METRON QA-90 Troubleshooting guide

QA-90
User & Service Manual
QA-90 Electrical Safety Analyzer
P/N 11025
V.3.13

ii
Copyright 2001 by METRON. All rights reserved.
METRON:
USA ____ FRANCE________ NORWAY ____
1345 Monroe NW, Suite 255A 30, rue Paul Claudel Travbaneveien 1
Grand Rapids, MI 49505 91000 Evry, France N-7044 Trondheim, Norway
Phone: [phone] Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone] Fax: [phone]
E-mail: [e-mail] E-mail: [email protected] E-mail: [e-mail]
Disclaimer
METRON provides this publication as is without warranty of any kind, either express or implied, including but
not limited to the implied warranties of merchantability or fitness for any particular purpose. Further, METRON
reserves the right to revise this publication and to make changes from time to time to the content hereof, without
obligation to METRON or its local representatives to notify any person of such revision or changes. Some jurisdic-
tions do not allow disclaimers of expressed or implied warranties in certain transactions; therefore, this statement
may not apply to you.
Limited Warranty
METRON warrants that the QA-90 Electrical Safety Analyzer will substantially conform to published specifi-
cations and to the documentation, provided that it is used for the purpose for which it was designed. METRON
will, for a period of twelve (12) months from date of purchase, replace or repair any defective analyzer, if the fault
is due to a manufacturing defect. In no event will METRON or its local representatives be liable for direct, indirect,
special, incidental, or consequential damages arising out of the use of or inability to use the QA-90 Electrical Safe-
ty Analyzer, even if advised of the possibility of such damages. METRON or its local representatives are not re-
sponsible for any costs, loss of profits, loss of data, or claims by third parties due to use of, or inability to use the
QA-90 Electrical Safety Analyzer. Neither METRON nor its local representatives will accept, nor be bound by any
other form of guarantee concerning the QA-90 Electrical Safety Analyzer other than this guarantee. Some jurisdic-
tions do not allow disclaimers of expressed or implied warranties in certain transactions; therefore, this statement
may not apply to you.
Trademarks
IBM is a registered trademark, and PC/XT is a trademark of IBM Corporation. Microsoft is a registered trademark
and Windows is a trademark of Microsoft Corporation.

iii
Table of Contents
MANUAL REVISION RECORD .........................................................................................................V
1. INTRODUCTION ................................................................................................................... 1-1
1.1 QA-90 Features...................................................................................................................1-1
1.2 Specifications......................................................................................................................1-1
1.3 General Information............................................................................................................1-3
2. INSTALLATION..................................................................................................................... 2-1
2.1 Receipt, Inspection and Return...........................................................................................2-1
2.2 Setup...................................................................................................................................2-2
2.3 Power..................................................................................................................................2-2
2.4 PRO-Soft QA-90.................................................................................................................2-2
3. OPERATING QA-90............................................................................................................... 3-1
3.1 Control Switches and Connections .....................................................................................3-1
3.2 Key Pad Functions..............................................................................................................3-3
3.3 Function of The Bar Code Reader ......................................................................................3-3
3.4 Menu and Function Keys....................................................................................................3-4
3.5 Display Menus and Messages.............................................................................................3-4
3.6 Measurements with Several Modules in Manual Mode....................................................3-10
3.7 Storing Setup Parame- ters in Flash Memory....................................................................3-11
3.8 Upgrading the QA-90 Software Program..........................................................................3-13
3.9 Cleaning the QA-90..........................................................................................................3-15
4. EXAMPLE TEST MEASUREMENTS ................................................................................. 4-1
4.1 Test Lead Calibration..........................................................................................................4-1
4.2 Connecting an Instrument without Patient Inputs ...............................................................4-2
4.3 Connecting an Instrument with Patient Inputs ....................................................................4-3
4.4 Power Cable Test................................................................................................................4-6
4.5 Current Measurement Test (Dual Lead)..............................................................................4-7
4.6 Voltage Measurement Test (Dual Lead).............................................................................4-9
4.7 Resistance Measurement (Dual Lead)...............................................................................4-11
4.8 Connecting Auxiliary Power Source / Isolating Transformer ...........................................4-12
5. CONTROL AND CALIBRATION........................................................................................ 5-1
5.1 Required Test Equipment ...................................................................................................5-1
5.2 Preparation and Adjustments..............................................................................................5-1
5.3 Calibration ..........................................................................................................................5-5
5.4 Other Calibration Procedures............................................................................................5-11
5.5 Calibration Constants........................................................................................................5-14

iv
6. COMPONENT FUNCTIONS AND PARTS......................................................................... 6-1
6.1 Theory of Operation............................................................................................................6-1
6.2 Measuring System...............................................................................................................6-2
6.3 Microprocessor System.......................................................................................................6-3
6.4 Component Parts.................................................................................................................6-4
APPENDIX A: IEC 601.1, UL 2601.1 AND VDE 0751 TESTING ................................................A-1
A.1 Classification of Equipment...............................................................................................A-1
A.2 Tests on Mains Powered Class 1 & 2 Equipment According To IEC 601.1/UL 2601.1 ...A-4
A.3 Tests on Internally Powered Equipment According To IEC 601.1/UL 2601.1 ...............A-13
A.4 System Tests Based on IEC 601.1/UL 2601.1.................................................................A-15
A.5 Tests According To VDE 0751-1, 10/1990.....................................................................A-16
APPENDIX B: DIAGRAMS..............................................................................................................B-1
Mains & EUT Connections Schematic Diagram ............................................................................B-3
Measuring Board Component Location Layer 1.............................................................................B-4
Measuring Board Component Location Layer 2.............................................................................B-5
Measuring System Schematic Diagram Part 1 (Measuring Preparation).......................................B-6
Measuring System Schematic Diagram Part 2 (High Voltage Interface).......................................B-7
Measuring System Schematic Diagram Part 3 (High Voltage Logic)............................................B-8
Measuring System Schematic Diagram Part 4 (High Voltage Drivers).........................................B-9
Measuring System Schematic Diagram Part 5 (Applied Part Matrix) .........................................B-10
Measuring System Schematic Diagram Part 6 (Measurement Matrix)........................................B-11
Measuring System Schematic Diagram Part 7 (Program Amplifier and Lowpass).............................B-12
Measuring System Schematic Diagram Part 8 (Relay Drivers)...................................................B-13
Microprocessor Board Component Location................................................................................B-14
Keypad Board Component Location ............................................................................................B-15
Microprocessor System Schematic Diagram Part 1 (QA-90)......................................................B-16
Microprocessor System Schematic Diagram Part 2 (Integrated Keypad)....................................B-17
Microprocessor System Schematic Diagram Part 3 (CPU) .........................................................B-18
Microprocessor System Schematic Diagram Part 4 (CPU) .........................................................B-19
Microprocessor System Schematic Diagram Part 5 (Printer and Display Interface)...........................B-20
Microprocessor System Schematic Diagram Part 6 (Series and Keypad Interface)............................B-21
APPENDIX C: ERROR REPORT FORM, QA-90.........................................................................C-1
APPENDIX D: SUGGESTION FORM, QA-90...............................................................................D-1

v
Manual Revision Record
This record page is for recording revisions to your QA-90 User and Service Manual that have been
published by METRON or its authorized representatives. We recommend that only the management
or facility representative authorized to process changes and revisions to publications:
•make the pen changes or insert the revised pages;
•ensure that obsolete pages are withdrawn and either disposed of immediately, or marked as su-
perseded and placed in a superseded document file, and;
•enter the information below reflecting that the revisions have been entered.
Rev No
Date Entered
Reason
Signature of Person Entering Change
0 - Initial Release
3.13-1
4-26-01
General update

vi
Symbols Used In This Manual
Caution (Refer to accompanying documents) (See NOTE)
Caution, Risk of Electrical Shock (see NOTE)
Earth (ground) TERMINAL

1-1
1. Introduction
This chapter describes the QA-90 Electrical Safety Tester’s features
and specifications.
1.1 QA-90 Features The QA-90 represents a new generation of safety testing equipment. It
is the only automatic safety analyzer that can test units with different
classes of protection in one test run (e.g., cardiac float and body float
defibrillators). It is simple to use. All you need do is select the type
and class of equipment to test. When you press START, QA-90 ex-
ecutes the tests prescribed to the selected standard.
Test results may be printed out immediately, or stored internally in the
unit for later use. QA-90 has full remote control, and may be operated
from PRO-Soft QA-90 software. PRO-Soft QA-90 enables you to
make your own test protocols, store the information on disk, and ex-
port formatted data to any other database or equipment management
program. Individual test sequences may be compiled to satisfy na-
tional and international standards.
The following standards may be compiled either fully or in part:
IEC 60601.1, UL 2601.1, IEC 60601.1.1, UL 2601.1.1, IEC
60601.2.4, IEC 61010-1, EN 60601-1, VDE 0750 Tl/12-91, BS 5724,
CAN/CSA-C22.2 No 601.1-M90, AS 3200.1, NZS 6150:1990, VDE
0751 T1/12-90, ÖVE 0751, UL 544, HEI 95, HEI 158 among others.
1.2 Specifications 1. Voltage Measurement
Measurements may be obtained in the following ways:
•Between leads 1 and 2 (in the power contact).
•Between lead 1 and ground (in the power contact).
•Between lead 2 and ground (in the power contact).
•Between input/output E+ and E- (floating inputs/outputs).
Range
0 - 400V true RMS.
Resolution 0.1V
Accuracy
DC - 100 Hz, 1% of full scale +1 LSD
100 Hz-10 kHz, 2% of scale +1 LSD
No. of Tests
4 or multiple (LSD = least significant digit)
2. Current Consumption

1-2
The current measurement may be executed in lead no. 1 (live).
Range 1
0 - 1000 mA RMS (@ <250VAC)
Resolution
1 mA
Accuracy
±
2% of full scale
±
1 LSD
No. of Tests 1 or multiple
Range 2
1 - 16A RMS (@ <250VAC)
Resolution
1 mA
Accuracy ±
1% of full scale
±
1 LSD
No. of Tests
1 or multiple
3. Protective Earth
The test current is selectable from 25A or 1A, delivered from a transformer
with a maximum idle voltage of 6V. The measurement can be performed
on ground leads or between E+ and E- (floating inputs/outputs).
Range
0 - 2000 mOhm
Resolution
1 mOhm
Accuracy ±
2% of full scale
±
1 LSD
No. of Tests
1, 2, or multiple
4. Insulating Resistance
The measurement of the insulating resistance may be executed between
casing and power unit, or between patient module and power unit.
Test voltage: 500VDC through a 130 kOhm limiting resistor.
No. of Tests: 1, 2 or multiple
Range
1 - 50 mOhm
Resolution 1 mOhm
Accuracy
±2% of full scale ±1 LSD
Range
51 - 200 mOhm
Resolution
1 mOhm
Accuracy
±
2% of full scale
±
1 LSD
5. Leakage Currents
All measurements can be performed with a IEC 601.1 filter (patient equiva-
lent), or without (flat frequency response). The filter can be exchanged with
filters covering other standards. All measurements can be performed as
true RMS measurements, or AC/DC measurements.
The following leakage currents can be measured:
Ground leakage current
No. of Tests: 4
Enclosure leakage current
No. of Tests: 6 or multiple

1-3
The following leakage currents are measured for each module:
Patient leakage current
No. of Tests: 6
Mains on applied part leakage current
No. of Tests: 2
Patient Auxiliary current
No. of Tests: 6
Floating dual lead measurement of
leakage currents
No. of Tests: Multiple
In one test run a maximum of 11 modules with different protection classes
may be tested.
6. Accuracy
Range 1
0- 100 µA
Resolution
1 µA
Accuracy
±
2% of full scale
±
1 LSD
Range 2
100- 1000 µA
Resolution
1 µA
Accuracy
±
2% of full scale
±
1 LSD
Range 3
1,0 - 10,0 mA
Resolution
1 µA
Accuracy
±
1% of full scale
±
1 LSD
7. Frequency Response
DC - 1 MHz (-3dB) with a crest factor of >2
The applied test voltage for patient leakage current is 110% of the line vol-
tage, delivered through a limiting resistor of 47 kOhm.
1.3 General Information Temperature Requirements
+15°C to +35°C when operating
0°C to +50°C in storage
Display
Type
LCD graphic display
Alphanumeric format
4 lines, 40 characters
Data Input/ Output (2)
Parallel printer port (1); Bi-directional
RS -232C (1) for computer control
Power
From 110 VAC to 240 VAC, 47/ 63 Hz
3900 VA
Do not exceed 16 Amps of current at
any voltage within the operating range.
Installation Category II
Fuses
Two 16 Amp, 250V slow blow fuses

1-4
Mechanical Specifications
Housing Metal case
Height 13.2 cm 3.9 in.
Width 34.2 cm 9.8 in.
Depth 30.5 cm 11.0 in.
Weight 5.8 kg 4.1 lbs.
Standard Accessories
User and Service Manual QA-90 (P/N 11025)
Additional Accessories
Carrying Case (P/N 11100)
Carrying case, ext. printer (P/N 10500)
Bar Code Reader (P/N 11400)
Isolating transformer 400VA (P/N 11401)
Isolating transformer 800VA (P/N 11410)
Test unit (ESA) (P/N 11402)
E input measuring cable (2m) (P/N 11411)
E input measuring cable (5m) (P/N 11415)
Clamp - crocodile type (P/N 11412)
PRO-Soft QA-90 software (P/N 11200)
PRO-Soft QA-90 DEMO (P/N 11201)
User/Service Manual PRO-Soft QA-90 (P/N 11225)
Storage
Store in the carrying case in dry surroundings within the tem-
perature range specified. There are no other storage require-
ments.
Periodic Inspection
The unit should be calibrated every 12 months.

2-1
2. Installation
This chapter explains unpacking, receipt inspection and claims, and
the general procedures for initial QA-90 setup. Example test setup
procedures are contained in Chapter 4, Example Test Measurements.
2.1 Receipt, Inspection
and Return 1. Inspect the outer box for damage.
2. Carefully unpack all items from the box and check to see that you
have the following items:
•QA-90 Electrical Safety Tester (P.N. 11200)
•QA-90 User and Service Manual (P.N. 11025)
3. If you note physical damage, or if the unit fails to function ac-
cording to specification, inform the supplier immediately. When
METRON AS or the company’s representative, is informed,
measures will be taken to either repair the unit or dispatch a re-
placement. The customer will not have to wait for a claim to be
investigated by the supplier. The customer should place a new
purchase order to ensure delivery.
4. When returning an instrument to METRON AS, or the company
representative, fill out the address label, describe what is wrong
with the instrument, and provide the model and serial numbers. If
possible, use the original packaging material for return shipping.
Otherwise, repack the unit using:
•a reinforced cardboard box, strong enough to carry the
weight of the unit.
•at least 5 cm of shock-absorbing material around the unit.
•nonabrasive dust-free material for the other parts.
Repack the unit in a manner to ensure that it cannot shift in the
box during shipment.
METRON’s product warranty is on page ii of this manual. The war-
ranty does not cover freight charges. C.O.D. will not be accepted
without authorization from METRON A.S or its representative.

2-2
2.2 Setup
1. Equipment connection is as shown in the typical setup below. At-
tach the printer cable to the 25-pin outlet port.
2. If PRO-Soft QA-90 is being used, attach an RS-232C (null mod-
em/data transfer configured) cable to the 9-pin D-sub outlet port
located at the rear of the QA-90. Do not attach the printer cable
to the QA-90. See below.
2.3 Power Main On/Off Switch. QA-90 should remain off for at least 5
seconds before switching on again, in order to allow the test circuits
to discharge fully.
2.4 PRO-Soft QA-90 PRO-Soft QA-90 is a front-end test automation and presentation tool
for METRON's QA-90 Electrical Safety Analyzer. It allows you to
conduct the same tests, but by remote control via an IBM-compatible
PC/XT with MS Windows (Version 3.1 or later). Additionally, the
NOTE
Some RS-232C cables are missing
the connection between the se-
venth and the eighth wires in the
cable. The cable may still be called
NULL-modem, but it will not work
with the QA-90. Refer to the PRO-
Soft QA-90 Users Manual for more
information.

2-3
program has additional features to automate and enhance your elec-
trical safety testing.
Each of the QA-90 tests can be run independently from PRO-Soft in
the “Manual” test mode. Results are shown on the PC screen during
testing, and the user is prompted to set the tested equipment accor-
dingly. At the conclusion of tests, the user may print a report, store the
test and results on disk, or both. Combinations of tests can be created
and stored as “Test Sequences.” The program maintains a library of
these sequences. In this way you can store and retrieve sequences that
are appropriate for each kind of equipment being tested at your facili-
ty.
Sequences can then be used independently, or can be attached to a
checklist, written procedure, and equipment data in the form of a test
“Protocol.” The equipment data can be entered manually into the pro-
tocol, or it may be retrieved by PRO-Soft from a database program or
other equipment files. Protocols can be created easily for each item of
equipment in your inventory, and stored for use. Test protocols with
results can be printed, or stored on disk, and the results of testing can
be sent back to the equipment database to close a work order and up-
date the service history.
NOTE
PRO-Soft QA-90 has its own
user manual, which contains all
the information concerning the
program. If you order a demon-
stration version of the program
you also receive the manual.

2-4
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3-1
3. Operating QA-90
This chapter explains the operating controls, switches and menus of
the QA-90, details how to use them in testing, and provides general
information on printouts and operator maintenance.
3.1 Control Switches and
Connections
Front Panel
1. Key Pad
11 alphanumeric keys, used to enter information.
Patient Leads: New window for recording patient inputs.
Clear: Clears the whole display
Return: Deletes the last character
Enter: Records entered data
2. Function Keys
F1-F4 are used to select the functions shown in the menu bar
at the bottom of the display, i.e., for selecting the function that
is directly above the key. F5-F7 are used to select the func-
tion, or enter information in the message field in the same
line.
3 LCD Display Shows messages, test results and function menus.
Max 265 VAC Max 500 VDC

3-2
4 Patient Leads
For connecting patient inputs.
Caution: Max 256 VAC Max 500 VDC can be present
during specified tests
5. Dual
E+ and E-, floating inputs/outputs. These function in the
manner of standard multimeter leads.
6. Encl. Enclosure (for connecting to the casing of the instrument un-
der test).
7. Earth
Extra earth connection for calibrating measuring leads.
8. Contact
For connecting the power plug of the instrument to be tested.
Rear Panel
9. Power Switch
Turns power ON and OFF.
10. RS-232 Serial Port 9-pin D-sub
11. Bar Code Port
9-pin D-sub. HP-Smartwand Interface (TTL).
12. Printer Outlet Port 25 pin D-sub. Centronic output.
13. Mains QA-90
Mains connection for test instrument.
14. Auxiliary Power
Auxiliary power connection for instrument under test.
15. Fuse Mains fuses 2 x 16 Amps @ 220V

3-3
16. Earthing Contact Extra earthing point.
3.2 Key Pad Functions The alphanumeric keys comprise both numbers and letters. Hold the
key in and it moves automatically from character to character.
3.3 Function of The Bar
Code Reader The bar code reader may be used in the main menu and in the patient
lead to record respectively the instrument code and class, module
code, number of leads and type. The program will select the correct
screen display, depending on the bar code format.
The program will give a beep if a wrong format is read.
INSTRUMENT CODE FORMAT
FIELD DESC.
VALUE ACCEPTED
MAX. CHARACTERS
Instrument code alphanumeric 20
Separator + 1 (must be included)
Instrument class CLI, CL2, I.P 3 (must be included)
Example: abcdefg + CL2 Instrument code = abcdefg
Instrument class = CL2
PATIENT LEAD FORMAT
FIELD DESC.
VALUE ACCEPTED
MAX. CHARACTERS
Module code alphanumeric 20
Separator + 1 (must be included)
No. of leads numeric (0-99) 2
Separator + 1 (must be included)
Type BF, CF, B 2 (must be included)
Example: mnopqrst + 2 + B Module code = mnopqrst
Number of leads = 2
Module type = B

3-4
3.4 Menu and Function
Keys The QA-90 uses displays, function keys and a keypad to provide flex-
ibility and control over operations. The top three lines in the display
are used for messages, status and results. The menu bar is shown at
the bottom of the display. Function keys are numbered from F1 to F7.
A function/menu is selected by pressing that key which is directly be-
low/to the right of the menu unit shown in the display.
3.5 Display Menus and
Messages 1. Startup Screen. The following screens will be displayed in se-
quence for the first 10 seconds after the QA-90 has been switched
on.
METRON QA-90 F7
F6
Boot software version: X.XX F5
F1 F2 F3 F4
METRON QA-90 F7
F6
Version: X.XX Date: DD/MM/YYYY F5
F1 F2 F3 F4
METRON QA-90 Electrical Safety Analyzer F7
TOTAL MEMORY : 114688 F6
TOTAL MEMORY USED : 6884 F5
TOTAL FREE SPACE : 107804
F1 F2 F3 F4
2. Main Menu

3-5
Equipment Code : ...> F7
Sequence Name : ...> F6
Class: CL1 ,0 leads in 0 modules.......> F5
MORE MEMORY SETUP START
F1 F2 F3 F4
3.MORE (F1). When MORE (F1) is pressed, the following dis-
play will appear:
Test according to : IEC60601.1 ......> F7
Test Type : Rapid ...........> F6
Test Mode : Automatic .......> F5
GO BACK START
F1 F2 F3 F4
This window offers the following functions:
•Press Test according to (F7) to select either IEC 601.1, IEC
601.2.4, IEC 1010-1, UL 2601.1, IEC61010, AS 3200.1,
HEI 95, ANSI/AAMI, VDE 751 or VDE 751-DEF Standard.
•Press Test Type (F6) to select either Rapid or Normal test
type.
•Press Test Mode (F5) to choose between Automatic and
Manual test.
•Press GO BACK (F2) to return to the previous display.
•Press START (F4) to start the test.
4. MEMORY (F2)
QA-90’s memory is divided into two parts: tests and sequences. If
you have several equivalent instruments to test, you can define one
test sequence for all the instruments and store it as a sequence.
You use this sequence to test all the instruments and store each of
the test results with the instrument’s respective equipment code.
The functions in the MEMORY menus enable you to store, re-
trieve, transfer, print and delete test results and sequences from the
memory. The four main memory displays are as follows.

3-6
Equipment Code : ...> F7
Store test in memory ..................> F6
Display test results ..................> F5
MORE SEQ.MEM TEST MAIN MENU
F1 F2 F3 F4
Equipment Code : ...> F7
Recall and transfer test from memory ..> F6
Recall and print test from memory .....> F5
MORE GO BACK MAIN MENU
F1 F2 F3 F4
Transfer all tests from memory ........> F7
List test in memory to printer ........> F6
Print all tests in memory .............> F5
MORE GO BACK MAIN MENU
F1 F2 F3 F4
Equipment Code : ...> F7
Delete test in memory .................> F6
Delete all tests in memory ............> F5
MORE GO BACK MAIN MENU
F1 F2 F3 F4
The F5 and F6 function keys generate new displays as confirma-
tion of an executed function or error message.
•Press GO BACK (F2) to return to the previous display.
•Press MAIN MENU (F4) to start the test.
The three main sequence displays are shown below.
Sequence name : ...> F7
Store seq. in memory ..................> F6
Print sequence ........................> F5
MORE GO BACK SEQ MAIN MENU