Battery Charger

Theory

Battery Charger Indicator Circuit

The green charger indicator light is located on the C-Arm’s Power Panel and is illuminated, as long as the
C-Arm is connected to the Workstation and the Workstation is plugged into an AC receptacle.

Battery Charger Light Circuit

Battery Charger Modes of Operation

Power Management circuits in the Workstation control the Battery Charger in the C-Arm. There are
basically four Battery Charger modes. Mode selection is based upon the input current and voltage at the
Workstation’s cord cap. The following table describes the relationship between the cord cap and the
voltage and current
Service AC Voltage... Current limited to...
20 Amp Service t 120 VAC 17.6 Amps
 120 VAC 19 Amps
15 Amp Service t 120 VAC 13.2 Amps
 120 VAC 14.5 Amps

The Workstation monitors the input current, and voltage, and sends commands to the Mobile C-Arm’s
Generator Interface PCB (GIB) via ARCNET communication. The GIB then sets the Battery Charger mode
of operation via a control signal.

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Battery Charger Block Diagram

The modes of operation are described in the following table:

Mode Description
Charge Boost Charge Boost mode (CHG_BOOST) is the default mode of Battery Charger
operation and is initiated at system startup. Battery voltage is maintained at 225
VDC. If the batteries are depleted of charge the battery voltage can increase to a
maximum of 235 VDC and charge current can reach a maximum of 3 Amps.
Normal Charge Normal charge mode is initiated by turning Charge Boost mode and Low Charge
mode off. Normal Charge mode maintains battery voltage at 225VDC with a
maximum charge current of 2.5 Amperes.
Low Charge Low Charge mode (LO_CHG_MOD) is initiated by turning Low Charge mode on.
Low Charge mode maintains battery voltage at 225 VDC with a maximum charge
current of 2.0 Amperes.
Off Charge Disable (CHG_DISAB) signal is set high disabling the Battery Charger if the
current drawn by the system is too high.
The GIB will also turn the Battery Charger off locally if the voltage and current are
sensed lower than 212 VDC and 1 Amp.

The HI_CHG_MOD input to the Battery Charger is not used but this mode can be initiated locally by
circuitry on the Battery Charger PCB. High Charge Mode will be initiated if the output current from the
Battery Charger PCB exceeds 1.5 Amps. If initiated the charge voltage is increased to 235 VDC.
The LINE_V_SEN signal is used to read the line voltage at boot-up. If the value read is below 85 VDC or
above 140 VDC an AD Channel Failure message is displayed. The line voltage value is stored in the shot
log along with kV and mA. The shot log is embedded in the debuglog.txt file
The CHG_I_SEN signal is used to measure charging current if the battery voltage falls below 212 VDC. If
the current measures less than 1 Ampere then the GIB disables the Battery Charger PCB for 5 seconds
via the CHG_DISAB signal, essentially acting as a reset.

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Functional Tests
The Mobile C-Arm performs several self tests while booting. If errors are detected an error messages is
written to the Control Panel display. Software monitors the charger during operation and if a failure
occurs issues warnings to the user but allows continued use. The user could continue to deplete the
batteries of charge for 1 – 3 hours without receiving technique error messages.

Boot Test
1. Connect the Interconnect cable to the C-Arm and then plug the Workstation’s power cord into an AC
receptacle.
2. Verify that the Green Battery Charger Light located on the C-Arm’s Power Panel is lit.
3. Boot the system and verify that the CHARGER FAILED error message in not written to the Control
Panel’s VFD.
4. Verify that an AD CHANNEL FAILURE message is not written to the Control Panel’s VFD.

Battery Pack Evaluation Test

Use this test to determine if the battery packs are performing adequately.

WARNING: Steps within this procedure produce X-rays. Use appropriate precautions.

1. Select Film Mode and set the technique for 75 kVp @ 200 mAs.
2. Make an exposure and verify that none of the following messages are displayed:
x X-ray Overtime
x kVp Error
x mA Error
3. With the C-Arm covers removed, make an exposure and verify that the red LED bargraph located on
the Battery Charger PCB indicates 170 to 190 volts, during the shot.

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Battery Charger Evaluation

High Charge Mode

WARNING: Dangerous voltages are present when the covers are removed. Observe safety
precautions stated in the safety section.

WARNING: Steps within this procedure produce X-rays. Use appropriate precautions.

1. Remove the Mobile C-Arm’s covers.

2. Connect a Digital Multimeter to the Filament Driver PCB, TP11 and TP3 (Gnd). Leave it connected for
step 3.
3. Select FLUORO MANUAL mode and observe the Voltage Bargraph Indicator while making an
exposure at 100 kVp and 5 mA. Verify that, after the exposure, approximately 235 VDC is indicated.
4. During the exposure, verify the Current Bargraph Indicator displays a charging current greater than
450 mA
5. After the exposure, ensure that the DVM indicates that the charging voltage is 235 ± 2 VDC. This will
drop to 225 VDC after the battery charge is topped-off.

Troubleshooting

Battery Charger Troubleshooting Table

Perform Test Failure
Boot Test Battery Charger Light does not
illuminate
Charger Failed Error Message
AD Channel Failure Message
Battery Pack Evaluation Test Error Message Displayed
Bargraph voltage measures less
than 170 VDC.
Possible Cause
Charger light is burned out
Fuse F2 or F4 blown on Power Signal
Interface
Faulty wiring connection
CB1 Blown
Batteries undervoltage or overvoltage
Battery Charger PCB
The line voltage was below 85 VDC or
above 140 VDC. Retrieve debuglog.txt file
to verify measured voltage.
Batteries
If the bargraph voltage indicates less
than 170 Volts, measure across the
battery terminal with a DMM while
making an exposure. If the batteries
measure less than 170 Volts, weak
battery packs or a fault with the Battery
Charger PCB may be indicated.

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Perform Test Failure Possible Cause

Battery Charger Evaluation Battery Charger Fails Check Charger 12 VDC Power Supply
Battery Charger PCB