw, 6-32 x 3/8 .............................................................................. 0140-6624-106
5. Internal tooth lock washer, #6 ........................................................... 6600-0399-400
6. Controller cover (beige) ..................................................................... 6600-0066-500
Controller cover (light grey) ............................................................... 6600-0066-501
7. High voltage harness (terminated AC entrance
& solid state relay wires, J1 and J2, battery holder) .......................... 6600-0313-700

6-20 6600-0292-000 10/15/97 6-20

6/Illustrated Parts
1 23 4 5 6

CI.02.125
Figure 6-14
Cover assembly

6-21 6600-0292-000 10/15/97 6-21

6/Illustrated Parts
Item Stock Number
1. Front cover, controller (light grey) ..................................................... 6600-0064-501
2. Washer .............................................................................................. 6600-0399-400
3. Screw, 6-32 x 3/8, TRS, PH .............................................................. 0140-6624-106
4. Nut ..................................................................................................... 6600-0382-400
5. Display board ESD shield .................................................................. 6600-0515-500
6. Display board kit ................................................................................ 6600-0080-850
7. Spacer ............................................................................................... 6600-0768-400
8. Spacer ............................................................................................... 6600-0544-400
9. Washer, #6, .3750 ............................................................................. 6600-0016-400
10. Switch panel assembly kit
Care Plus 1000 .................................................................................. 6600-0617-801
Care Plus 2000 .................................................................................. 6600-0617-802

6-22 6600-0292-000 10/15/97 6-22

6/Illustrated Parts

1 2 3

CI.02.197
10 7 8 6 9 5 4

Figure 6-15
Control panel assembly

6-23 6600-0292-000 10/15/97 6-23

6/Illustrated Parts
6.6 Board Components
Display Board
6600-0512-700

CI.23.080

6-24 6600-0292-000 10/15/97 6-24

6/Illustrated Parts

CI.23.070
Figure 6-16
Display Board

6-25 6600-0292-000 10/15/97 6-25

6/Illustrated Parts
Control Board
Controllers with software revisions 04.00 and higher

6600-0515-700

CI.02.309,311

6-26 6600-0292-000 10/15/97 6-26

6/Illustrated Parts

CI.02.310

Figure 6-17
Control Board, Surface Mount

6-27 6600-0292-000 10/15/97 6-27

6/Illustrated Parts
6.7 Label Sets
W WARNING: The front door inner wall must be in
Temp/Probe Patient Air place while a patient occupies the
incubator.
Control System Heater Air Heater may be hot.
Alarms Power Enable Power must be disconnected before

6600-2210-101

English .................................................................................................................. 6600-2210-101

French .................................................................................................................. 6600-2210-102
Spanish ................................................................................................................ 6600-2210-103
German ................................................................................................................ 6600-2210-104
Italian .................................................................................................................... 6600-2210-105
Russian ................................................................................................................ 6600-2210-108
Portuguese ........................................................................................................... 6600-2210-111
Mandarin .............................................................................................................. 6600-2210-113

W WARNINGS: Fire hazard. Keep matches, lighted cigarettes W WARNING: The humidity reservoir, or humidity reservoir Oxygen Concentration Chart Replace filter every three (3)
and all other sources of ignition out of the room in which the plugs, must be fully inserted for correct incubator operation, months. Replaced:
incubator is located. Textiles, oils, and other combustibles even if the humidifier feature is not used. Average oxygen

?
are easily ignited and burn with great intensity in air enriched W CAUTION: U.S. Federal and Canadian law restricts this Oxygen input concentration range
with oxygen. device to sale by or on the order of a licensed medical
5L/min 25-45%
Possible explosion hazard. Do not use in the presence of
flammable anesthetics.
Oxygen concentrations higher than 40% can increase the risk
practitioner.
Use only Ohmeda skin temperature probe. 10L/min 35-55% m
Use only hospital grade grounded power receptacle. 15L/min 45-75%
of retrolental fibroplasia. It is possible that even Ohmeda
concentrations of 40% or less (formerly considered safe) NOTE: Oxygen concentration levels in this Columbia MD 21046 1801
could be dangerous for some infants. Therefore, arterial blood Made in USA Oxygen Inlet: Ensure the
gas measurements are extremely important for regulation of chart are intended as a reference only. U.S. Pat. No. 4,936,824
Actual concentrations should be checked Controller is sealed and latched
the concentration of inspired oxygen when in an oxygen
enriched environment. with an oxygen analyzer.
prior to administering oxygen.
?
6600-2214-101

English .................................................................................................................. 6600-2214-101

French .................................................................................................................. 6600-2214-102
Spanish ................................................................................................................ 6600-2214-103
German ................................................................................................................ 6600-2214-104
Italian .................................................................................................................... 6600-2214-105
Russian ................................................................................................................ 6600-2214-108
Portuguese ........................................................................................................... 6600-2214-111
Mandarin .............................................................................................................. 6600-2214-113

Ohio® Care Plus® Incubator Ohmeda

Columbia MD 21046 1801
Made in USA
U.S. Pat. No. 4,936,824
WWARNING: Air Heater may be hot. Electrical
shock hazard. Do not remove cover. Refer
servicing to qualified service personnel.
WCAUTION: Federal law in the USA and Canada
restrict this device to sale by or on the order of
a licensed medical practitioner.
Note: Use only Ohmeda Skin Temperature Probe.
m
6600-2212-101
English .................................................................................................................. 6600-2212-101
French .................................................................................................................. 6600-2212-102
Spanish ................................................................................................................ 6600-2212-103
German ................................................................................................................ 6600-2212-104
Italian .................................................................................................................... 6600-2212-105
Russian ................................................................................................................ 6600-2212-108
Portuguese ........................................................................................................... 6600-2212-111
Mandarin .............................................................................................................. 6600-2212-113

W WARNING: The front door inner wall must be in place while a patient occupies the incubator.
Air Heater may be hot.
Power must be disconnected before removing bed platform.
6600-2225-101
English .................................................................................................................. 6600-2225-101
French .................................................................................................................. 6600-2225-102
Spanish ................................................................................................................ 6600-2225-103
German ................................................................................................................ 6600-2225-104
Italian .................................................................................................................... 6600-2225-105
Russian ................................................................................................................ 6600-2225-108
Portuguese ........................................................................................................... 6600-2225-111
Mandarin .............................................................................................................. 6600-2225-113

6-28 6600-0292-000 10/15/97 6-28

7/Schematics 7/Schematics

CI.23.053
Figure 7-1a
Control Board Schematic (page 1 of 7)

7-1 6600-0292-000 2/2/99 7-1

7/Schematics 7/Schematics

CI.23.054
Figure 7-1b
Control Board Schematic (page 2 of 7)

7-2 6600-0292-000 2/2/99 7-2

7/Schematics 7/Schematics

CI.23.055
Figure 7-1c
Control Board Schematic (page 3 of 7)

7-3 6600-0292-000 2/2/99 7-3

7/Schematics 7/Schematics

CI.23.056
Figure 7-1d
Control Board Schematic (page 4 of 7)

7-4 6600-0292-000 2/2/99 7-4

7/Schematics 7/Schematics

CI.23.057
Figure 7-1e
Control Board Schematic (page 5 of 7)

7-5 6600-0292-000 2/2/99 7-5

7/Schematics 7/Schematics

CI.23.058
Figure 7-1f
Control Board Schematic (page 6 of 7)

7-6 6600-0292-000 2/2/99 7-6

7/Schematics 7/Schematics

CI.23.059
Figure 7-1g
Control Board Schematic (page 7 of 7)

7-7 6600-0292-000 2/2/99 7-7

7/Schematics 7/Schematics

CI.23.071
Figure 7-2a
Display Board Schematic (page 1 of 2)

7-8 6600-0292-000 2/2/99 7-8

7/Schematics 7/Schematics

CI.23.072
Figure 7-2b
Display Board Schematic (page 2 of 2)

7-9 6600-0292-000 2/2/99 7-9

7/Schematics 7/Schematics

CI.23.073
Figure 7-3
Wiring Diagram

7-10 6600-0292-000 2/2/99 7-10

7/Schematics 7/Schematics

0202-1131-300 (2)
GND From
Motor 0202-3205-300
6600-0125-400 (4)
GND From
Rear Controller GND From
Grounding Post
Note: Sleeving
must extend
GND From beyond the
Power Receptacle motor bracket.

Detail A

Green/Yellow

Orange
Yellow

Blue
For all transformer conections install
Green/Yellow .125" x 1" long heat shrink tubing to
Brown cover exposed solder connections.

Blue
Red

6600-0404-800 For transformer and motor

connections see Figure 7-6.

Orange Black
0208-0335-300 Yellow
(all cable clamps)

CI.02.202
Brown For red and black wires install
Blue .125" x 1" heat shrink tubing to
cover exposed solder connections
and switch terminal.
0205-4737-300
See Detail A
Figure 7-4
Controller Plate Diagram

7-11 6600-0292-000 2/2/99 7-11

Notes
7/Schematics Notes
7/Schematics

7-12 6600-0292-000 2/2/99 7-12

Appendix
Patient Temperature Probe and Air Temperature Sensor
Characteristics
Temp Resistance Temp Resistance Temp Resistance Temp Resistance
(°C) (Ohms) (°C) (Ohms) (°C) (Ohms) (°C) (Ohms)

1.0 31483.8 31.6 7503.8 37.1 5956.4 42.6 4762.5

2.0 29909.8 31.7 7471.8 37.2 5931.8 42.7 4743.5
3.0 28423.7 31.8 7440.0 37.3 5907.4 42.8 4724.5
4.0 27020.2 31.9 7408.4 37.4 5883.1 42.9 4705.7
5.0 25694.1 32.0 7376.9 37.5 5858.9 43.0 4686.9
6.0 24440.8 32.1 7345.6 37.6 5834.8 43.1 4668.3
7.0 23255.9 32.2 7314.4 37.7 5810.8 43.2 4649.7
8.0 22135.4 32.3 7283.4 37.8 5786.9 43.3 4631.2
9.0 21075.3 32.4 7252.5 37.9 5763.1 43.4 4612.7
10.0 20072.1 32.5 7221.8 38.0 5739.5 43.5 4594.4
11.0 19122.4 32.6 7191.2 38.1 5716.0 43.6 4576.1
12.0 18223.1 32.7 7160.8 38.2 5692.5 43.7 4558.0
13.0 17371.3 32.8 7130.5 38.3 5669.2 43.8 4539.9
14.0 16564.2 32.9 7100.4 38.4 5646.0 43.9 4521.9
15.0 15799.1 33.0 7070.4 38.5 5622.9 44.0 4503.9
16.0 15073.8 33.1 7040.5 38.6 5599.9 44.1 4486.1
17.0 14385.9 33.2 7010.8 38.7 5577.0 44.2 4468.3
18.0 13733.2 33.3 6981.3 38.8 5554.3 44.3 4450.6
19.0 13113.9 33.4 6951.8 38.9 5531.6 44.4 4433.0
20.0 12526.0 33.5 6922.6 39.0 5509.0 44.5 4415.5
21.0 11967.8 33.6 6893.4 39.1 5486.6 44.6 4398.1
22.0 11437.6 33.7 6864.4 39.2 5464.2 44.7 4380.7
23.0 10933.8 33.8 6835.5 39.3 5441.9 44.8 4363.4
24.0 10455.1 33.9 6806.8 39.4 5419.8 44.9 4346.2
25.0 10000.0 34.0 6778.2 39.5 5397.7 45.0 4329.1
26.0 9567.3 34.1 6749.8 39.6 5375.8
27.0 9155.6 34.2 6721.5 39.7 5354.0 46.0 4161.9
28.0 8764.0 34.3 6693.3 39.8 5332.2 47.0 4002.1
34.4 6665.3 39.9 5310.6 48.0 3849.3
29.0 8391.3 34.5 6637.3 40.0 5289.0 49.0 3703.1
29.1 8355.1 34.6 6609.6 40.1 5267.6 50.0 3563.3
29.2 8319.0 34.7 6581.9 40.2 5246.2 51.0 3429.5
29.3 8283.0 34.8 6554.4 40.3 5225.0 52.0 3301.4
29.4 8247.3 34.9 6527.0 40.4 5203.9 53.0 3178.8
29.5 8211.7 35.0 6499.8 40.5 5182.8 54.0 3061.3
29.6 8176.4 35.1 6472.6 40.6 5161.9 55.0 2948.9
29.7 8141.1 35.2 6445.7 40.7 5141.0 56.0 2841.1
29.8 8106.1 35.3 6418.8 40.8 5120.2 57.0 2737.8
29.9 8071.2 35.4 6392.1 40.9 5099.6 58.0 2638.9
30.0 8036.5 35.5 6365.4 41.0 5079.0 59.0 2544.0
30.1 8002.0 35.6 6339.0 41.1 5058.5 60.0 2453.0
30.2 7967.6 35.7 6312.6 41.2 5038.2
30.3 7933.4 35.8 6286.4 41.3 5017.9
30.4 7899.4 35.9 6260.3 41.4 4997.7
30.5 7865.6 36.0 6234.3 41.5 4977.6
30.6 7831.9 36.1 6208.4 41.6 4957.6
30.7 7798.3 36.2 6182.7 41.7 4937.7
30.8 7765.0 36.3 6157.0 41.8 4917.9
30.9 7731.7 36.4 6131.5 41.9 4898.1
31.0 7698.7 36.5 6106.2 42.0 4878.5
31.1 7665.8 36.6 6080.9 42.1 4858.9
31.2 7633.1 36.7 6055.8 42.2 4839.5
31.3 7600.5 36.8 6030.7 42.3 4820.1
31.4 7568.1 36.9 6005.8 42.4 4800.8
31.5 7535.9 37.0 5981.1 42.5 4781.6

A-1 6600-0292-000 2/2/99 A-1

Appendix
Temperature Conversion Chart
°C °F °C °F °C °F

20.0 68.0 34.5 94.1 37.6 99.7

21.5 70.7 35.0 95.0 37.7 99.9
22.0 71.6 35.1 95.2 37.8 100.0
22.5 72.5 35.2 95.4 37.9 100.2
23.0 73.4 35.3 95.4 38.0 100.4
23.5 74.3 35.4 95.7 38.1 100.6
24.0 75.2 35.5 95.9 38.2 100.8
24.5 76.1 35.6 96.1 38.3 100.9
25.0 77.0 35.7 96.3 38.4 101.1
25.5 77.9 35.8 96.4 38.5 101.3
26.0 78.8 35.9 96.6 38.6 101.5
26.5 79.7 36.0 96.8 38.7 101.7
27.0 80.6 36.1 97.0 38.8 101.8
27.5 81.5 36.2 97.2 38.9 102.0
28.0 82.4 36.3 97.3 39.0 102.2
28.5 83.3 36.4 97.5 39.5 103.1
29.0 84.2 36.5 97.7 40.0 104.0
29.5 85.1 36.6 97.9 40.5 104.9
30.0 86.0 36.7 98.1 41.0 105.8
30.5 86.9 36.8 98.2 41.5 106.7
31.0 87.8 36.9 98.4 42.0 107.6
31.5 88.7 37.0 98.6 42.5 108.5
32.0 89.6 37.1 98.8 43.0 109.4
32.5 90.5 37.2 99.0 43.5 110.3
33.0 91.4 37.3 99.1 44.0 111.2
33.5 92.3 37.4 99.3 44.5 112.1
34.0 93.2 37.5 99.5 45.0 113.0

CarePlus Specifications
Electrical specifications
Power requirements

Designed to IEC 601-1 and IEC 601-2-19 specifications

120 Vac 50/60 Hz Models (115 Vac ± 10%, 5.7 Amps)
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)

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.

A-2 6600-0292-000 2/2/99 A-2

Appendix
Rated Current: 7 Amps
Trip Point: 9.8 Amps Minimum
Type: Manual Resetting
Model: ETA 41-06-P10 7 Amps

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°C
Resolution: ± 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 °F
Accuracy*: 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) with
internal 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 control
panel Override switch.

Thermal performance

Temperature Rise Time*: Less than or equal to 20 min

Temperature 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.

A-3 6600-0292-000 2/2/99 A-3

Appendix
Alarms

Indicator and Nonsilenceable Audio Alarm

Power Failure

Indicator and Silenceable Single Tone Alarm

Difference between patient temperature and patient control temperature exceeds 1.0°C
patient 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 control
mode; Disabled for 15 minutes after control temperature change and for 30 minutes
on power up).

Indicator, Silenceable Two Tone Alarm and Heater Shutdown

Air temperature sensor disconnected (both modes)
Patient probe disconnected or malfunctioning (patient control mode)
Air circulation system failure
Patient temperature > 42.0°C or < 30.0°C
Air 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 Code
System failure

Operator prompt tone

Intermittent audio tone sounds when the unit is first switched On and when the patient
control 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 controllers
with serial numbers beginning with HBJ, this 30 second tone also precedes all
silenceable alarms.

Proportional heat control

Features zero voltage switching to minimize radiated and conducted EMI. Heater
power 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

100

75 60 High Setting 48
%RH
(Incubator) 52 Low Setting
50
CI.23.042

35
40 Empty Reservoir 24.6
0
30 35 39

Incubator Temperature (°C)

Note: RH Values shown above may very by ±10%

A-4 6600-0292-000 2/2/99 A-4

Appendix
Humidifier specifications

Specification test conditions used to collect data:

Room temperature: 25°C
Room humidity: 50% RH
Readings taken two hours after reaching temperature equilibrium without an infant in
the incubator.

Oxygen concentration within unit

25 to 45% with 5 l/min. oxygen input

35 to 65% with 10 l/min. oxygen input
45 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 infant
compartment 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
equipment used with the Care Plus must comply with UL 544, UL 2601-1,
CSA 22.2 No. 601-1-M90 and IEC 601-1.

Leakage current

For all ground wire configurations with UL, CSA, or AAMI test load attached:

Power supply: 120V 50/60 Hz

Leakage current: less than 300 µA

Power supply: 220/240 V 50/60 Hz

Leakage current: less than 500 µA

Self test

The microprocessor performs self test and software verification functions when the
power is first switched On.

A-5 6600-0292-000 2/2/99 A-5

Appendix
D. Environmental specifications
Operating 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 hPa
Operating and Storage Relative Humidity Range: 0 to 95%

E. Electromagnetic Compatibility (EMC) Specifications

All models meet the requirements as specified in IEC 601-1-2
Collateral Standard Electromagnetic Compatibility - Requirements and Tests.

F. Mechanical specifications
Incubator 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
Height
to bed: 92.0 cm (36.0 in)

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: 0 degrees or 10 degrees

A-6 6600-0292-000 2/2/99 A-6

Warranty
This Product is sold by Ohmeda under the warranties set forth in the following
paragraphs. Such warranties are extended only with respect to the purchase of this
Product directly from Ohmeda or Ohmeda’s Authorized Dealers as new merchandise
and are extended to the Buyer thereof, other than for the purpose of resale.

For a period of twelve (12) months from the date of original delivery to Buyer or to
Buyer’s order, but in no event for a period of more than two years from the date of
original delivery by Ohmeda to an Ohmeda Authorized Dealer, this Product, other than
its expendable parts, is warranted to be free from functional defects in materials and
workmanship and to conform to the description of the Product contained in this
operation manual and accompanying labels and/or inserts, provided that the same is
properly operated under the conditions of normal use, that regular periodic
maintenance and service is performed and that replacements and repairs are made in
accordance with the instructions provided. This same warranty is made for a period of
thirty (30) days with respect to expendable parts. The foregoing warranties shall not
apply if the Product has been repaired other than by Ohmeda or in accordance with
written instructions provided by Ohmeda, or altered by anyone other than Ohmeda, or if
the Product has been subject to abuse, misuse, negligence, or accident.

Ohmeda’s sole and exclusive obligation and Buyer’s sole and exclusive remedy under
the above warranties is limited to repairing or replacing, free of charge, at Ohmeda’s
option, a Product, which is telephonically reported to the nearest Ohmeda Field Service
Support Center and which, if so advised by Ohmeda, is thereafter returned with a
statement of the observed deficiency, not later than seven (7) days after the expiration
date of the applicable warranty, to the Ohmeda Service and Distribution Center during
normal business hours, transportation charges prepaid, and which, upon Ohmeda’s
examination, is found not to conform with above warranties. Ohmeda shall not be
otherwise liable for any damages including but not limited to incidental damages,
consequential damages, or special damages.

There are no express or implied warranties which extend beyond the warranties
hereinabove set forth. Ohmeda makes no warranty of merchantability or fitness for a
particular purpose with respect to the product or parts thereof.

W-1
Ohmeda Inc
9065 Guilford Road
Columbia MD 21046-1801
USA
410-381-2555

North America Asia/Pacific India Netherlands

Datex-Ohmeda B.Z.
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