Service Manual
152 Pages
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T-2100 Treadmill Service Manual 2021403-031
Revision B
NOTE: The information in this manual only applies to the T-2100 Treadmill. It does not apply to earlier product versions. Due to continuing product innovation, specifications in this manual are subject to change without notice. CardioSoft, MAC and CASE are trademarks owned by GE Medical Systems Information Technologies GmbH, a General Electric Company going to market as GE Healthcare. © 2005, 2007 General Electric Company. All rights reserved.
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Contents
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Introduction... 1-1 Manual Information... 1-3 Revision History... 1-3 Manual Purpose... 1-3 Conventions... 1-4 Safety Information... 1-5 Responsibility of the Manufacturer... 1-5 General... 1-5 Equipment Symbols... 1-6 Warnings and Dangers... 1-7 Cautions... 1-10 Service Information... 1-11 Service Requirements... 1-11 Equipment Identification... 1-11 Serial Number... 1-12
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Equipment Overview... 2-1 General Description... 2-3 Intended Use... 2-3 Power Switch... 2-3 Emergency Stop Switch (ESTOP)... 2-3 Walking Belt... 2-3 Drive Controller System... 2-4 Elevation System... 2-4 Bed Assembly... 2-4 Electronic Assembly... 2-4 Side View... 2-5 Rear View... 2-6 Connection Panel... 2-7
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Installation... 3-1 Tools Required... 3-3 Safe Handling Guidelines... 3-3 Installation Checklist... 3-4
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Domestic Electrical Safety Tests... 3-5 AC Line Voltage Test... 3-5 Equipment Assembly... 3-6 Pre-Assembly Inspection... 3-6 Install Handle Set... 3-6 Install Emergency Stop Switch... 3-8 Ground Continuity Test... 3-9 Connect Controlling Devices... 3-9 Secure the Cables... 3-10 Check Walking Belt Tension and Tracking... 3-10 Check Emergency Stop Switch... 3-10 Self-Calibration... 3-10 Check T-2100 Treadmill Level... 3-12 Leakage Tests... 3-12 Leakage Test Diagrams... 3-13 Test #1... 3-13 Test #2... 3-14 Functional Checkout... 3-15 Functional Checklist... 3-15 Double-Check Handles... 3-17
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Maintenance... 4-1 Introduction... 4-3 Recommended Maintenance... 4-3 Required Tools and Supplies... 4-3 Inspection and Cleaning... 4-4 Visual Inspection... 4-4 Exterior Cleaning... 4-4 Interior Cleaning... 4-4 Walking Belt Tracking and Tension Adjustment... 4-5 When to Adjust... 4-5 Walking Belt Tension Adjustment... 4-5 Walking Belt Tracking Adjustment... 4-6
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Theory of Operation... 5-1 T-2100 Treadmill Block Diagram... 5-3 Power Board (PCB) Theory... 5-4 General Description... 5-4 Precautions... 5-4 Initial Board Conditions... 5-4
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Power Input Requirements... 5-4 Power Distribution/Isolation... 5-4 Power Inlet, Drive Power Outlet & Mains... 5-4 Power Supplies... 5-5 Logical Ride-Through Power... 5-5 Processor Board Connectors... 5-5 Isolation Transformer... 5-5 Elevation Relays... 5-5 Elevation Sensor... 5-6 ESD and EMI Compatibility... 5-6 Power Board Input/Output Signal Requirements... 5-7 Processor Board (PCB) Theory... 5-11 General Description... 5-11 Power Distribution... 5-11 Clock Generator... 5-11 Reset Generator... 5-11 Processor Circuitry... 5-12 Analog Inputs... 5-12 RS-232/422 Interfaces... 5-12 ESD and EMI Compatibility... 5-13 Isolation... 5-13 Operation... 5-13 Self-Calibration... 5-14 ESTOP... 5-14 Precautions... 5-14 Processor Board Power Input Requirements... 5-15 Processor Board Input/Output Signal Requirements... 5-15 Drive Controller Theory... 5-19 General Description... 5-19 Phases and Power Switches... 5-19 Motor Torque... 5-19 Motor Speed... 5-19 Electrical Requirements... 5-21
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Troubleshooting... 6-1 Quickcheck Items... 6-3 Speed and Elevation Table... 6-3 Emergency Stop Switch Verification... 6-3 Power Switch... 6-3 Burn-In Mode... 6-4 Activating Burn-In... 6-4 Visual Inspection... 6-7
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T-2100 Treadmill Diagnostic Utility (TDU)... 6-9 Overview of the TDU Application Interface... 6-9 TDU Application Error Definitions... 6-11 Download the TDU... 6-12 Launch TDU and Retrieve Event and Error Logs... 6-12 TDU Error Log Date and Time Information... 6-13 TDU Troubleshooting Tables and Status LEDs... 6-15 Processor Board Status LEDs... 6-15 TDU Troubleshooting Table... 6-17 Drive Controller Status LED... 6-21 TDU Troubleshooting Table for Drive Controller... 6-22 Power Supply Voltage Checks and Fuses... 6-26 Processor Board Voltage Checks... 6-26 Power Board Voltage Checks... 6-27 Power Board Fuse Locations... 6-28
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Assembly/Disassembly... 7-1 Assembly and Disassembly Procedures... 7-3 Required Tools and Supplies... 7-3 Leakage Tests... 7-3 Shroud Removal... 7-3 Location of Major Sub-Assemblies... 7-4 Front Roller Replacement... 7-6 Rear Roller Replacement... 7-8 Walking Belt and Board Replacement... 7-9 Walking Belt Replacement Instructions... 7-9 Drive Motor Replacement... 7-12 Drive Belt Replacement and Adjustments... 7-16 Replace the Drive Belt... 7-16 Drive Belt Adjustments... 7-16 Elevation Motor Replacement... 7-19 Drive Controller Replacement... 7-21 Drive Controller X1 PIN descriptions... 7-22 Elevation Potentiometer Replacement... 7-23 General... 7-23 Elevation Potentiometer Harness Assembly Replacement... 7-23 PCBs and Power Supply Replacement... 7-28
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Ordering Parts... 8-1 Ordering Parts... 8-3 Field Replaceable Units... 8-3
Appendix A – Technical Specifications...A-1 Technical Specifications... A-3 UL Classification...A-5
Appendix B – Electromagnetic Compatibility (EMC)...B-1 Electromagnetic Compatibility (EMC)... B-3 Electromagnetic Emissions... B-4 Electromagnetic Immunity... B-5 Electromagnetic Immunity... B-6 Separation Distance... B-7 Exceptions... B-8 Compliant Cables and Accessories... B-9
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1
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Introduction
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1-1
For your notes
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Introduction: Manual Information
Manual Information Revision History Each page of the document has the document part number and revision letter at the bottom of the page. The revision letter identifies the document’s update level. The revision history of this document is summarized in the table below. Revision
Date
Comment
A
20 October 2005
Initial release of this manual.
B
16 August 2007
Revised equipment symbols and warnings
Manual Purpose This manual contains the instructions necessary to setup and service the equipment safely in accordance with its function and intended use. These instructions include but are not limited to:
An explanation of functions and indicators
The setup and checkout procedure
Disassembly and assembly instructions for FRUs and accessories
Troubleshooting guides
Instructions for cleaning and preventative maintenance
Where necessary the manual identifies additional sources of relevant information and/or technical assistance.
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Introduction: Manual Information
Conventions These are the conventions used in this manual.
Safety Messages DANGER safety messages indicate an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING safety messages indicate a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. CAUTION safety messages indicate a potentially hazardous situation which, if not avoided may result in minor or moderate injury. NOTE messages provide additional user information.
Definitions
Items shown in Bold text are keys on the keyboard, text to be entered, or hardware items such as buttons or switches on the equipment.
Items shown in Italicized text are software terms which identify menu items, buttons, or options in various windows.
To perform an operation which appears with a plus (+)sign between the names of two keys, you press and hold the first key while pressing the second key once. This is called a keystroke combination. For example, “Press Ctrl+Esc” means to press and hold down the Ctrl key while pressing the Esc key.
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When instructions are given for typing a precise text string with one or more spaces, the point where the spacebar must be pressed is indicated as: <Space>. The purpose of the < > brackets is to ensure you press the spacebar when required.
Enter means to press the “Enter” or “Return” key on the keyboard. Do not type “enter”.
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Introduction: Safety Information
Safety Information Responsibility of the Manufacturer GE Medical Systems Information Technologies is responsible for the effects of safety, reliability, and performance only if:
Assembly operations, extensions, readjustments, modifications, or repairs are carried out by persons authorized by GE Medical Systems Information Technologies.
The electrical installation of the relevant room complies with the requirements of the appropriate regulations.
The equipment is used in accordance with the instructions for use.
General This device is intended for use under the direct supervision of a licensed health care practitioner. To ensure patient safety, use only parts and accessories manufactured or recommended by GE Medical Systems Information Technologies. Contact GE Medical Systems Information Technologies for information before connecting any devices to this equipment that are not recommended in this manual. Parts and accessories used must meet the requirements of the applicable IEC 601 series safety standards, and/or the system configuration must meet the requirements of the IEC 60601-1-1 medical electrical systems standard. The use of ACCESSORY equipment not complying with the equivalent safety requirements of this equipment may lead to a reduced level of safety of the resulting system. Consideration relating to the choice shall include:
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use of the accessory in the PATIENT VICINITY; and
evidence that the safety certification of the ACCESSORY has been performed in accordance to the appropriate IEC 60601-1 and/or IEC 60601-1-1 harmonized national standard.
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Introduction: Safety Information
Equipment Symbols The following symbols may appear on the equipment.
Caution, consult accompanying documents.
Dangerous voltage.
Type B applied part complying with IEC 60601-1.
~
Alternating current (AC) Equipotential (This is the ground lug.)
Protective earth (ground)
This symbol indicates that the waste of electrical and electronic equipment must not be disposed as unsorted municipal waste and must be collected separately. Please contact an authorized representative of the manufacturer for information concerning the decommissioning of your equipment. Manufacturer’s identification
Date of manufacture. The number found under this symbol is the date of manufacture in the YYYY-MM format. YYYY-MM
SN
Serial number Catalogue number
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Introduction: Safety Information
Authorized representative in the European community Medical Equipment With Respect to Electric Shock, Fire, and Mechanical Hazard Only, In Accordance with UL 60601-1 and CAN/CSA C22.2 No.601.1 Input/Output
Input
Fuse
Serial Interface Emergency stop
General symbol for recovery/recyclable
T 0.5AL, 250V
Time Lag, 0.5 Amp, Low breaking capacity, 250Vac rated fuse
Warnings and Dangers WARNING CONNECTION TO MAINS - This is class 1, type B electrical safety equipment. The mains plug must be connected to an appropriate power supply.
WARNING DEFIBRILLATOR PRECAUTIONS - Do not come into contact with patients or unit during defibrillation. Otherwise, serious injury or death could result.
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Introduction: Safety Information
WARNING EMERGENCY STOP - The emergency stop switch is a safety device for use only in emergency situations to stop the treadmill. The walking belt will stop quickly. Once stopped and while the switch is depressed the treadmill walking belt will not lock to allow for removal of foreign objects.
WARNING EQUIPMENT MALFUNCTION - Replace only with the same type and rating of fuse.
WARNING EXPLOSION HAZARD - Flammable anesthetic vapors or liquids can cause explosions. Do NOT use in the presence of flammable anesthetic vapors or liquids.
WARNING MOVING PARTS - To avoid injury, follow physicians’ or qualified health care providers’ instructions carefully during use of this equipment.
WARNING MOVING PARTS - To avoid injury, keep hands, hair, jewelry, loose clothing and patient cables away from moving parts.
WARNING MOVING PARTS - To avoid injury to patient, operate the treadmill with 6 feet of clearance at the rear (end opposite the motor).
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Introduction: Safety Information
WARNING MOVING PARTS - While the emergency stop switch is depressed or when power is not applied to the treadmill the walking belt is not locked. The walking belt in this condition is allowed to move which could cause a person to lose balance and fall if they are standing on the belt. Note, the risk of belt movement is increased with higher treadmill grades or inclines.
WARNING SHOCK HAZARD - Improper use of this device presents a shock hazard. Strictly observe the following warnings. Failure to do so may endanger the lives of the patient, the user, and bystanders. To reduce the risk of electric shock do NOT remove cover (or back). Refer servicing to qualified personnel. When disconnecting the device from the power line, remove the plug from the wall outlet first, before disconnecting the cable from the device. Otherwise there is a risk of coming in contact with line voltage by inadvertently introducing metal parts in the sockets of the power cord. Devices may be connected to other devices or to parts of systems only after making certain that there is no danger to the patient, the operators, or the environment as a result. Standards IEC 60601-1-1/EN60601-1-1 must be complied with in all cases.
WARNING SITE REQUIREMENTS - Do not route cables in a way that they may present a stumbling hazard. Do not route cables underneath the equipment. For safety reasons, all connectors for patient cables and leadwires are designed to prevent inadvertent disconnection, should someone pull on them. For devices installed above the patient, adequate precautions must be taken to prevent them from dropping on the patient.
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Introduction: Safety Information
WARNING TREADMILL CHANGES - Rapid changes in treadmill speed and/or grade during a stress test may result in injury. DO NOT rapidly change treadmill speed and/or grade during a stress test.
WARNING TREADMILL CHANGES - DO NOT place feet under the treadmill during operation or while decreasing the treadmill grade to avoid injury.
Cautions CAUTION INJURY - Do not use the treadmill without proper footwear as injury to feet may result. Always wear proper footwear when using the treadmill.
CAUTION POWER REQUIREMENTS - Before connecting the device to the power line, check that the voltage and frequency ratings of the power line are the same as those indicated on the unit's label. If this is not the case, do not connect the system to the power line until you adjust the unit to match the power source. This equipment is suitable for connection to public mains as defined in CISPR 11.
CAUTION RESTRICTED SALE - U.S. federal law restricts this device to sale by or on the order of a physician.
CAUTION SUPERVISED USE - This equipment is intended for use under the direct supervision of a licensed health care practitioner. Make sure all users are under the direct supervision of a licensed health care practitioner.
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Introduction: Service Information
Service Information Service Requirements Refer equipment servicing to GE Medical Systems Information Technologies authorized service personnel only. Any unauthorized attempt to repair equipment under warranty voids that warranty. It is the user’s responsibility to report the need for service to GE Medical Systems Information Technologies or to one of their authorized agents. Failure on the part of the responsible individual, hospital, or institution using this equipment to implement a satisfactory maintenance schedule may cause undue equipment failure and possible health hazards. Regular maintenance, irrespective of usage, is essential to ensure that the T-2100 Treadmill will always be functional when required
Equipment Identification The Equipment Identification tag that contains the Product Code and Serial Number is located on the lip of the connection panel (on the back of the T-2100 Treadmill).
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Introduction: Service Information
Serial Number Every GE Medical Systems Information Technologies device has a unique serial number for identification. An explanation of the Serial Number code is shown below.
A
1-12
B
C
D
A
Product Code (SBC = T-2100 Treadmill)
B
Year Manufactured (00-99) 00 = 2000 01 = 2001 02 = 2002 (and so on)
C
Fiscal Week Manufactured
D
Production Sequence Number
E
Manufacturing Site
F
Miscellaneous Characteristic
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F
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