Hall Surgical PowerPro PRO 3600 Battery Charger Instruction Manual Rev B Sept 2002

Proprietary Information This manual contains information deemed proprietary to Linvatec Corporation. The information contained herein, including all of the designs and related materials, is the sole property of Linvatec and/or its licensors. Linvatec and/or its licensors reserve all patent, copyright and other proprietary rights to this document, including all design, manufacturing methodology and reproduction. This document, and any related materials, is confidential and is protected by copyright laws and shall not be duplicated, transmitted, transcribed, stored in a retrieval system, or translated into any human or computer language in any form or by any means, electronic, mechanical, magnetic, manual or otherwise, or disclosed to third parties, in whole or in part, without the prior express written consent of Linvatec. Linvatec reserves the right to revise this publication and to make changes from time to time in the contents hereof without obligation to notify any person of such revision or changes, unless otherwise required by law.

Linvatec, Hall, SureCharge and PowerPro are trademarks or registered trademarks of Linvatec Corporation.

© Linvatec Corporation 2002. All Rights Reserved. Printed in USA

Record the Model and Serial Numbers of the charger and date received. Retain for future reference. Charger Model No. Charger Model No.

Serial No Serial No

Date Date

Page

Table of Contents

1.0

2.0

3.0

INTRODUCTION 1.1

Intended Use... 1

1.2

General Warnings... 2

1.3

Symbol Definitions... 3

1.4

Battery Charger... 4 1.4.1

Front Panel... 4

1.4.2

Rear Panel... 5

BATTERY CHARGER OPERATION 2.1

Charging Standard Large (PRO3010) and Small (PRO3020) Battery Packs without the SureCharge Sterilization/Charging Case... 8

2.2

Charging Standard Large (PRO3010) and Small (PRO3020) Battery Packs using the SureCharge Sterilization/Charging Case... 9

2.3

Charging Sterile Transfer Batteries... 13

MAINTENANCE 3.1

Cleaning and Sterilizing... 16 3.1.1

Cleaning Precautions... 16

3.1.2

Cleaning Instructions for the Battery Charger... 17

3.1.3

Cleaning Instructions for the Sterile Transfer Battery Platform... 17

3.1.4

Sterile Transfer Shroud, Sterile Transfer Battery Case and Sterile Transfer Battery... 18

3.1.5

Cleaning Instructions for Standard Battery Packs... 19

3.1.6

Cleaning Instructions for the SureCharge Battery Sterilization/ Charging Case... 19

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Page

Table of Contents

3.0

MAINTENANCE (Continued) 3.1.7

Sterilization Information... 20 3.1.7.1

Sterilization Warnings, Precautions and Notes... 20

3.1.7.2

Ethylene Oxide Sterilization Guidelines for Standard Battery Packs without the SureCharge Battery Sterilization/Charging Case... 22

3.1.7.3

STERRAD Sterilization System Guidelines for Standard Battery Packs without the SureCharge Battery Sterilization/Charging Case... 22

3.2

Troubleshooting... 23

3.3

Fuse Replacement... 26

3.4

Ground Bond Test... 26

3.5

Leakage Test... 27

3.6

Technical Specifications... 28

3.7

3.6.1

Battery Charger (PRO3600)... 28

3.6.2

System Environmental Requirements... 29

3.6.3

Power Cord Requirements for Battery Charger... 29

3.6.4

Batteries... 30 3.6.4.1

Standard Large Battery Pack (PRO3010)... 30

3.6.4.2

Standard Small Battery Pack (PRO3020)... 30

3.6.4.3

Sterile Transfer Battery (PRO3115)... 30

Accessories... 31

ii

1.0 INTRODUCTION

Standard batteries may be charged prior to sterilization by placing the battery pack directly on the battery charger. Or, they can be charged after sterilization by placing them in the SureCharge Sterilization/Charging Case. Charging the battery packs after sterilization prevents a loss of charge in the battery due to the extreme heat of the sterilization environment, thus allowing for longer use during surgery. When battery packs are charged after sterilization, they can either be transferred to the sterile field via the use of the SureCharge Sterilization/Charging Case or stored ready for use.

t is recommended that personnel study this manual before attempting to operate, clean and/or sterilize the Hall® PowerPro® Battery Charger (PRO3600), batteries and accessories. The safe and effective use of this equipment requires the understanding of and compliance with all warnings, cautionary notices and instructions marked on the product, and included in this manual and any associated information insert.

I

1.1

Intended Use

he PowerPro Battery Charger is used to charge all PowerPro batteries, which includes the Sterile Transfer Batteries (PRO3115) and the Standard Large (PRO3010) and Small (PRO3020) Battery Packs, with or without the use of the SureCharge™ Sterilization/Charging Case.

T

The Sterile Transfer System requires that only the Sterile Transfer Battery Case (PRO3110) be sterilized, not the battery. The battery only needs to be cleaned, and then charged using the Sterile Transfer Platform (PRO3135). This eliminates the loss of charge in the battery due to the extreme heat of the sterilization environment. Once charged, the battery is transferred into the sterile battery case within the surgical field.

1

9.

1.2

General Warnings

1.

This equipment is designed for use by medical professionals completely familiar with the required techniques and instructions for use of the equipment. Read and follow all warning and cautionary notices and instructions marked on the product and included in this manual.

2.

Do not open the battery charger, as this may void the warranty. There are no user-serviceable parts inside. Removing the cover may introduce an electric shock hazard by exposing you to dangerously high voltages or other risks.

3.

Do not expose the battery charger to moisture, operate in wet areas, or place liquids on or above the unit.

4.

Prior to use, inspect all equipment for proper operation.

5.

Do not handle the battery charger by the cord. Do not pull on the power cord or accessory cord to remove it from the battery charger or the power outlet.

6.

Do not excessively bend or kink the battery charger power cord or accessory cord. Always inspect cords for signs of excessive wear or damage. If wear or damage is found, discontinue use and replace immediately.

7.

Do not expose batteries to fire or incineration.

8.

Do not short circuit the battery pack metal contacts or allow them to contact metal objects. This could cause a shock or burn injury and also damage the battery.

Inspect battery pack for damage (i.e., cracks in battery case) prior to use or charging. Do not use or charge damaged battery packs. If battery pack is damaged and leakage or residue is noticed, do not allow it to come in contact with skin, eyes or clothing. These materials could contain Potassium Hydroxide (KOH) which is an alkaline and can burn. If leakage or residue comes in contact with skin or eyes, flush affected area with copious amounts of water and seek medical attention immediately.

10. Battery packs contain nickel cadmium or nickel metal hydride, which must be recycled or disposed of properly. The disposal of nickel cadmium or nickel metal hydride batteries as municipal waste is prohibited. Dispose or recycle in accordance with your local, state and government regulations. In the U.S. call 1-800-925-4255 for additional information on battery pack disposal or recycling. Outside the U.S. contact your local Linvatec representative. 11. After each use, thoroughly clean the charger (See “3.1 Cleaning and Sterilizing” on page 16). 12. Equipment grounding is vital to ensure safe operation. Plug the power cord of the battery charger into a properly earthed mains supply outlet whose voltage and frequency characteristics are compatible with those listed on the unit or in this manual. Do not use plug adapters or extension cords; such devices defeat the safety ground and could cause injury. 13. Do not use any equipment, especially the battery charger, in the presence of flammable anesthetics, gases, disinfecting agents, cleaning solutions, or any material susceptible to ignition due to electrical sparking. 2

1.3

Indicates battery is being charged when illuminated.

Symbol Definitions Power “ON”, connected to mains.

Indicates battery is fully charged when illuminated.

Power “OFF”, disconnected from mains. Power on, Stand-by mode.

Indicates a battery fault. See “3.2 Troubleshooting” on page 23 for more information.

Attention, consult accompanying documents.

Indicates that a battery is going through a quick-discharge cycle when blinking, and remains constantly lit when completely discharged.

Warning - For continued protection against risk of fire, replace only with the same type and rating fuse. Mains Fuse.

Rx ONLY

Type BF equipment. Pertains to the Battery Pack.

~

Caution: Federal Law restricts this device to sale by or on the order of a physician.

Alternating Current. Protective earth ground.

User service not recommended. Refer servicing to qualified Linvatec service personnel.

Batteries contain either nickel cadmium or nickel metal hydride which must be recycled or disposed of properly. The disposal of batteries as municipal waste is prohibited. Dispose or recycle in accordance with your local, state and governmental regulations. In the U.S. call 1-800925-4255, or outside the U.S. contact your local Linvatec representative for additional information on battery disposal or recycling.

Indicates product component should not be sterilized. Indicates product component should not be immersed in any type of fluid. Warning: Burn potential. Caustic materials. Single Use Only.

3

❶ ❷ ❸ ❹

❺ ❻

1.4

❹ Battery Fault Indicator Light - Steadily

Battery Charger

1.4.1

illuminates when there is a battery fault. See “3.2 Troubleshooting” on page 23 for more information.

Front Panel

❶ Battery Receptacle Platform (4) -

NOTE: During initial power up, all indicator lights will flash during the selfdiagnostic test.

Accepts the Sterile Transfer Battery Platform (PRO3135), used for charging Sterile Transfer Batteries (PRO3115); the Standard Large (PRO3010) and Small (PRO3020) battery packs; and the SureCharge Sterilization/Charging Case (PRO3200) used to charge standard battery packs after sterilization.

❺ Discharge Button and Indicator - Used to discharge standard battery packs prior to sterilization when using the SureCharge Sterilization/Charging Case. Depletes any residual charge that may be remaining in the battery. Discharge of the battery must be made within the first minute after the SureCharge Sterilization/Charging Case is attached to the battery charger. The indicator will blink during the discharge cycle and stop blinking when discharging is complete.

❷ Charging Indicator Light - Steadily illuminates to indicate the battery pack is connected and charging. NOTE: Battery pack must be cooled to room temperature prior to charging. Failure to do this will result in increased charge time.

❻ Power Indicator Light - Illuminates

❸ Charged Indicator Light - Steadily illu-

when the power is in stand-by mode.

minates when the battery pack is charged and the charging cycle is complete. 4

❶

❷

❺

❸

❹

1.4.2

❺ Mains Power Switch - Place this switch

Rear Panel

to the ON position to activate the charger.

❶ Cooling Fan - Removes heat build-up within the unit.

❷ Accessory Outlet - Allows for a second battery charger to be plugged into the primary charger using the accessory cord (PRO2601). Do not connect more than one charger.

❸ Mains Receptacle - Accepts the supplied hospital grade power cord to provide AC power.

❹ Fuse Holder - Contains two fuses. To replace fuses see “3.3 Fuse Replacement” on page 26.

5

2.0

BATTERY CHARGER OPERATION

3.

Any of the above conditions could shorten the life of the batteries and/or compromise the seal integrity, resulting in leakage of Potassium Hydroxide (KOH) which is alkaline and can burn skin, eyes or clothing.

4.

Do not allow battery leakage or residue to come in contact with your skin, eyes or clothing. If leakage does contact your skin, eyes or clothing, flush affected areas with copious amounts of water and seek medical assistance immediately. If there is any evidence of case cracking, white residue or fluid leakage, follow these guidelines:

NOTES: 1.

Batteries are shipped uncharged and non-sterile.

2.

Always clean and sterilize batteries prior to charging. Refer to “3.1 Cleaning and Sterilizing” on page 16 or the information insert supplied with the battery pack for sterilization guidelines and parameters.

3.

Charge batteries before initial use using only the PowerPro Battery Charger (PRO3600).

4.

(a) Handle product with protective gloves.

Do not charge batteries unless they are at room temperature. Failure to do this will result in increased charging time.

(b) Place battery in a leak-proof double bag, lined with absorbent material such as paper toweling. Secure the bag. If battery is damaged, package any loose parts in a separate bag to prevent short-circuiting.

WARNINGS: 1.

Inspect batteries for damage prior to use, i.e., cracks in battery case. DO NOT use or charge damaged batteries. Discard or recycle properly.

2.

Do not autoclave batteries above the recommended temperature, or leave them in the autoclave longer than recommended. See “3.1.7 Sterilization Information” on page 20 or the information insert supplied with the battery pack for sterilization guidelines and parameters. Damage to the battery pack could result, possibly causing injury.

5.

6

Improper fuse size in the charger could result in fire. Replace only with time delay fuses as marked on the charger or listed in “3.6.1 Battery Charger (PRO3600)” on page 28 in the Technical Specifications section.

1.

2.

Ensure the charger is turned off. Plug the power cord into the receptacle on the rear of the charger and a properly earthed mains supply outlet.

A second charger may be powered from the primary charger by connecting the accessory cord (PRO2601) from the second charger to the primary charger’s accessory output.

NOTE: Do not connect more than one charger.

3.

Using the power switch located on the back of the charger, turn the charger on. The green indicator light on the front of the charger will illuminate.

7

4.

When initially turned on, the charger will perform a self-diagnostic test, at which time the LED’s will blink and the charger fan will cycle on and off several times. When the charger has satisfactorily completed its diagnostic test, all LED’s will go off indicating that the charger is ready for use. If any LEDs stay illuminated, see “3.2 Troubleshooting” on page 23 for more information.

5.

The charger icons and indicator light colors designate the following:

•

Yellow: Battery is charging.

•

Green: Battery is fully charged.

•

Red:

Battery fault. If the red LED illuminates, see “3.2 Troubleshooting” on page 23 for more information.

2.1

Charging Standard Large (PRO3010) and Small (PRO3020) Battery Packs without the SureCharge Sterilization/Charging Case

NOTES: 1.

Always clean the battery pack prior to charging. Refer to “3.1.5 Cleaning Instructions for Standard Battery Packs” on page 19, or the information insert supplied with the battery pack. Charging must be performed prior to sterilization.

2.

Battery packs must be cooled to room temperature prior to charging. Failure to do this will result in increased charging time.

1.

To charge a battery pack, perform the following: (a) Slide the battery pack onto one of the charger receptacles. Ensure it is seated completely in the receptacle. If it is not completely seated, a battery fault (red LED will illuminate) will result (see “3.2 Troubleshooting” on page 23 for more information). Up to four battery packs may be placed on each charger.

8

2.

Charging of the battery pack will begin automatically. During the charge cycle, the yellow “charging” LED will illuminate.

3.

When the battery pack has completed its charge cycle, the yellow “charging” LED will go out and the green “charge complete” LED will illuminate. It takes approximately 55 minutes to obtain a complete charge.

4.

If the red LED illuminates, or no LED illuminates, see “3.2 Troubleshooting” on page 23 for more information.

5.

After charging, sterilize the battery packs. Refer to “3.1.7 Sterilization Information” on page 20 or the information insert supplied with the battery pack for sterilization guidelines and parameters.

6.

To remove the battery pack from the charger, simply slide it off.

2.

2.2

Charging Standard Large (PRO3010) and Small (PRO3020) Battery Packs using the SureCharge Sterilization/ Charging Case

When using the SureCharge Sterilization/ Charging Case, cleaning and sterilization are performed on the battery packs prior to charging. Reference “3.1 Cleaning and Sterilizing” on page 16.

Prior to sterilization, inspect the lid of the case. Ensure the seal is not damaged or missing. Ensure the filter is placed correctly within the designated area of the lid, and the filter bracket is latched correctly. Also ensure there are no tears or holes in the filter, as sterility of the batteries will be compromised and patient infection may occur. If there are any tears or holes, replace the filter. Seal

WARNINGS: 1.

Do not short circuit the SureCharge Sterilization/Charging Case contacts or allow them to come into contact with metal objects. This could cause a shock or burn injury, damage the battery pack and/or the charger. Latch

9

3.

Do not reuse filters. Filters are single-use only. Whenever the case is opened after sterilization the filter must be removed and disposed of properly.

4.

Inspect the SureCharge Sterilization/ Charging Case for any damage, such as: damaged or worn connectors on the underside or within the case, faulty and/ or missing battery clips, cracks, dents, or broken latches. If damage is found, do not use. Sterility may be compromised and patient infection may occur.

1.

Prior to sterilizing battery packs, remove them from the handpiece and clean them according to “3.1 Cleaning and Sterilizing” on page 16.

2.

Place a new disposable filter onto the underside of the lid: (a) Remove the filter plate by pressing inward on the release knobs.

CAUTIONS: 1.

Always clean battery packs prior to placing in the SureCharge Sterilization/ Charging Case.

2.

Do not immerse any part of the SureCharge Sterilization/Charging Case in any fluids.

3.

(b) After removing the filter plate, install a filter by aligning the cutouts in the filter with the brackets on the underside of the lid.

Charge batteries only on the PowerPro Battery Charger (PRO3600).

10

(c) Insert the flange of the filter plate behind the metal bar on the underside of the lid.

4.

Slide the metal contacts of the battery pack into the receiving receptacle of the inner basket.

5.

Attach and secure the lid to the case by engaging both side latches of the case lid.

(d) Firmly press on the side tabs until both latches lock into place. A clicking sound must be heard from each latch. 3.

Insert the inner basket into the outer case.

11

Important: Battery packs must be cooled to room temperature prior to discharging them on the battery charger. Failure to do this will result in an increased discharge time. 6.

7.

(a) During the discharge cycle, the associated yellow LED will blink. When the battery packs are completely discharged, the associated yellow LED will illuminate steadily.

Prior to placing the SureCharge Battery Sterilization/Charging Case in the autoclave, and after the battery packs have cooled to room temperature, slide the case onto the PowerPro Battery Charger.

8.

Press the discharge button to deplete any residual charge remaining in the battery pack(s).

Remove the SureCharge Battery Sterilization/Charging Case from the battery charger and place it in the autoclave. See “3.1.7 Sterilization Information” on page 20.

9.

After sterilization is complete, and the battery packs have cooled to room temperature, they can be charged. To charge the battery packs:

Important: Battery packs must be cooled to room temperature prior to charging them on the battery charger. Failure to do this will result in increased charging time. (a) Slide the SureCharge Battery Sterilization/Charging Case onto the PowerPro Battery Charger. (b) Charging of battery packs begins automatically. During the charge cycle the yellow “charging” LED will illuminate. (c) When battery packs are completely charged, the yellow “charging” LED will go out and the green “charging complete” LED will illuminate. It will take approximately 55 minutes to obtain a full charge.

NOTE: Discharge of the battery packs must be made within the first minute after the case is attached to the charger. Once the charging process begins, the discharge button becomes inoperative.

12

(d) If no LED illuminates, or the red (replace) LED illuminates, reference “3.2 Troubleshooting” on page 23 for more information.

2.3

Charging Sterile Transfer Batteries

(e) If all three LEDs flash, this is a system fault. Reference “3.2 Troubleshooting” on page 23 for more information. (f) After battery packs are charged, the case may be removed from the charger and stored ready for use. NOTES:

(g) Note that nickel cadmium batteries lose approximately 15 - 20% of their charge per month during storage in nominal room temperature. Recharge periodically to ensure use of a fully charged battery. 10. The circulator will remove the case from the charger, remove the lid from the case, then present the case to the scrub person. 11. The scrub will grasp the handle of the inner basket, remove it from the case, and place it within the sterile field. 12. The scrub will remove the battery pack(s) from the basket and attach one to the handpiece.

13

1.

Only the battery case (PRO3110) and shroud (PRO3130) require sterilization. Refer to “3.1.7 Sterilization Information” on page 20, or the information insert supplied with each battery case for sterilization information.

2.

Do not sterilize the battery (PRO3115).

3.

Never charge the battery while it is in the battery case (PRO3110).

4.

The battery can only be charged using the Sterile Transfer Platform (PRO3135).

5.

Always clean the battery and battery case after each use and prior to charging the battery.

6.

Use only one battery and one shroud per battery case per procedure. Do not reuse the shroud without sterilizing it first. Do not put a second battery into the battery case without sterilizing the case first.

1.

To charge a battery, perform the following:

2.

Charging of the battery will begin automatically and will take approximately 5 to 70 minutes to fully charge each battery, depending on the amount of charge remaining in the battery.

3.

During the charge cycle, the yellow “charging” LED will illuminate.

4.

When charging is completed, the yellow “charging” LED will go out and the green “charge complete” LED will illuminate. The battery may be stored on the charger to ensure a fully charged battery, as long as the charger is left powered on.

5.

If no LED illuminates, or the red LED illuminates, see “3.2 Troubleshooting” on page 23 for more information.

6.

After charging, the circulator will remove the battery from the sterile transfer platform on the charger.

(a) Slide the sterile transfer battery platform (PRO3135) onto the battery charger until it completely snaps into place. If the platform is not completely seated on the charger, a battery fault (red LED will illuminate) will result (see “3.2 Troubleshooting” on page 23 for more information).

(b) Insert the battery into a receptacle of the battery platform. Press on the battery until it completely engages in the platform.

NOTE: All nickel metal hydride batteries lose approximately 15-20% of their charge per month during storage in nominal room temperature. Recharge periodically if stored for any period of time to ensure use of a fully charged battery. 7.

14

The scrub will place the sterile transfer shroud (PRO3130) onto the sterile transfer battery case. The pins on the underside of the shroud go on the outside of the case to center the shroud on the case.

8.

The circulator will insert the battery through the sterile transfer shroud and into the battery case. Press the battery into the case until it is completely engaged.

9.

The circulator removes the sterile transfer shroud from the battery case by pulling on either finger pull.

11. The scrub secures the lid by pressing first on the bottom of the latch, then on the front of the latch, ensuring the latch is fully engaged on the tabs of the Sterile Transfer Battery Case.

10. The scrub closes the lid of the battery case and flips the latch mechanism up and over the lid. 12. The scrub then attaches the battery case to the handpiece. 15

3.0

MAINTENANCE

3.1

Cleaning and Sterilizing

CAUTION: Prior to cleaning and/or sterilization, always inspect batteries for damage or leakage. If any is found, discard battery. Do not attempt to repair. Batteries contain nickel cadmium or nickel metal hydride which must be recycled or disposed of properly. Disposal of batteries as municipal waste is prohibited. Dispose or recycle in accordance with your local, state and governmental regulations. In the U.S. call 1-800-925-4255. Outside the U.S. contact your local Linvatec representative for additional information on battery disposal or recycling.

Regular and proper maintenance of your PowerPro Battery Charger are the best ways to protect your investment. It is essential that you have your equipment serviced, as scheduled, in order to retain its optimum performance and reliability, which will reward you with safer, less problematic product performance over time. Linvatec recommends that the Hall PowerPro Battery Charger be returned to the factory for routine maintenance every 24 months. Recommended care and handling of the battery charger includes proper day-to-day operation, cleaning, and sterilization which are extremely important to ensure safe and efficient operation. Your authorized Hall Surgical service department is the most knowledgeable about the PowerPro instruments and will provide competent and efficient service. Service at Linvatec/ Hall Surgical at the recommended service interval is mandatory to keep your product warranties in effect. Any services and/or repairs done by any unauthorized repair facility may result in reduced performance of the instruments or instrument failure.

3.1.1

Failure to follow this routine maintenance schedule may result in damage to the battery charger and may invalidate the product warranty.

16

Cleaning Precautions

1.

Follow universal precautions for protective apparel when handling and cleaning contaminated instruments.

2.

Never immerse battery charger, SureCharge Battery Sterilization/ Charging Case, batteries, or power cords.

3.

Never clean equipment in an ultrasonic cleaner or combination washer/sanitizer.

4.

Do not use bleach, chlorine based detergents, or caustic solutions that contain phenol to clean the SureCharge Battery Sterilization/Charging Case, battery case or battery packs.

5.

Do not rinse batteries under running water.

6.

Always remove battery pack from handpiece prior to cleaning and sterilization.

7.

Always clean battery pack before inserting into the SureCharge Battery Sterilization/ Charging Case.