Midmark 6251, 6252, 6256 (Powered Carts

60 Vista Drive

Versailles, OH 45380-0286

1.800.MIDMARK

www.midmark.com

Operating Manual

for the

Series 301-1001 & Series 301-1003

Motive DC Controllers

MMDCOM09_Rev.B_5.0

Page 3 of 53

Table of Contents

1 SAFETY PRECAUTIONS 5

1.1 H

AZARDS AND OTHER SYMBOLS 5

1.2 W

ARNINGS AND CAUTIONS 6

1.3 C

ONDITIONS OF ACCEPTABILITY 7

2 SYSTEM OVERVIEW 8

2.1 A

PPLICATION 8

2.2 P

OWER 8

2.3 C

HARGING 8

2.4 M

ONITORING 8

2.5 A

LARM 9

2.6 C

OMMUNICATION/SOFTWARE 9

2.7 I

NTENDED USE 11

3 SYSTEM DESCRIPTION 11

3.1 E

NCLOSURE 11

3.2 P

OWER SUPPLIES 12

3.3 M

OTHER BOARD 12

3.4 I

NTERFACE BOARD 12

3.5 R

EMOTE DISPLAY 12

3.6 T

EMPERATURE SENSORS 13

3.7 F

AN CONTROL 13

4 SYSTEM CONNECTION 13

4.1 AC P

OWER 17

4.2 S

EALED LEAD ACID BATTERIES 18

4.3 H

OST COMPUTER 19

4.4 R

EMOTE DISPLAY 19

4.5 DC O

UTPUT POWER 20

4.6 F

AN AND THERMAL SENSOR 20

5 INSTALLATION OF SOFTWARE 21

H

OST PC SOFTWARE 21

6 INITIAL TESTING AND ERROR CONDITIONS 21

6.1 R

EMOTE DISPLAY 21

6.2 B

ATTERY 21

6.3 AC P

OWER 22

6.4 S

YSTEM COMMUNICATION WITH THE HOST 22

6.5 S

LEEP MODE 22

6.6 E

RROR CONDITIONS 23

6.6.1 Over Temperature 23

6.6.2 Over Load 23

6.6.3 Charger Time Out or Bad Battery 23

6.7 S

YSTEM RESET 24

7 OPERATION 24

7.1 T

URN ON 24

7.2 S

LEEP MODE 25

7.3 S

YSTEM SET UP 26

7.3.1 Series 301 Setup 27

7.3.2 GUI Setup 29

7.3.3 Distribution Board Setup [optional] 30

7.3.4 Email Setup 31

7.3.5 Test Email 32

7.3.6 Sleep Mode Activation 33

7.3.7 Buzzer 33

7.3.8 Upload EEPROM Data 33

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7.4 CHARGING 34

7.5 D

ISCHARGING 36

8 FIELD DIAGNOSTICS 39

8.1 A

DVANCED FUNCTIONS DESCRIPTION 40

8.2 P

ULL DOWN MENUS 40

8.3 G

AUGE AND LED INDICATORS 41

8.4 T

HERMAL SENSORS 41

8.5 DC V

OLTMETER 41

8.6 A

MP METER 41

8.7 O

UTPUT 41

8.8 S

YSTEM DIAGNOSTICS 42

8.8.1 Events Log 42

8.8.2 Maintenance Schedule 42

8.8.3 Data Logger 42

8.8.4 LED Test 42

8.8.5 Current Watts 42

8.8.6 Firmware Version 42

8.8.7 GUI Version 42

8.8.8 Exit 42

8.9 E

VENT LOG SCREEN 43

8.9.1 Event Log File 43

9 MAINTENANCE 44

9.1 M

AINTENANCE SCREEN 44

9.2 G

ENERAL MAINTENANCE 45

9.3 B

ATTERY MAINTENANCE 46

10 POTENTIAL HAZARDS, INTERFERENCE AND AVOIDANCE 46

11 WARRANTY STATEMENTS 47

NEW EQUIPMENT LIMITED WARRANTY 47

EQUIPMENT REPAIR LIMITED WARRANTY 47

SOFTWARE LIMITED WARRANTY 48

12 SYSTEM SPECIFICATION 49

CLASSIFICATION 49

IDENTIFICATION, MARKING AND DOCUMENTS 49

INPUT 49

INPUT/OUTPUT: DC BATTERY 49

OUTPUT: DC LOAD 49

OUTPUT: FAN 50

OUTPUT: TEMP SENSORS 50

INPUT/OUTPUT: USB 50

OUTPUT: REMOTE DISPLAY 50

GENERAL 50

ENVIRONMENTAL 50

MECHANICAL 50

BATTERY PROFILES 50

FEATURES 50

13 TUV CERTIFICATION STATEMENT 52

14 APPENDIX A: SERIES 301 CONFIGURATIONS. 53

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1 Safety Precautions

1.1 Hazards and Other Symbols

The following symbols are relevant to either this manual or the power system.

SYMBOL TITLE Description

ALTERNATING CURRENT

DIRECT CURRENT

ATTENTION Attention: consult ACCOMPANYING DOCUMENTS

ELECTRICAL HAZARD Indicates an electrical hazard may exist

Follow Operating Instructions

Note: On ME EQUIPMENT

“Follow instructions for use”.

Low Battery

Symbol used for low battery on the remote display

device.

Product Powered by DC

Symbol used for indicating that the power supply is

currently running off of DC power [battery]. Used on

the remote display device.

Product Powered by AC

Symbol used for indicating that the power supply is

currently running off of AC power [wall power]. Used

on the remote display device.

Earth Ground

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1.2 Warnings and Cautions

All operating instructions should be thoroughly reviewed prior to the use of the system.

Warnings and instructions should be followed while installing or operating the system.

Definitions:

CAUTION: indicates a hazardous situation, which if not

avoided, may result in minor or moderate injury or product or

property damage.

WARNING: Indicates a potentially hazardous situation, which,

if not avoided, could result in serious injury or death.

CAUTION:

The AC power conductors must be assembled to a certified plug assembly by a qualified

technician. For compliance to the safety and EMC specifications, the plug assembly must

meet the requirements dictated within this operations manual.

Appropriate airflow is required for this system to operate correctly under normal and fault

conditions. The user must provide airflow of 19 CFM for adequate operation if a fan is not

included in the configuration purchased from MIDMARK.

WARNING:

DO NOT allow untrained technicians install, modify or otherwise handle this equipment.

This equipment is intended to be installed into an Original Equipment Manufacturer’s

product in a controlled setting with precise work instructions and trained assembly

personnel.

DO NOT operate the power system without the covers completely installed and the

connectors attached properly. The covers provide safety from potentially dangerous

voltages.

Do not connect or disconnect the system while power is applied. Do not open or in any

other manner change the access to the internal portion of the system while power is

applied.

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Do not allow the system to come in contact with fluids. Do not operate the system if wet.

1.3 Conditions of Acceptability

CAUTION: When installed in an end-product, consideration must be given to the

following;

 Appropriate airflow is required for this unit to operate correctly under normal and

fault conditions. Thermal testing must be performed as part of the end-product

investigation.

 This unit can be installed as an open or closed frame in the end product. Suitable

fire enclosure must be provided as part of the end-use system investigation. The

component shall be installed in compliance with enclosure, mounting, packing,

casualty and segregation requirements of end-use system requirements.

 Leakage testing must be performed on end-use system.

 IEC 60601-1-4 not performed and must be considered for end-use system.

 Clause 15b limitation of Voltage and/or Energy must be performed on end-use

system.

 Mains AC input fusing may be required on end-use equipment.

 DC output short circuit and reverse polarity testing shall be considered on end use

equipment.

 DC output fusing shall be considered as part of the end-use equipment.

 Equipment has not been evaluated for use in the presence of a flammable anesthetic

mixture with air or with oxygen or nitrous oxide; end-use equipment.

 Equipment has not been evaluated for use with Oxygen enriched atmospheres; end-

use equipment requirement.

 Component shall be properly bonded to the main protective earth termination in the

end-use system and comply with end-system bonding impedance requirements.

 Complies with requirements for US for outside the patient environment. (May

require an isolation transformer for use within patient environment as part of end

system equipment.)

This product contains electrical

components. Observe local, state and

federal guidelines for proper disposal.

The end product manufacturer should be

contacted for procedures. For further

information on disposal, contact

MIDMARK at 1-800-MIDMARK.

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2 System Overview

2.1 Application

The 301 Line of Motive DC Controllers are Medical Grade systems designed

specifically for use with Sealed Lead Acid [SLA] Absorbent Glass Matt [AGM]

Batteries in Mobile Point of Care [MPOC] products for Hospitals and Long Term

Health Care facilities. The product uses microprocessor based technology for

intelligent charging, reconditioning, state of charge monitoring and DC power control.

It is designed and manufactured to meet EN 60601 Medical Safety Standards and has a

compact open or closed frame design for flexibility in hospital retrofit or OEM

applications.

2.2 Power

MIDMARK Series 301 Motive DC Controllers uniquely combine the “By-Pass” feature

of AC Systems with the high efficiency and long run times of traditional DC Systems. It

uses an automatic transfer of load to ensure smooth uninterrupted supply switching

from AC Wall power to DC Battery power.

The 301 has the capability of powering multiple DC devices up to a combined load of

150 watts while simultaneously providing 150 Watts of charging power to the battery.

The battery choices available for the Series 301 will charge in approximately 5.5 hours.

The exact charging time will be dependent on the health of the battery as well as other

battery specific variables. The battery will charge to approximately 80% of charge in

approximately 4 hours [stage 2 complete; reference below].

2.3 Charging

There are 3 stages of intelligent charging algorithms; bulk, absorption and float. The

bulk stage provides the initial charge to the battery using constant current and high

voltage. The second stage, absorption, reconditions the battery through a controlled

charge with constant voltage and diminishing current. The last stage, float, conditions

the battery using a safe constant voltage and low current to accept a complete and full

charge.

2.4 Monitoring

The system has an on-board microprocessor that monitors multiple sensors for use with

the State of Health [SoH] predictions; DC voltage, DC current, ambient temperature,

battery temperature, total charge, discharge amp hours since activation and battery

experience. A key monitoring feature is Event Logging which logs key information

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each time the battery experiences a specific event. Using the power system’s memory,

up to 1000 events can be logged and used for diagnostics and maintenance scheduling.

Using the host system’s memory, the total number of events is limited only by the host

system’s available storage capacity.

2.5 Alarm

The alarm is an audible buzzer at a frequency of 2.4 kilohertz nominal at an audible

intensity of typically 92 decibels at 10 centimeters. The alarm may be enabled or

disabled by the user. If disabled, the alarm will not sound for ANY circumstance. The

alarm, if enabled, will alarm if the battery power goes below a pre established voltage

threshold indicating an imminent need for charging and/or discontinuing computer

usage.

2.6 Communication/Software

The system communication software includes two user interfaces; the Main User’s

interface and the Advanced Functions interface. These interfaces are provided on the

display on the host computer. The information provided in these interfaces is ported to

the host computer via a standard USB connection between the Series 301 Power

Monitor and the host computer. The Main User’s interface is also available through a

remote display mounted directly to the cart. It is constructed to mimic the display as

viewed on the host computer’s display. It is essentially identical however it does not

include the time to charge/discharge information.

Main User’s Interface

The Main User’s interface provides a variety of information to the user [typically the

Nurse] relating to

1. The current connection as AC or DC

2. Whether the unit is charging the battery

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3. Whether the battery charge is low

4. Whether the unit is being shutdown due to insufficient battery charge

5. Whether the unit is recovering severely discharged battery

6. The current charge status of the battery

7. The status of the battery charge to either (1) the time remaining until

discharge or (2) the time remaining to full charge

The Main User interface can be resized using the standard window resizing feature.

If this display is cancelled, the “x” in the upper right hand corner is activated; the

software will continue to run. The HES logo icon is displayed in the notification area of

the windows toolbar.

Advanced Functions

The Advanced Functions screen provides a variety of detailed information to be used

for evaluation of the power system and the components attached. It also allows for the

System Setup of the different types of batteries, the length to scheduled maintenance

and other one time set up parameters.

There are two available Advanced Functions. The Advanced Function used by the

user’s IT department or other skilled technician is that which is described in this

manual. There is another Advanced Function available to MIDMARK as the

manufacturer or, in limited and controlled instances, to the Cart OEM if deemed

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necessary by MIDMARK. There are two different passwords providing access to these

Advanced Functions.

To completely exit the software and turn off the MIDMARK Series 301 interface to the

computer, the user must select the “Software Exit” tab beneath the “File” pull down

menu on the Advanced Functions display screen. This will turn off the software and

remove the icon from the notifications toolbar.

2.7 Intended Use

The Power System is intended for use within a powered cart application. The system

provides a sustainable and rechargeable source of energy for mobile applications. The

system is intended for indoor use within an office environment. The system is not

intended to experience significant vibration or physical shock. The system is intended

to be placed within a protective enclosure provided by the cart manufacturer that will,

among other things, eliminate it’s exposure to liquids or materials that may

unintentionally be dropped onto the system.

3 System Description

3.1 Enclosure

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The Enclosure is to envelop the components (mother board, power supplies and

interface board) and to provide safety. The enclosure is made out of steel and is earth

grounded when connected to a wall outlet or other grounded AC source of power [AC

source interface is provided by the cart manufacturer].

The enclosure is optional to the use of the system. If the Series 301 enclosure is not

used in an OEM configuration, then the OEM’s enclosure must provide the essential

elements typically provided by the Series 301 enclosure.

3.2 Power Supplies

The power supplies are open frame switching power supplies that provide output power

of 150 Watts each with active Power Factor Correction [PFC]. They accept universal

inputs from 85 to 265 Volts, 47-63 hertz of AC. The supplies are fully approved

[independently] to EN60950 and IEC 60601 Medical Safety Requirements.

3.3 Mother Board

The mother board is the main system element, the primary circuit board, containing the

intelligence and the logical connections by which the other components of the system

communicate. It is also the location of onboard memory used to store SoH monitoring

of events and the operational firmware.

3.4 Interface board

The Interface board consists of multiple connectors providing the main power interfaces

to the host computer and the attached components [including an optional remote

distribution board interface] as well as the control interfaces; a Universal Serial Bus

(USB) connector, Remote display connector, 2 temperature sensor connectors and a fan

connector.

3.5 Remote display

The Remote display is the remote user interface representing the information necessary

for normal operation of the power system and cart. The Remote display displays,

among other items, a gas gauge representation of the charge state of the battery.

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Remote Display

3.6 Temperature Sensors

The temperature sensors provide both the ambient temperature of the system controller

as well as the internal temperature of the SLA battery.

3.7 Fan Control

The system provides fan power that is switched to an “on” state when the battery is

being charged in stage #1 or stage #2 or if the temperature is above a threshold

condition. In all other conditions the fan is in the “off” state.

4 System Connection

The system connection is through an Interface board on the Power System enclosure. The

Interface board can be mounted facing one of two directions in relation to a face of the

enclosure [reference below]. This allows multiple mounting configurations through the use of

the same hardware. In configuration #1, the AC Power is on the left near the USB connection

as depicted below while configuration #2 [enabling the use of the other face of the

Front Mount of Interface Board Top Mount of Interface Board

enclosure for I/O] swaps the AC Power and the “DC Outputs and Battery Outputs” end for end.

Each configuration will have the I/O clearly marked. It will be readily distinguishable as well,

through the physical differences in the cabling. The DC Outputs and Battery have blue, red and

black Anderson® Power Pole connectors while the AC cable, a much heavier gage, has a

pigtail.

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For Series 301-1001 Controller

AC Power USB Remote Thermal Sensor Thermal Sensor DC Output(s)

display I

2

C bus I

2

C bus and Battery(s)

Distribution Brd Fan

(

Optional) I

2

C bus

Illustration of Interface Board Depicting System I/O

Configuration #1

AC Power Fan Distribution Brd Remote USB DC Output(s)

(Optional) I

2

C bus display and Battery(s)

Thermal Sensor Thermal Sensor

I

2

C bus I

2

C bus

Illustration of Interface Board Depicting System I/O

Configuration #2

Series 301-1001

(Config #2; Front Mount Shown)

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For Series 301-1003 Controller

AC Power USB Remote Thermal Sensor Thermal Sensor DC Output(s)

display I

2

C bus I

2

C bus and Battery(s)

Distribution Brd Fan

(

Optional) I

2

C bus

Illustration of Interface Board Depicting System I/O

Configuration #1

AC Power Fan Distribution Brd Remote USB DC Output(s)

(Optional) I

2

C bus display and Battery(s)

Thermal Sensor Thermal Sensor

I

2

C bus I

2

C bus

Illustration of Interface Board Depicting System I/O

Configuration #2

Series 301-1003

(Config #1; Top Mount Shown)

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We recommend, when possible, to connect the battery to the system prior to providing

AC power to the system. This allows the system to reset with a battery attached; a more

common configuration.

The diagram below represents the basic system connection. The following paragraphs

provide detail regarding each connection.

System Interconnect Figure

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4.1 AC Power

AC Power is applied to the system through a medically approved AC power cord. AC

Power is assumed to be consistent with standard wall power [European or U.S.]. The

delivered system leaves this 3 conductor cable in a pigtail configuration for the OEM’s

use in the Cart enclosure. A medically approved RFI filter for the AC plug must be

used in support of EN60601 EMC requirements. The suggested part is listed below.

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4.2 Sealed Lead Acid Batteries

The battery (or batteries) is (are) connected to the power system through “in-line”

Anderson® Power Pole connectors; positive red and negative black. Two connectors

are used for each pole of the battery. If two batteries are used, they must be connected

in a “parallel” configuration thereby providing 12 volts to the system.

The cart manufacturer is responsible for the connection from the battery to the Power

Poles. The recommended gage of wire for the connection from the battery pole to the

Power Pole connector is insulated stranded 16 AWG for each of the two wires per

battery terminal.

The system configuration, one or two batteries, will determine if one or two temperature

sensors are necessary. The temperature sensors are connected to the negative pole of

each battery. The sensors are addressed uniquely thereby providing access to each

battery temperature independently.

The battery temperature sensors are controlled using an I

2

C bus. Each item is

specifically addressed therefore the connection to each can be through any I

2

C

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connector. In the above diagram, therefore, any I

2

C connection can be interchanged

with any other without any functional effect.

4.3 Host Computer

The host computer connects to the power system through a standard USB connection.

The cart uses a standard USB cable and connector to interface to the power system USB

header.

When connecting the system to the host computer it may take up to 30 seconds for

Windows to recognize the system and begin communication. If this does not occur,

please contact the manufacturer.

If the host computer is a laptop and its associated battery is left installed, the Series 301

will not operate correctly. The time estimations for charging and discharging will be

effected by the requirement to charge and discharge the laptop battery.

While calling for charge current to charge the laptop battery, the System 301 will over

estimate the current necessary to support the loads attached to the system and will not

factor in the reduced current need after the laptop battery reaches full charge. This will

result in a significant error during the discharge cycle as the laptop battery requires

recharging from the System 301 battery.

If the laptop battery is in place while charging, the Series 301 will estimate the time

remaining to discharge accurately however the total current required to charge both the

laptop battery and Series 301 battery[s] may exceed the available wattage available

from the system. This may cause the system to shut down due to over current draw

[reference error conditions in future sections] or it may cause the Series 301 batteries to

charge more slowly than anticipated due to the unanticipated draw from the laptop

battery.

It is strongly recommended to remove the laptop’s battery prior to use with the Series

301 system. The time available to the PC is unchanged since the Series 301 battery

depletion will be similar regardless of the laptop battery’s presence; the system will

require the Series 301 batteries to be recharged regardless of the state of the laptop

battery.

4.4 Remote display

The remote display uses a standard Category 5 connection (CAT5) to the system;

straight through type [not patch type]. This is used for the convenience of a standard

cable and does not infer that the system is compatible for use within a networked

system.

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4.5 DC Output Power

The DC Output Power is provided through two ”in-line” Anderson® Power Poles; Red

positive and blue negative.

System Interconnect Figure

4.6 Fan and Thermal Sensor

The optional remote distribution board and thermal sensor connections are

interchangeable. They are addressed through an I

2

C bus protocol and will operate

appropriately with any connection to the bus.

The Thermal sensors are marked “94” or “Bat 1” for Battery 1 and “98” or “Bat 2” for

Battery 2, in concert with their appropriate permanent addresses as manufactured, if

more than one sensor is necessary. These channels will correspond with the

designations on the Advanced Function Screen references. The User should note which

of the batteries is designated as 1 and which is designated as 2 prior to final OEM

system assembly. DO NOT use two battery sensors of the same address in the same

system. This will cause bus address conflicts and will not provide reliable data.

The connector type is that which is meant for few connect/disconnect cycles and should

not be abused through repeated connections.

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5 Installation of Software

Host PC Software

The licensed Host software will be provided by MIDMARK for customer use. The PC

software is easy to install from a CD. The CD will prompt the user through typical

Windows setup instructions.

It is critical that the appropriate driver is loaded for the MIDMARK product. If

the driver is not loaded appropriately the system will not function. The driver is part of

the software provided.

6 Initial Testing and Error Conditions

6.1 Remote display

The Advanced Function screen provides a convenient LED Test. This test will cycle

through all of the LEDs on the Remote display providing an easily recognizable

sequence of on/off for each. A failed LED will not light. If the LEDs are not

sequencing, then the processor or a connector has failed.

6.2 Battery

If AC power is not

connected and the battery is appropriately connected and has charge,

then the Pop Up on the host computer [Main User’s Interface Screen] will provide a

time to discharge. Also, the LED indicator on both the Remote display and the Pop Up

will indicate DC Power. The time to discharge calculation may take up to 5 minutes to

display due to the delay in the power system evaluating data and preparing a state of

charge [SoH] approximation. Prior to evaluation, the time to discharge may display

solid “-“marks with a flashing on/off colon. The flashing on/off colon indicates that the

system is operational and communicating.

The LOW BATTERY indicator will activate if the battery power is below a prescribed

limit.

Main User’s Interface

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Midmark 6251, 6252, 6256 (Powered Carts - DC) Owner's manual

Midmark 6251, 6252, 6256 (Powered Carts - DC) Owner's manual

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