Atom Incu i 101 Troubleshooting guide

Equipment for neonatal and premature infants: Incubator
Atom Infant Incubator Model 101
TO THE OPERATOR AND THE PERSON IN CHARGE OF
MAINTENANCE AND CARE OF THE UNIT:
쎲This Manual describes various kinds of inspection needed to ensure proper op-
eration of the Incu i, including instructions for troubleshooting, those proce-
dures to change certain settings which are not mentioned in the Operation
Manual, and important points to bear in mind in handling the unit.
쎲Various kinds of inspection, including periodical inspection, are described in detail
in this Manual. They should be carried out only by those who are fully familiar
with the operation of the unit, having adequate technical knowledge and skills
required in inspecting the unit.
쎲If repairs seem to be required as a result of any inspection described in this
Manual, either personnel with more advance knowledge and skills should un-
dertake the repair or you should contact your local Atom representative for re-
pair service.
Service Manual & Parts List
0123

Via F. Croce, 65 - 20081 Abbiategrasso (MI) - Italy
Tel: [phone] Fax: [phone]
EU OFFICE

1
INTRODUCTION
This Service Manual describes procedures for inspecting, repairing and changing the settings of the Incu i. It also
describes precautions and troubleshooting in alarm conditions. The procedures described in this Service Manual
should be carried out only by personnel trained in electricity and the operation of the unit. Neither Atom Medical
Corporation nor its representative will be responsible for the quality and performance of the unit if the unit should
not be handled as instructed or if unauthorized parts should be used in repairs. It should be noted that any respon-
sibility arising from inspecting, repairing or changing the settings of the unit lies with the person who carried it
out.
Read this Service Manual carefully and familiarize yourself thoroughly with its contents before inspecting, repair-
ing or changing the settings of the unit. Keep this Manual where it is readily accessible for reference when needed.
For more detailed information on inspecting, repairing and changing the settings of the unit, contact your local
Atom representative.
Read the Operation Manual thoroughly before using the Service Manual.
SAFETY INFORMATION
Please read the Manual carefully before operating the unit. Please follow the instructions when operating the unit.
zBasic Instructions
1. Medical institutions are responsible for the maintenance, inspection and care of the unit.
2. When you choose to have the unit maintained and inspected or when the unit is found to be in need of repairs
from the results of inspection, consult your local Atom representative and take one of the following mea-
sures.
1) Ask someone who has completed a training course specified by Atom and who has sufficient technical
knowledge and skills to do the work.
2) Ask Atom to send its service engineer if a person who has completed a training course specified by Atom
and who has sufficient technical knowledge and skills is not available.
3) Ask Atom for its approval of returning the unit for repair service.
3. Follow the instructions for safety.
Read the operating precautions thoroughly before operating the unit.
4. Inspect the unit on a periodical basis.
Periodical inspection is needed to use the unit in the optimum condition.
5. Ensure that the unit will not be used if it is found to be defective.
Take proper measures to ensure that a defective unit will not be used by mistake before it is properly inspected,
repaired and has its settings changed for normal operation. Such measures include indicating on the unit that it
is under inspection/repair and keeping it away from other devices that function correctly.

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xDefinitions of Warning Indication
Three levels of warning indication are used throughout this Manual and on the unit. They are defined as
follows.
DANGER:
A DANGER notice indicates an immediately hazardous situation which, if not avoided,
will result in death or serious injury, serious damage to property such as total loss of use
of equipment or fire.
WARNING :
WARNING: A WARNING notice indicates an indirectly (potentially) hazardous situ-
ation which, if not avoided, will result in death or serious injury, serious damage to
property such as total loss of use of equipment or fire.
CAUTION:
A CAUTION notice indicates a hazardous situation which, if not avoided, can result in
minor or moderate injury, partial damage to equipment, and loss of data stored
in computers.
cDefinition of Symbols
1. Symbols to indicate danger, warning or caution
Symbol Title and indication
General attention
Indicates unspecified general danger, warning or caution.
Caution: Hot surface
Indicates that the surface can be dangerously hot under certain conditions.
2. Symbols to prohibit action
Symbol Title and indication
General prohibition
Indicates unspecified general prohibition.
Prohibition of disassembly
Indicates prohibition of disassembly of the unit where it may cause an electric shock or other
hazards.
Prohibition of use of fire
Indicates prohibition of use of fire where an external use of fire may cause the unit to ignite
under certain conditions.

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Symbol Title and indication
General instruction
Indicates unspecified general action on the part of the user.
Connect a ground wire
Instructs the user to connect the ground wire without fail where the unit is provided with a
ground terminal.
Remove the power plug from the power outlet
Instructs the user to remove the power plug from the power outlet in the case of malfunction or
when there is a threat of lightning.
3. Symbols to give instructions for action
4. Symbols of international standards (IEC)
Symbol Title and indication
Power on
Indicates in relation to the power switch that the device is connected to the power source.
Power off
Indicates in relation to the power switch that the device is not connected to the power source.
Type BF applied part
Indicates that the device is classified as Type BF in terms of the degree of protection against an
electric shock.
Bell silenced
Indicates either a control switch to silence the bell permanently or temporarily, or that the bell is
silenced.
Date of manufacture
Indicates the date when the unit was manufactured in the factory.
Recyclable (battery)
Indicates that recycling is recommended.
WEEE symbol
In the EC area, an electrical and electronic product falling in one of the categories specified by
“DIRECTIVE 2002/96/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 27
January 2003 on Waste Electrical and Electronic Equipment (WEEE)” should be disposed of in a
manner consistent with relevant laws and regulations.
This symbol indicates that the above-mentioned requirement applies to this product.

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5. Other symbols
Symbol Title and indication
Setting
Indicates that a setting is increased.
Setting
Indicates that a setting is decreased.
Main screen display switch
Indicates a switch to display the main screen.
Trend screen display switch
Indicates a switch to display the trend screen.
Menu screen display switch
Indicates a switch to display the menu screen.
Pulse oximeter screen display switch
Indicates a switch to display the pulse oximeter screen or the function related to the pulse rate.
Weight screen display switch
Indicates a switch to display the weight screen or the function related to weighing the infant.
Battery
Indicates whether the incubator is being powered by a battery or not.
Incubator air circulation
Indicates the function related to air circulation in the incubator in the incubator mode or that the
incubator is in manual control.
Setting
Indicates set values or the setting procedure.
Skin temperature
Indicates the function related to the infant’s skin temperature or that the incubator is in servo
control.
Temperature
Indicates, with this symbol alone or with other symbols, a detected temperature or a set tempera-
ture alarm.
Peripheral temperature
Indicates the function related to the infant’s peripheral temperature (skin temperature 2).
Low water level/no water
Indicates that there is little or no water in the humidity chamber.
Defective humidity chamber
Indicates that something is wrong with the humidity chamber.

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Symbol Title and indication
Humidity chamber off
Indicates that the humidity chamber is not attached properly.
Humidity
Indicates the function related to humidity.
O2
Oxygen
Indicates the function related to oxygen.
Load capacity
Indicates the maximum load capacity.
Avoid getting caught
Indicates that the user must avoid getting caught in the gap in the device.
(Nellcor)
Interference
Indicates that interference exists.
(Nellcor)
Pulse search
Indicates that no pulse is detected.

CONTENTS
INTRODUCTION .................................................... 1
PLEASE READ WITHOUT FAIL
[1] Operating Precautions............................... 8
1-1. DANGER.................................................... 8
1-2. WARNING.................................................. 9
1-3. CAUTION................................................. 11
[2] Parts Identification ................................... 13
2-1. Main Body ..................................................... 13
2-2. Control Panel ................................................ 16
2-3. Display Screens ........................................... 17
2-3-1. General Description of
the Screens .......................................... 17
2-3-2. Screen Transition Diagram ................ 19
2-3-3. List of Operations Available
on Each Screen ................................... 20
2-3-4. Main screen.......................................... 20
2-3-5. Pulse Oximeter Screen ...................... 23
2-3-6. Weight Screen ..................................... 27
2-4. Service Menu (How to Operate
the Service Menu Screen) .......................... 35
2-4-1. How to Enter the Service Menu ........ 35
2-4-2. Operating the Service
Menu Screen........................................ 36
MAINTENANCE
[3] Maintenance Inspection .......................... 41
3-1. Inspection before Use ................................. 42
3-1-1. Visual Inspection ................................. 42
3-1-2. Functional Inspection.......................... 43
3-1-3. Performance Inspection ..................... 46
3-1-4. Checking and Calibrating
the Weight Monitor .............................. 47
3-2. Quarterly Inspection..................................... 48
3-3. Inspection Checklist..................................... 49
3-4. Periodical Replacement Parts and
How to Replace them .................................. 50
3-4-1. Replacing the Filter ............................. 51
3-4-2. Replacing the Oxygen Sensor .......... 52
2-3-7. Menu Screen........................................ 29
2-3-8. Trend Screen ....................................... 33
[4] Cleaning and Disinfection ...................... 54
4-1. Hood Assembly............................................. 55
4-2. Mattress Platform and Parts Beneath....... 57
4-3. Humidity Chamber ....................................... 59
4-5. Others ............................................................ 60
[5] Troubleshooting ........................................ 61
5-1. Alarms ............................................................ 61
5-2. Troubleshooting ............................................ 67
5-3. Troubleshooting Flowchart ......................... 69
5-3-1. Troubleshooting When the Unit
Cannot Be Controlled Properly ......... 69
5-3-2. Troubleshooting When the Unit
Does Not Function Properly .............. 71
4-5. Others ...................................................... 78
DISASSEMBY AND REPLACEMENT
[6] Disassembly and Replacement
Procedures ................................................. 95
6-1. Stand .............................................................. 95
6-1-1. Removing the Main Body
from the HL Stand ............................... 95
6-1-2. Replacing the Actuator ....................... 97
6-1-3. Replacing the Foot Switch ................. 97
6-1-4. Replacing the Relay Board of the
Pedals for Height Adjustment ............ 99
6-1-5. Replacing the Caster .......................... 99
6-2. Hood............................................................. 100
6-2-1. Replacing the Hood Assembly ........ 100
6-2-2. Replacing the Admittance
Panel Lock Holder............................. 101
6-2-3. Replacing the Sensor Module
Holder.................................................. 101
6-2-4. Replacing the Snap-open
Access Port S/W................................ 102
6-2-5. Replacing the Admittance
Panel Assembly ................................. 102
6-2-6. Replacing the Admittance Panel
Hinge (with X-ray Cassette Tray
Door).................................................... 103
6-2-7. Replacing the Admittance Panel
Operating Lever R/L.......................... 104
6-2-8. Replacing the Admittance Panel
Operating Knob.................................. 104
6-2-9. Replacing the Inner Wall
Lever R/L ............................................ 105
6-2-10. Replacing the Inner Wall
(for the Incu
i )..................................... 105
6-2-11. Replacing the Inner Wall Bearing ... 106
6-2-12. Replacing the Inner Wall Shaft........ 106
6-3. Main Body ................................................... 107
6-3-1. Removing the Upper Section of the
Main Body from the Main Body....... 107
6-3-2. Replacing the Heater ........................ 108
6-3-3. Replacing the Motor.......................... 109
6-3-4. Replacing the High Temperature
Sensor................................................. 110
6-3-5. Replacing the Control Box Cover ... 111
6-3-6. Replacing the Power Switch............ 111
6-3-7. Replacing the Detection Board ....... 112
6-3-8. Replacing the Tilting Unit ................. 113
6-3-9. Replacing the Position Detection
Board (for the Detection of the
Middle Board)..................................... 113
6-3-10. Replacing the Filter Joint.................. 114
6-3-11. Replacing the Humidity Chamber
Cover Packing A ................................ 115

MAINTENANCE INFORMATION APPENDIX
PLEASE READ WITHOUT FAIL
DISASSEMBLY AND REPLACEMENT
6-3-12. Replacing the Humidity Chamber
Cradle.................................................. 115
6-3-13. Replacing the Humidity Chamber
Cover ................................................... 116
6-3-14. Replacing the Humidity Chamber
Cover Packing C................................ 116
6-3-15. Replacing the Connector of the
Humidity Chamber ............................ 117
6-3-16. Replacing the Position Detection
Board (for the Detection of the
Boiler Cap).......................................... 117
6-3-17. Replacing the Position Detection
Board (for the Detection of the
Humidity Chamber Cover) ............... 118
6-3-18. Replacing the Control Power
Transformer ........................................ 118
6-3-19. Replacing the Drive Power
Transformer ........................................ 119
6-3-20. Replacing the Oxygen Controller
Assembly ............................................ 120
6-3-21. Replacing the Mass Flow Valve ...... 120
6-3-22. Replacing the Solenoid Valve.......... 121
6-4. Power Unit................................................... 122
6-4-1. Replacing the Control Board
(for the Dual Incu
i )............................ 122
6-4-2. Replacing the Battery ....................... 123
6-4-3. Replacing the Heater Control
Board (for the Incu
i )......................... 124
6-4-4. Replacing the Power Cord Inlet ...... 126
6-4-5. Replacing the Buzzer........................ 127
6-4-6. Replacing the Noise Filter................ 127
6-4-7. Replacing the Height Adjustment
Drive Board ........................................ 128
6-4-8. Replacing the Rectifier Board.......... 128
6-4-9. Replacing the Fuse ........................... 129
6-4-10. Replacing the Insulating Substrate
(SpO2Unit) ......................................... 129
6-5. Control Panel .............................................. 130
6-5-1. Replacing the Arm for Mounting
the Function Rail................................ 130
6-5-2. Replacing the Cable Guide.............. 130
6-5-3. Replacing the Front Panel ............... 131
6-5-4. Replacing the Rear Panel
(with Alarm Lamp) ............................. 132
6-5-5. Replacing the LCD Module.............. 133
6-5-6. Replacing the Speaker ..................... 134
6-5-7. Replacing the Alarm Lamp
Board ................................................... 135
6-5-8. Replacing the Power Indicator
Board ................................................... 135
6-5-9. Replacing the LCD Display
Board ................................................... 136
6-5-10. Replacing the CCFL Inverter ........... 137
6-5-11. Replacing the Button Cell Battery
for the Control Panel......................... 137
6-5-12. Replacing the Connector
Cap A/B............................................... 138
6-6. Mattress Platform ....................................... 139
6-6-1. Replacing the Baby Guard/Side
Baby Guard ........................................ 139
6-6-2. Replacing the Latch .......................... 139
6-6-3. Replacing the Weight Monitor
Module ................................................ 140
INFORMATION
[7] Electrical Block Diagram....................... 141
[8] Wiring Diagram ........................................ 142
8-1. Drive Unit..................................................... 142
8-2. Main Body ................................................... 143
8-3. Peripheral Units .......................................... 144
[9] Parts List ................................................... 145
9-1. Fig-1 Main Body and Accessories ........... 146
9-2. Fig-2 Control Panel .................................... 148
9-3. Fig-3 Humidity Chamber ........................... 150
9-4. Fig-4 Mattress Platform............................. 152
9-5. Fig-5 Upper Section of the
Main Body 1 ................................................ 154
9-6. Fig-6 Upper Section of the
Main Body 2 ................................................ 156
9-7. Fig-7 Upper Section of the
Main Body 3 ................................................ 158
9-8. Fig-8 Lower Section of the Main Body...160
9-9. Fig-9 Power Unit......................................... 162
9-10. Fig-10 Oxygen Controller Assembly ....... 164
9-11. Fig-11 Upper and Lower Sections of
the Main Body and Filter Case
Assembly ..................................................... 166
9-12. Fig-12 Stand ............................................... 168
9-13. Fig-13 Pulse Oximeter (Masimo)............. 170
9-14. Fig-14 Pulse Oximeter (Nellcor) .............. 172
APPENDIX
[10] Technical Information ............................ 174
10-1. Technical Data ............................................ 174
10-2. EMC Level and Classification .................. 179
[11] Disposal..................................................... 183

Operating Precautions
8
[1] Operating Precautions
Please follow the operating instructions described in this Service Manual & Parts List for the safe use of the
unit. The unit should be operated only by those who have been trained and instructed properly in its operation.
The unit should be operated only for its intended use.
1-1. DANGER
Death or serious injury, damage to equipment or a fire will result if the instructions given below are not fol-
lowed.
Only those who have been trained properly should operate the unit.
Be sure to keep the admittance panels and the access ports closed when the unit is in use.
Using the unit with an admittance panel or an access port left open may cause the infant to fall out of the baby
compartment. Be sure to close the admittance panels and the access ports when performing phototherapy on an
infant inside the incubator.
Monitor the infant’s skin temperature when operating the unit.
If the incubator air temperature should rise during phototherapy, proceed with the photo-
therapy after placing the infant in a cot or an open-type incubator (an infant warmer), as
directed by the doctor.
Since a mature infant emits much heat, the incubator air temperature may rise if you place the infant in the
incubator and perform phototherapy. The incubator air temperature may also rise if you use multiple photo-
therapy units at the same time or if the room temperature is high. In such a case, proceed with the phototherapy
after placing the infant in a cot or an open-type incubator, as directed by the doctor. Take sufficient care when
using a cot, as it becomes difficult to observe the infant. Alternatively, placing an ice bag inside the incubator has
the effect of decreasing the incubator air temperature.
However, be sure to close the admittance panels and the access ports in this case also.
Do not leave the unit unattended when an admittance panel or an access port is open.
If an admittance panel or an access port is left open, the infant may fall out of the baby compartment and get fatally
injured. Never leave the unit unattended when an admittance panel or an access port is open.
Stop using the unit immediately and seek repair if an admittance panel, a snap-open access
port or a press lever should be found loose or faulty in any way.
The infant may fall out of the baby compartment.
Never place a body warmer or any other possible ignition source in or near the unit.
Use of oxygen will increase the risk of explosion or fire. Body warmers or other devices in which fire is used or
which will generate a spark may cause an explosion or a fire if used near the unit.
Do not use the unit in the presence of a flammable anesthetic gas.
The unit may cause an explosion or a fire if used in the presence of such a gas.
Do not use ether, alcohol or any other ignitable substance.
Even a small amount of ether, alcohol or other ignitable substances may cause a fire when mixed with the oxygen
in the incubator.