Abbott Abbott 4100 PCA Plus II Service Manual Abbott 4100 PCA Plus II Service Manual

ABBOTT LABORATORIES - HPD

ABBOTT LABORATORIES - HPD

TECHNICAL SUPPORT OPERATIONS

TECHNICAL SUPPORT OPERATIONS

ELECTRONIC TECHNICAL SERVICE MANUAL

ELECTRONIC TECHNICAL SERVICE MANUAL

PCA Plus

and Plus II

Series Infusers

EPS-04502-003 (Rev. 4/99)

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TO CONTINUE

LifeCare 4100

PCA PLUS AND PLUS II

SERIES INFUSERS

For use with list 1950-04

1950-13

Technical
Service
Manual

Abbott Laboratories
North Chicago, IL 60064
USA

430-04502-003 (Rev. 4/99)

©Copyright 1999 Abbott Laboratories AllRights Reserved
Thisdocumentandthesubjectmatterdisclosedhereinareproprietaryinformation.AbbottLaboratories

retainsalltheexclusiverightsofdissemination,reproduction,manufactureandsale.Anypartyusingthis
documentacceptsitinconfidence,andagreesnottoduplicateitinwholeorinpartnordiscloseitto
otherswithoutthe writtenconsent of AbbottLaboratories.

430-04502-003 (Rev. 4/99) LifeCare PCA Plus and Plus II Series Infusers

ChangeHistory

Insert

Removeand Change

PartNumber Descriptionof Change Destroy Pages Pages

430-04502-001(Rev.6/93) Originalrelease.Thismanual

replacesmanualpart numbers
430-04461-001(Rev.6/91)and
430-04287-002(Rev.1/91).

430-04502-A01 Updated cover andcopyrightpageCover Cover

onthereverse side
Updated Change History i,ii i,ii
Updated PCA+CONTINUOUS 5-7, 5-8 5-7, 5-8

test
UpdateSyringeEmpty Switch 7-9, 7-10 7-9, 7-10

Adjustment Procedureandreverse
side page

Note:Stand-alonechangepagesare identifiedaspartnumber 450-04502-A01.
Abbott-assembledmanualswhich containchangepagesare identifiedonthecoverpage as
partnumber 430-04502-A01.

430-04502-B01 Updated cover andcopyright Cover Cover

Updated Change History and itoviii itoviii
Contents

RevisedSection1 1-1 to1-4 1-1 to1-6
Updated Section4.3.3 4-15, 4-16 4-15, 4-16
Updated Table5-1 5-1 to5-4 5-1 to5-4
Updated Section6.1 6-1, 6-2 6-1, 6-2
Updated Section7.2.7.4 7-15, 7-16 7-15, 7-16
Updated Section7.3.19 7-28, 7-29 7-27 to7-30
Updated Section7.3.43 7-53, 7-54 7-53, 7-54
Added index I-1 toI-6
Updated back page Back page Back page

Note:Stand-alonechangepagesare identifiedaspartnumber 450-04502-B01.
Abbott-assembledmanualswhich containchangepagesare identifiedonthecoverpage as
partnumber 430-04502-B01.

TechnicalServiceManual i 430-04502-003(Rev.4/99)

CHANGE HISTORY

Part Number Description of Change

430-04502-002 (Rev. 2/95) Second issue

430-04502-003 (Rev. 4/99) Third issue

Remove and
Destroy Pages

Insert
Change
Pages

430-04502-003 (Rev. 4/99) ii LifeCare PCA Plus and Plus II Series Infusers

Contents

Section1

INTRODUCTION...... ...... ...... .......... 1 - 1

1.1SCOPE ...... ...... ...... .......... 1 - 1

1.2CONVENTIONS... ...... ...... ...... .... 1 - 2

1.3ACRONYMS ANDABBREVIATIONS. ...... ...... .... 1 - 2

1.4USERQUALIFICATION...... ...... ...... .... 1 - 4

1.5ARTIFACTS .... ...... ...... ...... .... 1 - 4

1.6INSTRUMENTINSTALLATIONPROCEDURE ... ...... .... 1 - 5

1.6.1 UNPACKING . ...... ...... ...... .... 1 - 5

1.6.2 INSPECTION . ...... ...... ...... .... 1 - 5

1.6.3 SELFTEST .. ...... ...... ...... .... 1 - 6

Section2

WARRANTY.. ...... ...... ...... ...... .... 2 - 1

Section3

SYSTEM OPERATING MANUAL ...... ...... ...... .... 3 - 1

Section4

THEORYOF OPERATION... ...... ...... ...... .... 4 - 1

4.1GENERALFUNCTIONS...... ...... ...... .... 4 - 1

4.1.1 STARTING OPERATION... ...... ...... .... 4 - 1

4.1.1.1WARM-STARTSEQUENCE ..... ...... .... 4 - 1

4.1.1.2COLD-STARTSEQUENCE ..... ...... .... 4 - 1

4.1.2 SETUP.... ...... ...... ...... .... 4 - 2

4.1.3 DELIVERYMECHANISM... ...... ...... .... 4 - 2

4.1.4 PATIENT CONTROLLEDANALGESIA(PCA) . ...... .... 4 - 2

4.1.5 STATUSMESSAGES .... ...... ...... .... 4 - 2

4.2ELECTRONICSOVERVIEW .... ...... ...... .... 4 - 3

4.2.1 CPU/DISPLAYPWA..... ...... ...... .... 4 - 3

4.2.1.1CPU/DISPLAYPWASYSTEMINTERFACES..... .... 4 - 4

4.2.1.2MICROPROCESSORCIRCUITRY... ...... .... 4 - 5

4.2.1.3CHIPSELECTCIRCUITRY ..... ...... .... 4 - 5

4.2.1.4ANALOG-TO-DIGITALCONVERTER (ADC) .... .... 4 - 6

4.2.1.5LCDDISPLAYINTERFACE ..... ...... .... 4 - 6

4.2.1.6LEDDISPLAYCIRCUIT ...... ...... .... 4 - 7

4.2.1.7WATCHDOG CIRCUIT. ...... ...... .... 4 - 7

4.2.2 POWERSUPPLYPWA .... ...... ...... .... 4 - 7

4.2.2.1POWERSUPPLYPWASYSTEM INTERFACES .... .... 4 - 8

4.2.2.2UNREGULATEDDC VOLTAGE ... ...... .... 4 - 8

4.2.2.3ON/OFF LATCH ... ...... ...... .... 4 - 8

4.2.2.4PRINTERDATALATCH ...... ...... .... 4 - 8

4.2.2.5MOTORDRIVER... ...... ...... .... 4 - 9

4.2.2.68255PROGRAMMABLEPERIPHERALINTERFACE .. .... 4 - 9

4.2.3 BATTERYBOOSTCHARGERPWA ..... ...... .... 4 - 9

4.2.3.1ACOPERATION ... ...... ...... .... 4 - 10

4.2.3.2DC OPERATION ... ...... ...... .... 4 - 10

4.3MECHANICSOVERVIEW..... ...... ...... .... 4 - 10

4.3.1 SLIDEASSEMBLY ..... ...... ...... .... 4 - 11

4.3.1.1MOTORASSEMBLY.. ...... ...... .... 4 - 12

4.3.1.2SLIDEMECHANISM . ...... ...... .... 4 - 13

TechnicalServiceManual iii 430-04502-003(Rev.4/99)

Contents

4.3.1.3CRADLEASSEMBLY . ...... ...... .... 4 - 13

4.3.2 SYRINGELOWANDSYRINGEEMPTYALARMSYSTEM .. .... 4 - 13

4.3.3 OCCLUSIONPRESSURE ALARMSYSTEM .. ...... .... 4 - 15

4.3.4 VIALAND INJECTORSENSOR ALARMSYSTEM ..... .... 4 - 17

4.3.4.1CHECKVIALALARM . ...... ...... .... 4 - 17

4.3.4.2CHECKINJECTORALARM..... ...... .... 4 - 18

4.3.4.3CHECKSYRINGEALARM ..... ...... .... 4 - 18

4.4BATTERYOPERATION OVERVIEW . ...... ...... .... 4 - 18

Section5

MAINTENANCEANDSERVICETESTS ... ...... ...... .... 5 - 1

5.1PREVENTIVEMAINTENANCE ... ...... ...... .... 5 - 1

5.1.1 INSPECTING THEINFUSER . ...... ...... .... 5 - 1

5.1.2 CLEANINGTHEINFUSER .. ...... ...... .... 5 - 2

5.1.3 SANITIZINGTHE INFUSER.. ...... ...... .... 5 - 3

5.2PERFORMANCEVERIFICATION TEST...... ...... .... 5 - 3

5.2.1 EQUIPMENT REQUIRED... ...... ...... .... 5 - 3

5.2.2 INSPECTION . ...... ...... ...... .... 5 - 4

5.2.3 INFUSERTESTSETUP.... ...... ...... .... 5 - 4

5.2.4 SERVICETESTMODETEST.. ...... ...... .... 5 - 4

5.2.5 DELIVERYACCURACY TEST . ...... ...... .... 5 - 6

5.2.6 OCCLUSIONTEST ..... ...... ...... .... 5 - 7

5.2.7 PCA+ CONTINUOUS TEST.. ...... ...... .... 5 - 8

5.2.8 PATIENT CONTROLJACKTEST...... ...... .... 5 - 9

5.2.9 PATIENT PENDANTASSEMBLYTEST ... ...... .... 5 - 9

5.2.10BATTERYCHARGERTEST .. ...... ...... .... 5 - 10

5.2.11ELECTRICAL SAFETYTEST.. ...... ...... .... 5 - 10

5.2.12PRINTERTEST. ...... ...... ...... .... 5 - 11

5.2.13ENDOFPERFORMANCEVERIFICATIONTEST ...... .... 5 - 12

5.3PVTDATAFORM .. ...... ...... ...... .... 5 - 13

Section6

TROUBLESHOOTING .... ...... ...... ...... .... 6 - 1

6.1TECHNICAL ASSISTANCE .... ...... ...... .... 6 - 1

6.2DIAGNOSTIC MODE. ...... ...... ...... .... 6 - 1

6.3ALARMANDDISPLAYMESSAGE OVERVIEW... ...... .... 6 - 2

6.3.1 AUDIBLE ALARMS..... ...... ...... .... 6 - 3

6.3.2 ALARMCAUSESAND ACTIONS...... ...... .... 6 - 3

6.3.3 MALFUNCTION CODES ... ...... ...... .... 6 - 3

6.4INFUSERTROUBLESHOOTING .. ...... ...... .... 6 - 5

6.5PVTTROUBLESHOOTING .... ...... ...... .... 6 - 8

Section7

REPLACEABLEPARTSAND REPAIRS.... ...... ...... .... 7 - 1

7.1REPLACEABLEPARTSLIST .... ...... ...... .... 7 - 1

7.2ADJUSTMENTPROCEDURES ... ...... ...... .... 7 - 3

7.2.1 REQUIREDTOOLSANDMATERIALS.... ...... .... 7 - 3

7.2.2 SEPARATINGFRONT ANDREAR CASEASSEMBLIES ... .... 7 - 4

7.2.3 INJECTORSENSORSWITCHADJUSTMENT . ...... .... 7 - 5

7.2.4 VIALSENSOR SWITCH ADJUSTMENT ... ...... .... 7 - 7

7.2.5 SYRINGELOWSWITCHADJUSTMENT(PCAPLUSONLY).. .... 7 - 9

7.2.6 SYRINGEEMPTY SWITCHADJUSTMENT .. ...... .... 7 - 10

7.2.7 OCCLUSIONALARM SWITCHTESTANDADJUSTMENT .. .... 7 - 12

7.2.7.1MODIFYINGTHESYRINGE..... ...... .... 7 - 12

430-04502-003(Rev.4/99) iv LifeCarePCAPlusandPlusIISeriesInfusers

7.2.7.2OCCLUSIONALARM SWITCHTEST . ...... .... 7 - 13

7.2.7.3OCCLUSIONALARM SWITCHANDPRESSURE

ADJUSTMENT(-008AND LOWER) .. ...... .... 7 - 14

7.2.7.4OCCLUSIONALARM SWITCHANDPRESSURE

ADJUSTMENT(-010AND HIGHER).. ...... .... 7 - 16

7.2.8 LCDINTENSITYADJUSTMENT ...... ...... .... 7 - 17

7.2.9 SETTING THEREALTIMECLOCK(PCAPLUSII) ..... .... 7 - 18

7.2.10DOOR LOCKSWITCHADJUSTMENT.... ...... .... 7 - 19

7.2.11LEADSCREWLUBRICATION. ...... ...... .... 7 - 20

7.3REPLACEMENTPROCEDURES... ...... ...... .... 7 - 20

7.3.1 SAFETYANDEQUIPMENTPRECAUTIONS.. ...... .... 7 - 20

7.3.2 REQUIREDTOOLSANDMATERIALS.... ...... .... 7 - 21

7.3.3 SEPARATINGFRONT ANDREAR CASEASSEMBLIESFOR

REPLACEMENTPROCEDURES ...... ...... .... 7 - 21

7.3.4 BATTERYPACKCOVERREPLACEMENT .. ...... .... 7 - 21

7.3.5 BATTERYPACKREPLACEMENT...... ...... .... 7 - 22

7.3.6 FUSEREPLACEMENT .... ...... ...... .... 7 - 23

7.3.7 POLECLAMPASSEMBLYREPLACEMENT .. ...... .... 7 - 24

7.3.8 VELCROSTRAPAND RETAINER PLATEREPLACEMENT .. .... 7 - 25

7.3.9 SECURITY DOORREPLACEMENT ..... ...... .... 7 - 25

7.3.10SECURITY DOORLATCHREPLACEMENT.. ...... .... 7 - 26

7.3.11PATIENT PENDANTCONTROLCABLEREPLACEMENT... .... 7 - 26

7.3.12ACPOWERCORD REPLACEMENT..... ...... .... 7 - 26

7.3.13ACPOWERCORD PLUGREPLACEMENT .. ...... .... 7 - 27

7.3.14GASKET SEALREPLACEMENT ...... ...... .... 7 - 27

7.3.15POWERSUPPLYPWAREPLACEMENT ... ...... .... 7 - 28

7.3.16CPU/DISPLAYPWAREPLACEMENT .... ...... .... 7 - 29

7.3.17LEDREPLACEMENT .... ...... ...... .... 7 - 30

7.3.18LCDASSEMBLY REPLACEMENT...... ...... .... 7 - 31

7.3.1940PIN RIBBONCABLEREPLACEMENT ... ...... .... 7 - 31

7.3.2015CONDUCTORDIAGNOSTICCABLEREPLACEMENT... .... 7 - 32

7.3.21CRADLEASSEMBLYREPLACEMENT.... ...... .... 7 - 33

7.3.22VIALSENSOR SWITCH REPLACEMENT... ...... .... 7 - 34

7.3.23SLIDECLAMPKNOBAND LEVERREPLACEMENT(-008 ANDLOWER). 7 - 35

7.3.24SLIDECLAMPLEVERREPLACEMENT(-010 ANDHIGHER) . .... 7 - 36

7.3.25SYRINGELOWANDSYRINGEEMPTYSWITCHREPLACEMENT ... 7 - 37

7.3.26OCCLUSIONPRESSURE SWITCHREPLACEMENT..... .... 7 - 38

7.3.27INJECTORSENSORSWITCHREPLACEMENT. ...... .... 7 - 39

7.3.28MOTORASSEMBLYREPLACEMENT (-008AND LOWER) .. .... 7 - 39

7.3.29MOTORASSEMBLYREPLACEMENT (-010AND HIGHER) .. .... 7 - 41

7.3.30SLIDEASSEMBLYREPLACEMENT(-008 ANDLOWER) ... .... 7 - 43

7.3.31SLIDEASSEMBLYREPLACEMENT(-010 ANDHIGHER)... .... 7 - 44

7.3.32INJECTORFLANGECLAMPREPLACEMENT . ...... .... 7 - 45

7.3.33PRINTER/DATAWAYCONNECTORANDCONTROL PANEL

HARNESSREPLACEMENT.. ...... ...... .... 7 - 46

7.3.34PIEZOELECTRICALARMREPLACEMENT .. ...... .... 7 - 48

7.3.35PATIENT PENDANTJACKREPLACEMENT.. ...... .... 7 - 49

7.3.36AUDIBLE LEVELSWITCHREPLACEMENT.. ...... .... 7 - 50

7.3.37INTERCONNECTPWAREPLACEMENT ... ...... .... 7 - 51

7.3.38INTERCONNECTPWACABLEREPLACEMENT ...... .... 7 - 52

7.3.39BATTERYBOOSTCHARGERPWAREPLACEMENT .... .... 7 - 53

7.3.40FRONTPANELREPLACEMENT ...... ...... .... 7 - 53

7.3.41DOOR LOCKSWITCHREPLACEMENT ... ...... .... 7 - 54

7.3.42DOOR LOCKASSEMBLYREPLACEMENT .. ...... .... 7 - 56

7.3.43CHANGINGTHEKEYNUMBER...... ...... .... 7 - 57

7.3.44DOOR LATCH ASSEMBLY REPLACEMENT.. ...... .... 7 - 58

7.3.45REARCASEASSEMBLYREPLACEMENT... ...... .... 7 - 59

TechnicalServiceManual v 430-04502-003(Rev.4/99)

Contents

7.3.46FRONTCASEASSEMBLY REPLACEMENT .. ...... .... 7 - 60

7.3.47RUBBER FOOT PADREPLACEMENT .... ...... .... 7 - 61

Section8

SPECIFICATIONS...... ...... ...... .......... 8 - 1

8.1PCAPLUS ..... ...... ...... ...... .... 8 - 1

8.2PCAPLUSII .... ...... ...... ...... .... 8 - 2

Section9

DRAWINGS.. ...... ...... ...... ...... .... 9 - 1

Section10

INDEX .... ...... ...... ...... ...... .... I - 1

430-04502-003(Rev.4/99) vi LifeCarePCAPlusandPlusIISeriesInfusers

Figures

Figure 4-1.InfuserSlide Assembly(-008 andLower) ..... ...... .... 4 - 11

Figure 4-2.InfuserSlide Assembly(-010 andHigher)..... ...... .... 4 - 12

Figure 4-3.Syringe Low andSyringe Empty AlarmSystem (-008and Lower) .. .... 4 - 14

Figure 4-4.Syringe Empty AlarmSystem(-010 andHigher)... ...... .... 4 - 15

Figure 4-5.OcclusionPressureAlarmSystem (-008and Lower) . ...... .... 4 - 16

Figure 4-6.OcclusionPressureAlarmSystem (-010and Higher) . ...... .... 4 - 17

Figure 5-1.Modification of Syringe Plunger .. ...... ...... .... 5 - 7

Figure 5-2.SamplePrinterTest. ...... ...... ...... .... 5 - 12

Figure 6-1.SampleEvent Log and MalfunctionLog ..... ...... .... 6 - 2

Figure 7-1.SeparatingFrontandRearCase Assemblies .... ...... .... 7 - 5

Figure 7-2.Injector Sensor Switch (-008and Lower) ..... ...... .... 7 - 6

Figure 7-3.Injector Sensor Switch (-010and Higher) ..... ...... .... 7 - 7

Figure 7-4.Vial SensorSwitch and Syringe Low Switch (-008and Lower) ... .... 7 - 8

Figure 7-5.Vial SensorSwitch (-010 andHigher) ...... ...... .... 7 - 9

Figure 7-6.Syringe Empty Switch (-008and Lower). ...... ...... ... 7 - 11

Figure 7-7.Syringe Empty Switch (-010and Higher) ..... ...... .... 7 - 12

Figure 7-8.Modification of Syringe Plunger .. ...... ...... .... 7 - 13

Figure 7-9.OcclusionAlarmTestSetup.... ...... ...... .... 7 - 14

Figure 7-10.OcclusionAlarmPressure Adjustment(-008and Lower) ..... .... 7 - 15

Figure 7-11.OcclusionAlarmPressure Adjustment(-010and Higher) ..... .... 7 - 17

Figure 7-12.CPU/Display PWA,LED, andLCD Assembly ... ...... .... 7 - 18

Figure 7-13.BatteryPack Replacement .... ...... ...... .... 7 - 22

Figure 7-14.ReplaceableParts on Backof Infuser ...... ...... .... 7 - 24

Figure 7-15.Power SupplyPWAandCPU Display PWA.... ...... .... 7 - 29

Figure 7-16.15ConductorDiagnosticCable... ...... ...... .... 7 - 33

Figure 7-17.CradleAssembly Replacement... ...... ...... .... 7 - 34

Figure 7-18.Location of Slide ClampHandle AllenScrews (-008and Lower)... .... 7 - 36

Figure 7-19.Motor Assembly Replacement(-008and Lower) .. ...... .... 7 - 40

Figure 7-20.Motor Assembly Replacement(-010and Higher) .. ...... .... 7 - 42

Figure 7-21.Location of Slide Assembly Mounting Bolts.... ...... .... 7 - 42

Figure 7-22.Printer/DatawayConnector, ControlPanelHarness, andPiezoelectric

AlarmReplacement ...... ...... ...... .... 7 - 47

Figure 7-23.Interconnect PWAand BatteryBoostChargerPWAReplacement .. .... 7 - 52

Figure 7-24.Front Panel Replacement..... ...... ...... .... 7 - 54

Figure 7-25.Door Latch Assembly(Type A)... ...... ...... .... 7 - 55

Figure 7-26.Door Latch Assembly(Type B)... ...... ...... .... 7 - 56

Figure 7-27.Door Lock Assembly ...... ...... ...... .... 7 - 57

Figure 7-28.Door Latch Torsion Spring Placement(TypeA)... ...... .... 7 - 59

Figure 9-1.IPBfor the Infuser . ...... ...... ...... .... 9 - 9

Figure 9-2.Block Diagram,PCAII...... ...... ...... .... 9 - 41

Figure 9-3.Interconnect Schematic,PCAII (2 sheets) ..... ...... .... 9 - 43

Figure 9-4.CPU,PWASchematic,LC 4100/4200 . ...... ...... .... 9 - 47

Figure 9-5.Power SupplyPWASchematic, PCAII(8 sheets) .. ...... .... 9 - 49

Figure 9-6.CurrentBoostChargerSchematic,MDL 4/PCA... ...... .... 9 - 65

Figure 9-7.Interconnect PWASchematic ... ...... ...... .... 9 - 67

TechnicalServiceManual vii 430-04502-003(Rev.4/99)

Contents

Tables

Table1-1.Conventions .... ...... ...... ...... .... 1 - 2

Table4-1.Status Messages andDefinitions... ...... ...... .... 4 - 2

Table4-2.CPU/Display PWAControl Signals.. ...... ...... .... 4 - 6

Table5-1.Cleaning Solutions.. ...... ...... ...... .... 5 - 2

Table5-2.Service Tests.... ...... ...... ...... .... 5 - 5

Table5-3.Service Options... ...... ...... ...... .... 5 - 6

Table6-1.Malfunction Codes.. ...... ...... ...... .... 6 - 4

Table6-2.InfuserTroubleshooting...... ...... ...... .... 6 - 5

Table6-3.Troubleshooting with the PVT ... ...... ...... .... 6 - 8

Table9-1.Drawings ..... ...... ...... ...... .... 9 - 1

Table9-2.IPBfor theInfuser.. ...... ...... ...... .... 9 - 2

430-04502-003(Rev.4/99) viii LifeCarePCAPlusandPlusIISeriesInfusers

Section1

INTRODUCTION

TheLifeCare®PCAPlusandPlusIISeriesInfusers,hereinreferredtoastheinfuser,provide
analgesic deliverytopatientsthroughtheintravenousorepiduralroutesinawiderange
ofclinicalsettings.

1.1

SCOPE

Thismanualisorganized into11 sectionsas follows:

❏Section1 Introduction ❏Section2 Warranty ❏Section3 SystemOperating Manual ❏Section4 TheoryofOperation ❏Section5 MaintenanceandService Tests ❏Section6 Troubleshooting ❏Section7 ReplaceableParts andRepairs ❏Section8 Specifications ❏Section9 Drawings ❏Section10 Index ❏Technical Service Bulletins

Ifaproblemintheinfuseroperationcannotberesolvedusingtheinformationinthis
manual,contactAbbottLaboratoriesTechnicalSupportOperations(seeSection6.1,

TechnicalAssistance).

Thesystemoperatingmanualcontainsspecificinstructionsforoperatingtheinfuser.
ProvisionismadeforinclusionofthesystemoperatingmanualinSection3ofthismanual.

Note:Figuresarerenderedasgraphicrepresentationstoapproximatetheactualproduct;
therefore,figuresmaynotexactlyreflecttheproduct.Displayscreensandtouchswitch
labelsmay vary slightly,dependingontheconfigurationof theinfuserinuse.

TechnicalServiceManual 1 -1 430-04502-003 (Rev. 4/99)

Section1INTRODUCTION

1.2

CONVENTIONS

TheconventionslistedinTable1-1,Conventions, are usedthroughoutthismanual.

Table1-1. Conventions

Convention Application Example

Italic

[ALLCAPS] Touchswitchlabels onthe infuser

ALL CAPS Screen displays (as appropriate) ADMINISTERLOADINGDOSE

Bold Emphasis CAUTION:Infuser damage may

Throughoutthismanual,warnings,cautions,andnotesareusedtoemphasizeimportant
informationas follows:

Reference to a section, figure,
table,or publication

are describedinallcaps and
enclosed inbrackets

Removepower supply PWA and
CPU/display PWAas described in

Section 7.3.15, Power Supply
PWA Replacement

[LOADINGDOSE]

NOW?

occurunless propercareis
exercised duringunpacking,
inspection,and self test

WARNING

AWARNINGCONTAINSSPECIALSAFETYEMPHASISANDMUSTBEOBSERVEDAT
ALLTIMES. FAILURETOOBSERVEAWARNINGISPOTENTIALLYLIFE
THREATENING.

CAUTION:ACAUTIONusuallyappearsinfrontofaprocedureorstatementand
containsinformationthatcouldpreventirreversibleequipmentdamageorfailure.

Note:A note highlights informationthathelpsexplaina conceptorprocedure.

1.3

ACRONYMSANDABBREVIATIONS

Acronymsandabbreviationsused inthis manualareas follows:

AC Alternating current
ADC Analog-to-digitalconverter
BRD Busread

BWR Buswrite

430-04502-003 (Rev. 4/99) 1 -2 LifeCarePCAPlusandPlusII SeriesInfusers

ACRONYMS ANDABBREVIATIONS

cm Centimeter

CPU Central processor unit

CS Chip select
dB Decibel

DC Direct current

DISBATT Disable battery

DPM Digitalpressuremeter

ECG Electroencephalogram
EKG Electrocardiograph

EMG Electromyogram

EPROM Erasable/programmable read-onlymemory

ESD Electrostaticdischarge

ETO Ethyleneoxide

Hr Hour

IC Integratedcircuit

INJECTORSW Injector switch

I/O Input/output

kPa Kilopascal
LCD Liquid crystaldisplay
LED Lightemittingdiode

LIM Limit

LOBAT,LOWBATT Lowbattery

mA Milliampere

MALF Malfunction

MCS Main controlswitch

mg Milligram

MHz Megahertz

mL Milliliter
MOTO1 Motor 1
MOTO2 Motor 2
MOTO3 Motor 3
MOTO4 Motor 4

ms Millisecond

mV Millivolt

OFF/RECHG Off/recharge

PCA Patient-controlledanalgesia

PPI Programmableperipheralinterface

PRESSURESW Pressureswitch

TechnicalServiceManual 1 -3 430-04502-003 (Rev. 4/99)

Section1INTRODUCTION

psi Poundsper squareinch

psig Poundsper squareinch gauge

PVT Performance verificationtest

PWA Printed wiring assembly

RAM Random-accessmemory

RD Read

ROM Read-onlymemory

SYRINGEEMPTYSW Syringe empty switch

SYRINGELO Syringe low

SYRINGELOSW Syringe lowswitch

V Volt

VDC Volt, direct current

VIALSW Vialswitch

VIAL/INJT Vial/injector

VRECT Voltage rectified

VAC Volt, alternatingcurrent

WR Write

µg

µs

Microampere
Microgram
Microsecond

µA

1.4

USERQUALIFICATION

Theinfusersareforuseatthedirectionorunderthesupervisionoflicensedphysicians
orbylicensedorcertifiedhealthcareprofessionalswhoaretrainedintheuseoftheinfusers
andtheadministration ofparenteralorenteralfluidsordrugs.

1.5

ARTIFACTS

Nonhazardous,low-levelelectricalpotentialsarecommonlyobservedwhenfluidsare
administeredusinginfusiondevices.Thesepotentialsarewellwithinacceptedsafety
standards,butmaycreateartifactsonvoltage-sensingequipmentsuchasECG,EMG,and
EEGmachines.Theseartifactsvaryataratethat isassociatedwith theinfusionrate.If
themonitoringmachineisnotoperatingcorrectlyorhaslooseordefectiveconnectionsto
itssensingelectrodes,theseartifactsmaybeaccentuatedsoastosimulateactual
physiologicalsignals.Todetermineiftheabnormalityinthemonitoringequipmentis
causedbytheinfusiondeviceinsteadofsomeothersourceintheenvironment,setthe
infusiondevicesothatitistemporarilynotdeliveringfluid. Disappearanceofthe
abnormalityindicatesthatitwasprobablycausedbyelectronicnoisegeneratedbythe
infusiondevice. Propersetupandmaintenanceofthemonitoringequipmentshould

430-04502-003 (Rev. 4/99) 1 -4 LifeCarePCAPlusandPlusII SeriesInfusers

INSTRUMENT INSTALLATIONPROCEDURE

eliminatetheartifact.Refertotheappropriatemonitoringsystemdocumentationforsetup
andmaintenance instructions.

1.6

INSTRUMENT INSTALLATION
PROCEDURE

CAUTION:Infuserdamagemayoccurunlesspropercareisexercisedduringproduct
unpacking,inspection,andselftest.Thebatterymaynotbefullychargedupon
receiptoftheinfuser.Donotplacetheinfuserinserviceifitfailstheselftest.

Theinfuserinstallationprocedureconsistsofunpacking, inspection,andself test.
Note:Donotplacetheinfuserinserviceifthebatteryisnotfullycharged.Tomake

certainthebattery isfullycharged, connect theinfusertoACpower for24 hours.

1.6.1

UNPACKING

InspecttheinfusershippingcontainerasdetailedinSection1.6.2,Inspection.Usecare
whenunpackingtheinfuser.Retainthepackingslipandsaveallpackingmaterialinthe
eventitisnecessarytoreturntheinfusertothefactory.Verifythattheshippingcontainer
containsa copy ofthesystem operatingmanual.

1.6.2

INSPECTION

Inspecttheinfusershippingcontainerfordamagepriortoopening.Shouldanydamage
be found, contactthedelivering carrier immediately.

Inspecttheinfuserforevidenceofdamage.Donotusetheinfuserifitappearstobe
damaged.Shoulddamagebefound,contactAbbottLaboratories(seeSection6.1,Technical

Assistance).

Inspecttheinfuserperiodicallyforsignsofdefectssuchaswornaccessories,broken
connections,ordamagedcableassemblies.Alsoinspecttheinfuserafterrepairorduring
cleaning.Replaceany damaged or defective externalparts.

TechnicalServiceManual 1 -5 430-04502-003 (Rev. 4/99)

Section1INTRODUCTION

1.6.3

SELFTEST

CAUTION:Donotplacetheinfuserinserviceiftheselftestfails.

Toconducttheinfuserself test,proceedas follows:

1.Unlock and openthesecurity door.

2.ConnectACpowercordtoaproperlygroundedACoutlet.ConfirmthattheAC
powersymbolonthefrontpanelis illuminated.

3.Pressandreleasethe[ON]touchswitch.Theinfuserperformsaselftestverifying
itsfunctionalintegrity.Iftheinfuserfailstheselftest,donotplaceitinservice;

contactAbbottLaboratories.

4.PCAPlusIIonly:SettherealtimeclockasdescribedinSection7.2.9,Settingthe

Real TimeClock(PCAPlus II).

Note:Toassurethebatteryisfullycharged,connecttheinfusertoACpowerfor24hours
before placing itinservice.

430-04502-003 (Rev. 4/99) 1 -6 LifeCarePCAPlusandPlusII SeriesInfusers

Section2

WARRANTY

Subjecttothetermsandconditionsherein,AbbottLaboratories,hereinreferredtoas
Abbott,warrantsthat(a)theproductshallconformtoAbbott'sstandardspecifications
andbefreefromdefectsinmaterialandworkmanshipundernormaluseandservicefor
aperiodofoneyearafterpurchase,and(b)thereplaceablebatteryshallbefreefromdefects
inmaterialandworkmanshipundernormaluseandserviceforaperiodof90days after
purchase.Abbottmakesnootherwarranties,expressorimplied,astomerchantability,
fitness for a particular purpose, or anyothermatter.

Purchaser'sexclusiveremedyshallbe,atAbbott'soption,therepairorreplacementofthe
product.Innoeventshall Abbott'sliability arising outofanycausewhatsoever(whether
suchcausebebasedincontract,negligence,strictliability,othertortorotherwise)exceed
thepriceofsuchproduct,andinnoeventshallAbbottbeliableforincidental,
consequential,orspecialdamagesorlossesorforlostbusiness,revenues,orprofits.
WarrantyproductreturnedtoAbbottmustbeproperlypackagedandsentfreightprepaid.

Theforegoingwarrantyshallbevoidintheeventtheproducthasbeenmisused,damaged,
altered,orusedotherthaninaccordancewithproductmanualssoas,inAbbott's
judgment,toaffectitsstabilityorreliability,orintheeventtheserialorlotnumberhas
been altered,effaced,orremoved.

Theforegoingwarrantyshallalsobevoidintheeventanyperson,includingthePurchaser,
performsorattemptstoperformanymajorrepairorotherserviceontheproductwithout
havingbeentrainedbyanauthorizedrepresentativeofAbbottandusingAbbott
documentationandapprovedspareparts.Forpurposesoftheprecedingsentence,"major
repairorotherservice"meansanyrepairorserviceotherthanthereplacementofaccessory
itemssuchasbatteries,flowdetectors,detachableACpowercords,andpatientpendants.

Inprovidinganypartsforrepairorserviceoftheproduct,Abbottshallhave no
responsibilityorliabilityfortheactionsorinactionsofthepersonperformingsuchrepair
orservice, regardless ofwhethersuchpersonhasbeentrained toperformsuchrepairor
service. ItisunderstoodandacknowledgedthatanypersonotherthananAbbott
representative performing repair or serviceisnotan authorizedagentofAbbott.

TechnicalServiceManual 2-1 430-04502-003(Rev.4/99)

Section2WARRANTY

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430-04502-003(Rev.4/99) 2-2 LifeCarePCAPlusandPlusIISeriesInfusers

Section3

SYSTEM OPERATINGMANUAL

A copyof the systemoperatingmanualis includedwith everyinfuser.Insertacopyhere
forconvenientreference.Ifacopyofthesystemoperatingmanualisnotavailable,contact
AbbottLaboratoriesTechnicalSupportOperations(seeSection6.1,TechnicalAssistance).

TechnicalServiceManual 3 -1 430-04502-003 (Rev. 4/99)

Section3SYSTEM OPERATINGMANUAL

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430-04502-003(Rev.4/99) 3-2 LifeCarePCAPlusandPlusIISeriesInfusers

Section4

THEORYOF OPERATION

ThissectiondescribestheprinciplesofoperationfortheLifeCarePCAPlusandPlusII
SeriesInfusers. Relateddrawingsare provided inSection9,Drawings.

4.1

GENERALFUNCTIONS

Thissectiondescribesthegeneralfunctionsoftheinfuser(seeFigure9-2,BlockDiagram,

PCA II).

4.1.1

STARTINGOPERATION

Theinfuserispoweredonbyinsertingorremovingavial,orbypressingthe
[ON]touchswitch.Oncepoweredon,theinfuserbeginsawarm-startoracold-start
sequence,dependingonthetimeelapsedsincethe[OFF/RECHG]touchswitchwaslast
pressed.

4.1.1.1

WARM-STARTSEQUENCE

Theinfuserinitiatesawarm-startsequenceifitispoweredonwithin60minutesofprevious
operation.Inthewarm-startsequence,allprevioustherapyparametersanddosehistory
informationareretainedinmemory.Beforetheinfusercanoperate,previoussettings
mustbeconfirmedorcleared.Ifprevioussettingsarecleared,theusermustprogramthe
infuserwithnewtherapy parameters.

4.1.1.2

COLD-STARTSEQUENCE

Theinfuserinitiatesacold-startsequenceifitispoweredonafter60minutessince
previousoperation. Theinfuseralsoinitiatesacold-startsequenceifthe
[OFF/RECHG]touchswitchispressedforapproximatelyfoursecondstoclearallmemory.

After60minutes,mostmajorelectroniccircuitsturnoffandalltherapysettingsanddose
historydataarelost.Duringacold-startsequence,aselftestisperformedtoverifythe
functional integrityoftheinfuser.Aftersuccessfulcompletionoftheselftest,theinfuser
mustbe reprogrammedwithnewtherapyparameters.

TechnicalServiceManual 4 -1 430-04502-003 (Rev. 4/99)

Section4GENERALFUNCTIONS

4.1.2

SETUP

Duringsetup,theliquidcrystaldisplay(LCD)screendisplayspromptsforeachstepof
programming theinfuser.Theinfusermust be programmedbefore itwilloperate.

4.1.3

DELIVERYMECHANISM

Thedeliverymechanismisactuatedbyafour-phasesteppermotorthatcontrolsdelivery.
Thedelivery mechanismisconstantlymonitored by theinfuserelectronics.

4.1.4

PATIENTCONTROLLEDANALGESIA(PCA)

WhentheinfuserisoperatingineitherthePCAorthePCA+CONTINUOUSmodes,the
patientcaninitiatearequestforanalgesiabypressingthepatientpendantpushbutton.
Thepatientrequestisansweredbasedonthestatusofthelockoutintervalandthe
four-hourdoselimit.Adoseisdeliveredonlyifthelockoutintervalhasexpiredandthe
four-hourdoselimithasnotbeenreached.Timingofthelockoutintervalandthefour-hour
doselimitisprogrammedbythemedicalprofessional,andismaintainedbythecentral
processorunit(CPU).Thefour-hourdoselimitisthemaximumPCAdosedeliverableby
theinfuserinanyrollingfour-hour period.

Note:ThePCAPlusIIwillnotdiscontinueanindividualdoseuponreachingthefour-hour
dose limit;thedose continues untilcompletion.

4.1.5

STATUSMESSAGES

InfuserstatusisdisplayedontheLCDscreenduringnormaloperation.Statusmessages
are listedinTable 4-1,Status Messagesand Definitions.

Table 4-1.Status Messages and Definitions

Message Definition

DOORLOCKED Displays for 30 secondswhen security dooris closed andlocked
PATIENTLOCKOUT Displays after a successful patient-initiateddosedelivery.

Messageremains untilthe lockout intervalelapses. Message
appearsonlywhen the security dooris locked andthe infuser is
in PCAor PCA+CONTINUOUSmode

4 HR LIMREACHED Displays if four-hourdoselimitis enabled andthe limitis

reachedwith security doorlocked

430-04502-003(Rev.4/99) 4-2 LifeCarePCAPlusandPlusIISeriesInfusers

ELECTRONICSOVERVIEW

Table 4-1.Status Messages and Definitions

Message Definition

* ** Indicatesthat patientcan initiatea doseinPCAor

PCA+ CONTINUOUSmode
PCA Displays when infuser is inPCAmode
CONTINUOUS Displays when infuser is inCONTINUOUSmode
PCA+CONTINUOUS Displays when infuser is deliveringa PCAdoseinadditiontoa

continuous delivery inthe PCA+ CONTINUOUS mode

4.2

ELECTRONICS OVERVIEW

ForinterconnectdiagramsoftheLifeCarePCAPlusandPlusIISeriesInfuser,see

Figure9-3,InterconnectSchematic,PCAII.

Note:Avinculum(overscore)aboveasignaldesignation(e.g.
signal.

TheinfuserelectronicssystemcontainstheCPU/displayprintedwiringassembly(PWA)
andthepowersupplyPWA.ThemicroprocessorontheCPU/displayPWAcommunicates
withcomponentsonbothPWAs throughan8-bitdatabus(D7-D0)anda16-bitaddress
bus (A15-A0).

Low-levelsignalsfromthefrontpaneltouchswitchesandsensorswitchesareinputdirectly
bytheCPU/displayPWAwheretheyareplacedinbuffersonthemicroprocessordatabus.
Data buffers ontheCPU/display PWAalsoreceiveinput fromthepower supplyPWA.

PrimaryACpowerisroutedthroughlinefusesF1andF2totheprimaryofthepower
transformerT1.Low level alternatingcurrent(AC) fromthesecondaryof T1isappliedto
arectifier,CR14,onthepowersupplyPWA.Thedirectcurrent(DC)outputofCR14
connectstothebatteryinputandbatterychargercircuitryonthepowersupplyPWA.The
power supplyPWAprovides+5VDClogicpower,driversforthedrivemotor,powerto the
audiblealarm,accesstotestpointsthroughoutthesystemthroughatestport,anda
printer/Datawayport.

BWR)denotesanactivelow

4.2.1

CPU/DISPLAYPWA

ForaschematicoftheCPU/displayPWA,seeFigure9-4,CPU,PWASchematic,LC

4100/4200.

TheCPU/DisplayPWAcontainsthefollowing:

❏8032single-chipmicroprocessorcontainingread-onlymemory(ROM),

random-access memory(RAM),an8-bitinput/output(I/O)port,twotimercircuits,
64K addressing capability,and an8-bitdatabus

TechnicalServiceManual 4 -3 430-04502-003 (Rev. 4/99)

Section4ELECTRONICSOVERVIEW

❏32Kerasable/programmableread-onlymemory(EPROM) forfirmwareprogram

storage, includingallCPUfirmware

❏8Kstatic RAMmounted inasocket that containsa real-timeclockchipthatcanbe

readfromandwrittentobythe8032microprocessor.Abatteryinthesocketsupplies
power tothereal-timeclockwhenlogic power isturnedoff

❏Watchdogcircuitthatsoundsanalarmifthe8032microprocessordoesnot execute

a code asdesignedor does notstart upproperly

❏DC-to-ACconverterthatprovidespowerfortheelectroluminescentpanelontheLCD

screen

❏LCDcontainingitsowncontrollingcircuitryonaPWAconnectedtotheCPU/display

PWA

❏Lightemittingdiode(LED)displays:fiveseven-segmentLEDs,one singleLED,and

twomulti-LEDs, along withdriving,multiplexing,and monitoring components

❏Eight-channelanalog-to-digitalconverterthatmonitorsthe+5VDCpowersupply,

the+2.5VDCprecisionvoltagereference(usedtoregulatethe+5VDCsupplyand
thebattery monitoring circuits), andthecurrent consumptionoftheLEDs

4.2.1.1

CPU/DISPLAY PWASYSTEMINTERFACES

TheCPU/displayPWAinterfaceswiththefrontpaneltouchswitches,theLCDscreen,and
thepowersupply(see Figure 9-3,InterconnectSchematic,PCAII).

The12frontpaneltouchswitchesinterfacewiththeCPU/displayPWAviaP/J13.The
YES/ENTER, REV/CHG, ONSW,and OFFSWtouchswitchsignalsareroutedoffthe
CPU/displayPWAviaP/J12tothepowersupplyconnectorP/J7.The
REV/CHGsignalsinputthedatabufferU8onthepowersupplyPWA.Asimilardata
buffer,U4,ontheCPU/display PWA inputstheremainingeight touchswitchsignals.U8
andU4placedataonthesystemdatabus(D0-D7).Whenoneofthetouchswitchesis
pressed,agroundisappliedtothecorrespondingtouchswitchsignalline,whichprovides
anactivelowsignalattheappropriatedatabufferinputpin.The
thepowersupplyPWAasaninputtotheON/OFFlatchconsistingofU14BandU14C.

OFFSWline isrouted tothetest portvia connector P/J9,pin8.

The
TheLCDscreeninterfaceswiththeCPU/displayPWAviaP/J15andP/J14.ACpower

fromtheDC-to-ACconverterU17issuppliedtotheLCDscreenviaP/J15.TheLCDscreen
alsoreceivesaddressesA0andA1anddatabitsD0throughD7viaP/J14fordisplay
control.

TheprimaryinterfacebetweentheCPU/displayPWAandthepowersupplyPWAinterface
isthroughthepowersupplyPWAconnectorP/J12ontheCPU/displayPWAwhich
connectsviaaribboncablewithconnectorP/J7onthepowersupplyPWA. The
CPU/displayPWAinterfaceconsistsofaddresslinesA1andA2,datalinesD0through
D7,+5VDCpower, +2.5VDCreferencevoltage,andvarioussignals.

ONSWsignalisusedon

YES/ENTERand

430-04502-003(Rev.4/99) 4-4 LifeCarePCAPlusandPlusIISeriesInfusers

ELECTRONICSOVERVIEW

4.2.1.2

MICROPROCESSORCIRCUITRY

Themicroprocessor circuitryconsistsofthefollowing:

❏8032 single-chip CPU,U11
❏10-MHzcrystaloscillator,Y1
❏Bustransceiver, U12
❏Transparentlatch, U13
❏8Kx8 RAMchip,U21
❏32Kx8 EPROMchip,U22

U11,the8032single-chipCPU,controlsallfunctionsoftheinfuser.U11hasinternal
RAMfortheprogramstackandforstorageoftemporaryvariables.U11usesamultiplexed
16-bitaddressbus, an8-bitdata bus, anda built-in8-bitI/Oport.

ThemicroprocessorisclockedbyY1,aparallel-resonant10-MHzcrystaloscillator.Test
pointsE1-E2andE3-E4areusedtodisconnectY1duringdepotlevelrepairinorderto
single-step U11 for control.

AlloperatingparametersfortheinfuserarestoredinU21,thenonvolatile8Kx8RAM
chip,whichdecodesthe8032addressbits(A0throughA14)toreadfromorwritetothe
systemdatabus(databitsD0throughD7).Readandwriteoperationsare controlledby
the

BRDand BWRsignalsderivedfromthe CPURDand WRsignals.

U21ismountedonasocketthatcontainsalithiumbattery,avoltagemonitorchip,and
areal-timeclockchip.ThelithiumbatteryisusedtoretainthedatastoredinRAMduring
shortperiodsofinfuserpowerloss.Thevoltagemonitorchipmonitorsthepowersupplied
tothesocketandconnectsthelithiumbatterytothereal-timeclockchipifthelogicpower
supplyshutsdown.

U22isa32Kx8EPROMthatstores theinfusersoftwareprogram. U22 places firmware
instructionsonthesystemdatabusaccordingtothestatusofaddresslinesA0through
A15 whenenabled by the

Theoctaltri-statebusreceiver,U12,andtheoctalD-typetransparentlatch,U13,provide
aninterfacebetweentheCPUandthesystemdataandaddressbusses.U12andU13
connecttotheCPUlinesAD0throughAD7.U12usesAD0throughAD7asadatainterface
betweentheCPUandthesystemdatabus(D0throughD7),transmittingdatatoand
receivingdatafromthevariouscomponentsthroughoutthesystemthatconnecttothe
databus.U13latchesintheselinesandusesthemwithCPUlinesAD8throughAD15
forthesystem addressbus, consistingofaddresses A0 throughA15.

4.2.1.3

PSENsignalfromtheCPU.

CHIPSELECTCIRCUITRY

U6isa3-to-8multiplexerthatdecodesaddressbitsA6throughA4whengatedbyA7and
A15toprovideeightI/Ochipselectsignals,
thebusreadcommand(
controlsignals(seeTable 4-2,CPU/DisplayPWA ControlSignals).

BRD),andthebuswritecommand(BWR)areusedassystem

CS0through CS7.Thesechipselectsignals,

TechnicalServiceManual 4 -5 430-04502-003 (Rev. 4/99)

Section4ELECTRONICSOVERVIEW

Table 4-2. CPU/DisplayPWA Control Signals

Signal Function

CS0
CS1
CS2
CS3 NANDed with BWRto gates U2 andU14
CS4 NANDed with BRDto enable output of U19
CS5 RoutedtopowersupplyPWA;used as chipselectinput(CS) to PPIU7
CS6 ANDed with BRDto gate front panelswitch databuffer U4
CS7
BRD CPUbus readcommand(a functionof the CPURDcommand)
BWR

4.2.1.4

ANALOG-TO-DIGITALCONVERTER(ADC)

TheADC,U19,inputstheenablesignalstotheLEDs.TheADCprovidesdataoutputs
that representLEDdisplaystatustothemicroprocessor data busbydecodingaddresses
A0,A1,andA2.TheADCprovidesadigitalrepresentationofeightanaloginputs(IN0
throughIN7)toU11.IN0monitorsthecurrentconsumptionofU3andtheLEDdisplay
bufferthroughdifferentialamplifierU18A.AnaloginputsIN1throughIN6monitorthe
outputsofU3(cathodesoftheLEDdisplays)tocheckforshortedoropenLEDs.IN7
monitorsthe+2.5VDCprecisionvoltagereferencetocompareitagainstthesupplyvoltage
appliedtotheADC.

4.2.1.5

LCDDISPLAYINTERFACE

TheLCD subassemblyconnectstothesystemdatabus,addressbitsA1throughA0,and
anI/Ochipselect.TheLCDbackgroundlightingisprovidedbyanelectroluminescent
panelpoweredbyaDC-to-ACconverteratU17.Theconverterconvertsthe+5VDCto
approximately90VAC.Thebackgroundlightingisturnedoffby disablingtransistorQ2
twominutesafteratouchswitchispressedor30secondsafterthedoorislocked.The
viewingangleissettoprovidemaximumcontrastbyadjustingpotentiometerR19.
PotentiometerR19isfactoryadjustedtogivemaximumcontrastataviewingangle
perpendiculartotheLCDscreen.U10,aDC-to-DCconverter,provides-5VDCtoallowa
full10 voltadjustmentrangeofR19.

430-04502-003 (Rev. 4/99) 4 -6 LifeCarePCAPlusandPlusII SeriesInfusers

ELECTRONICSOVERVIEW

4.2.1.6

LEDDISPLAY CIRCUIT

TheLEDsaredrivenonatime-multiplexedbasis. Thepatternofsegmentstobe
illuminatedislatchedintoU14byU11.DuringthesameCPUcycle,theseven-segment
LEDthatdisplaysthepatternisenabledbyaddressbitswrittentothelatchatU2,which
isbufferedby U3.

TheanodesofthesingleLEDthatprovidesthedecimalpointandtheLEDarraythat
illuminatesthebatterysymbolareilluminatedbythe
Informationrepresentedbythe
enabled withthetenthsdisplayandbythebatteryLEDwhenit isenabledwith theunits
display.

4.2.1.7

DPsignalisdisplayedbythedecimalpointwhenitis

DPsignalfromtheU14latch.

WATCHDOGCIRCUIT

ThewatchdogcircuitconsistsofthedualoneshotatU15andthetwoNANDgatesfrom
U16thatformaset/resetflipflop.TheoneshotisperiodicallytriggeredbyU11aspart
ofitsfirmwareprogram. Beforetheoneshottimesoutandcausestheflip flop to set the
MALFline,U11mustactivateRWAT,whichresetstheflipflopandpreventsitfrom
activating
andthatU11isexecutingcode.ThewatchdogcircuitalsoassuresthatU11isthecorrect
lengthandthatthereal-timeclock,whichsetsU11toactivateRWAT,iskeepingcorrect
timeandcanbeaccessed by U11.

MALF.Thewatchdogcircuitassuresthatthefirmwarecontainsthecorrectcode

4.2.2

POWERSUPPLYPWA

ForschematicsofthepowersupplyPWA,seeFigure9-5,PowerSupplyPWASchematic,

PCA II.

Thepower supply PWA contains thefollowing:

❏Powersupplycircuitrythatconvertsthelow-voltage(11to17VAC)fromtheline

transformer toregulated DC

❏Batterychargingandmonitoringcircuitrythatkeepsthebatteryatfullchargeand

providestheLOWBATTalarm

❏8255programmableperipheralinterface(PPI),U7,thatcontainsthree8-bitI/Oports

toallowU11tocontrolthemotor,readdatafrom andsend data totheprinterport,
and read thestate oftheswitches

❏Set/resetflipflop(ON/OFFlatch),U14B/U14C,thatmonitorsthestateofthevial

andinjectorswitchesandthe[ON]touchswitchtocontrolpowertothelogiccircuitry,
and ispowered by thebattery whenAC poweris off

❏MotordriversU17A,U17B,U17C,andU17Dthatstepthemotorthroughitsphases,

andmotormonitoringcircuitryU15A,U15B,U15C,U15Dthatdetectsdriverand
motormalfunctions

TechnicalServiceManual 4-7 430-04502-003(Rev.4/99)

Section4ELECTRONICSOVERVIEW

4.2.2.1

POWERSUPPLYPWASYSTEMINTERFACES

ThepowersupplyPWAreceivesinputfromeithertheisolationtransformerT1orthebattery
packviaP/J3.ThepowersupplyPWAinterfaceswiththeCPU/displayPWAthrougha
ribboncableconnectedatP/J7,whichconsistsofthemicroprocessordatabuslines,
addresslines A0 and A1,+5 VDCpower,and varioussignallines.

ThepowersupplyPWAreceives the
signals(
P/J4.Themotordrivesignalsandtheshaftsensorfeedbacksignalsareroutedtothe
powersupply PWAvia P/J5.

Theaudiblealarmsignal,audiblelevelswitchinputs,doorswitchsignal,andpatient
pendantinputinterfacewiththepowersupplyPWAthroughaconnector,P/J8.P/J8also
routeslinestotheprinter/Datawayconnector J10.

TestportJ11interfaceswiththepowersupplyPWAviaP/J9toprovideexternalaccess
totest points throughoutthesystem.

4.2.2.2

PRESSURESW, SYRINGELO, SYRINGEEMPTYSW,and INJECTORSW)from

VIALSWsignalfromP/J6andtheother microswitch

UNREGULATEDDCVOLTAGE

TheoutputofACpowertransformerT1isappliedtoCR14viaconnectorP/J3.CR14is
afull-waverectifier;capacitorC16filterstheresultingDCvoltage.WhenACpowerison,
operational amplifierU12A,transistorsQ4andQ2,andvoltagereferenceU18chargethe
battery.TransistorQ1gatestheunregulatedvoltagetoU9andU10,whichare+5VDC
regulatorsforthelogic power andmotorpower.

OperationalamplifierU3monitorstheunregulatedvoltageandprovides
LOBATsignalstoU11.The DISBATTand LOBATsignalsarederivedfromtwovoltage
thresholds produced from aprecisionresistor network.

DISBATTand

4.2.2.3

ON/OFFLATCH

UnregulatedDCvoltageispresentinthepowersupplywheneitherACorbatterypower
isavailable.Asupplyof+5VDCisavailablefromtheunregulatedDCvoltagebyprecision
voltagereferencesU5andU6.ThevoltagepowersU13andU14,whichmakeupthe
ON/OFFlatch.TheON/OFFlatchisaset/resetflipflopsetbytheinjectororvialswitches
beingclosedorbythe[ON]touchswitchbeingpressed.TheoutputoftheON/OFFlatch
drivesthegateofQ5.Q5drivesthebaseofQ1,whichconnectsthe+5VDClogicand
motorregulatorswiththeunregulatedDCvoltage.GatesfromU13 and U14preventthe
[OFF/RECHG]touchswitchfromresettingtheON/OFFlatchwhenamalfunctionisbeing
reported viathe

4.2.2.4

MALFline.

PRINTERDATALATCH

TheprinterdatalatchlatchesdatafromU11tosendoutoftheprinterportasprinterdata.

430-04502-003(Rev.4/99) 4-8 LifeCarePCAPlusandPlusIISeriesInfusers

ELECTRONICSOVERVIEW

4.2.2.5

MOTORDRIVER

ThegatesofU17drivetransistorsQ9throughQ6fromthe8255portAoutputsandare
disabledby
generatethe
drive signals tothemotor.

4.2.2.6

MALF,preventingmotormovementduringamalfunction.ThegatesofU15

MOTORBADsignaliftheinputstoU17arenotofoppositepolaritytothe

8255PROGRAMMABLEPERIPHERALINTERFACE

The8255programmableperipheralinterfacechip,U7,isanI/Operipheralthatiswritten
toand read from by U11via themicroprocessor databuswhenaddresses A0 andA1 are
properlydecoded.U7contains three8-bitI/Oports: portA,portB, andportC.

PortA(PA0throughPA7)isusedformotorcontrol,thestrobefortheprinterport,andthe
signalthatenablestheLCDbacklighting.PortBisusedfortheprinterdatainputand
paritybitI/O.PortCisageneralpurposeinputportthatmonitorsmostcriticalswitches
andindicators.

4.2.3

BATTERYBOOSTCHARGERPWA

ForaschematicofthebatteryboostchargerPWA,seeFigure9-6,CurrentBoostCharger

Schematic,MDL4/PCA.

ThebatteryboostchargerPWAisinstalledininfuserswiththefollowingfinalassembly
numbers andservicerevisionletters:

❏850-04250-005(Landabove)
❏850-04250-008(Candabove)

Note:Thefinalassemblynumberandservicerevisionletterarelocatedonthelowerright
side onthebackoftheinfuser.

Thebattery boostcharger PWAcontains thefollowingcircuitry:

❏Differentialamplifier, U3
❏20 mAshut-offcircuitry,Q2
❏Windowcomparatorwithhysteresis, U1
❏60 minute batterychargertimer,U2
❏200mAconstantcurrentsource(transistorsQ7,Q8,Q9)andassociatedlogic

(transistors Q3, Q4,Q5, Q6)

❏ACdetector,transistor Q1

ThebatteryboostchargerPWAfunctionsduringinfuserACpowerandbatterypower
operation,as describedinthefollowing sections.

TechnicalServiceManual 4-9 430-04502-003(Rev.4/99)

Section4MECHANICSOVERVIEW

4.2.3.1

AC OPERATION

VoltagedetectorU1,withassociatedcapacitorsandresistors,functionsasawindow
comparatorwithhysteresis.Whenthebatteryisinitiallyconnected,theoutputofU1is
atlogichigh.Afterthebatteryvoltagereaches10VDC,theoutputofU1goeslow,disabling
transistors Q3 andQ4 andtriggering thetimer,U2.

TheclockfrequencyofU2isdeterminedbyC5andR9;time-outispendingthebiasingof
theU2programinputsA,B,C,andD.Upontime-out,theDECODEsignalonoutputpin
13ofU2goeshigh;thissignaldisablesQ5,removesthesupplytoQ9,andcausesbattery
chargingtostop.TheDECODEsignalalsolocksinU2,preventingoperationbyplacing
alogichigh ontheSETinput,pin1, ofU2.

TheAC/DCdetectorconsistsoftransistorQ1andassociatedresistors.Whentheinfuser
operatesonACpower,thecollectorofQ1isatlogiclow,enablingtimerU2andtransistor
Q6.During DCoperation, the+VRDCsignalis atgroundleveland keepsQ1 off.

Currentislimitedto200 mA by thequotientoftheVBEoftransistor Q8 dividedby R17.
Transistor Q7 acts as a power switch thatis enabledanddisabled by transistor Q9.

TheIC,U3-B,actsasadifferentialamplifierwithagainof20decibels(dB).Currentis
sensedacrossresistorR62inthebatterychargingcircuitryofthepowersupplyPWA.
Whencurrentdropsbelowapproximately20mA,theoutputofU3-B,pin1(whichisalso
the inputtocomparatorU3-A,pin6),isat100 mVorbelow.Pin3 ofU3-A isreferenced
at500mVfromthebatterychargercircuitryonthepowersupplyPWA.Also,whencurrent
dropsbelow20mA,U3-AswitchestoalogichighandturnsontransistorQ2,disabling
thecharging circuit(Q1 andQ19)onthepowersupplyPWA.Resistor R26andcapacitor
C8act as a noise filtertoQ8.

4.2.3.2

DCOPERATION

Whentheinfuseroperatesonbatterypowerandthebatterypackdrainstoapproximately
8VDC,pin4ofthevoltagedetectorU1switchestologichigh;thisresetsthetimerU2,
enablingtransistorsQ3,Q4,andQ5.TransistorQ6remainsdisabledbecauseQ1is
disabled.

4.3

MECHANICS OVERVIEW

Mechanicalelementsoftheinfuserconsistoftheslideassembly,thesyringelow(-008and
lower)andsyringeemptyalarmsystem,theocclusionpressurealarmsystem,andthevial
andinjector sensoralarm system.

430-04502-003(Rev.4/99) 4-10 LifeCarePCAPlusandPlusIISeriesInfusers

MECHANICSOVERVIEW

4.3.1

SLIDEASSEMBLY

ThemaincomponentsoftheslideassemblyareshowninFigure4-1,InfuserSlideAssembly

(008andLower),andFigure4-2,InfuserSlide Assembly(-010 and Higher).The following

sections describetheoperationoftheslide assembly.

GUIDES

TOP PLATE

RIGHT LEAD

SCREW CLAMP

SPLIT NUT

LEFT LEAD
SCREW CLAMP
SPLIT NUT

LEFT CLAMP
KNOB

UPPER SYRINGE

MOUNT

SYRINGE EMPTY

BRACKET ARM

SYRINGE LOW
BRACKET ARM

SYRINGE LOW

SWITCH

SYRINGE

EMPTY

SWITCH

LEAD SCREW

SWITCH

MOUNTING

BRACKET

MOTOR

GEARBOX

RIGHT CLAMP
KNOB

CRADLE
ASSEMBLY

VIAL

PLUNGER

MOTOR

CASE

OPTO SWITCH

INJECTOR
FLANGE
CLAMP

95F01008

Figure4-1. InfuserSlideAssembly (-008and Lower)

TechnicalServiceManual 4-11 430-04502-003(Rev.4/99)

Section4MECHANICSOVERVIEW

SWITCH ACTUATOR

OCCLUSION ALARM

SWITCH

THUMB NUT

VIAL SENSOR

SWITCH

LEAD SCREW

SYRINGE EMPTY

SWITCH

SYRINGE EMPTY

SWITCH ACTUATOR

ARM (BEHIND

SWITCH)

SYRINGE EMPTY

SWITCH ADJUSTMENT

SCREW (2)

CRADLE
ASSEMBLY

VIAL

PLUNGER

MOTOR GEARBOX

MOTOR CASE

INJECTOR

INJECTOR SENSOR

SWITCH

Figure4-2. InfuserSlideAssembly (-010and Higher)

4.3.1.1

FLANGE CLAMP

95F01009

MOTORASSEMBLY

Themotorassemblyconsistsofafour-phasesteppermotorhousedinthemotorcase(see

Figure4-1,InfuserSlideAssembly,(-008andLower)).Themotorcaseattachestothe

gearbox.Thegearboxconsists ofreductiongears thatprovidea 50-to-1 reductioninthe
rotationofthemotorshaft.Thereductiongearsdrivetheleadscrew.Fiftyrevolutionsof
themotor produce onerevolutionof theleadscrew.

Thesteppermotorreceivesitscommands(MOTO1,MOTO2,MOTO3,andMOTO4)from
motordriversonthepowersupplyPWA.TheMOTO1,MOTO2,MOTO3,andMOTO4
commandsareissuedbythePPIU7undercontrolofthe microprocessoronthe
CPU/display PWA.

430-04502-003(Rev.4/99) 4-12 LifeCarePCAPlusandPlusIISeriesInfusers

MECHANICSOVERVIEW

DatabufferU4ontheCPU/displayPWAinputssignalsfromthetouchswitchesonthe
infuserfrontpanel. Thetouchswitchsignalsrepresentdeliverydataplacedonthe
microprocessor databusbyU4(D0throughD7) when U4isgatedbythe ANDedproduct
ofthebusreadcommand(
interpretedbythemicroprocessoraccordingtotheprograminEPROM.Thedataprovides
thestepper motorcommandsfor thedelivery dataset up by thetouchswitches.

Areduced-diameterextensionofthegearboxshaftprotrudesthroughthebottomofthe
gearbox;thisextensionisflattenedtoallowanoptoswitchmountedonabracketonthe
motorcasetosenserotationof the lead screw. Theopto switch sensestheflattenedarea
oftheextension.Foreachrotationoftheleadscrew,theoptoswitchgeneratesasignal,
SHAFT,whichis routedtodatabuffer U8 onthepowersupply PWA.

TheSHAFT signalisreadbythemicroprocessoronthe CPU/displayPWAas databitD6
when U8isgatedbythe
providesafeedbacklooptoallowthemicroprocessortocontroltherotationofthelead
screw for thedeliverydata set up by thetouchswitches.

4.3.1.2

BRD)andchipselectsignal CS6.Digitizeddeliverydatais

SWSTSELsignalfromtheCPU/displayPWA.TheSHAFTsignal

SLIDEMECHANISM

Theslideblockconnectstotheleadscrewbyahalfnut.Thesurfaceofthehalfnutthat
contactstheleadscrewismachinedsothatitengagesthethreadsontheleadscrew.
Whentheleadscrewisrotatedandthehalfnutisengaged,theslideblockmovesdownward
towardsthemotorassembly.Squeezingthearmabovethecradlewithnosyringemounted
inthecradlecausesthe halfnutto disengage fromtheleadscrew.The slidemechanism
canthenbemovedupanddownonthetwoguideshaftstothefullextentofcradletravel.

4.3.1.3

CRADLEASSEMBLY

Whenaninvertedvialisinsertedinthecradleassembly,theinjectorflangeisheld
stationaryintheinjectorflangeclamp.Whentheslideblockisdrivendownwardbythe
rotationoftheleadscrew,thevialisforceddownwardandthestationaryinjectorplunger
movesfurtherintothevial.Fluidinthevialisforcedintotheadministrationsetinan
amount proportionaltothedownward movement ofthecradle andslide mechanism.

4.3.2

SYRINGELOWANDSYRINGEEMPTYALARM SYSTEM

Note:Software version3.1 and higher deactivates thesyringelowswitch.
Asyringestatusmicroswitchmountedtotheslideassemblyprovidesasignaltothepower

supplysupplyPWAwhenactivatedbythedownwardmovementofthecradleassembly

(seeFigure4-3,SyringeLowandSyringeEmptyAlarmSystem(-008andLower)and
Figure4-4,SyringeEmptyAlarmSystem(-010 andHigher)).Whenactivated,thesyringe

emptyswitchsendsthe
PWA.DatabufferU8placesswitchstatusdataonthemicroprocessordatabusasdata
bitsD1andD2forprocessingbytheCPU/DisplayPWAmicroprocessorwhenthebuffer
isgated by

TechnicalServiceManual 4- 13 430-04502-003 (Rev. 4/99)

SWSTSEL.

SYRINGEEMPTYSWsignaltodatabufferU8onthepowersupply

Section4MECHANICSOVERVIEW

Oninfuserswithfinalassemblynumber-008andlower,twobracketarmsattachtothe
slide block; twosyringe status microswitchesmount on abracketattached to thebaseof
theslideassembly.Thetwobracketarmsareorientedto theswitchessothat downward
movementoftheslideblockcausesthebracketarmstopressagainstactuatorarmson
theswitches.Theinnermicroswitch(thesyringelowswitch)isclosedfirst,bythelonger,
innermostarm,sendingthe

SYRINGELOSWsignaltothepowersupplysupplyPWA.
Further downwardmovementcausestheshorterof the twobracket arms(theouter arm)
topresstheactuatorarmontheouterswitch(thesyringeemptyswitch),whichsendsthe
SYRINGEEMPTYSWsignaltothepowersupply supply PWA.

Note: Laterconfigurationsof-008andlowerhaveonebracketarmcontainingboth
actuators,allowingboththesyringelowandsyringeemptyalarmstobeadjustedwitha
single adjustmentontheonebracket arm.

The

SYRINGELOSWsignaloccurswhenthedistancebetweenthebottomofthesyringe
vialstopandthebottomofthesyringeinjectorflangegrooveis4.628
(11.57
vial. The

+0.155centimeters(cm)),whichindicatesapproximately5mLoffluidisleftinthe

SYRINGE LOSWsignalgeneratesthe syringelow alarmandtheLOWSYRINGE

+0.062inches

messageontheLCD.
The

SYRINGEEMPTYSWsignaloccurswhenthedistancebetweenthebottomofthe
syringevialstopandthebottomofthesyringeinjectorgrooveis4.328
(10.82

+0.155cm),whichindicatesapproximately1mLremaininginthevial. The

+0.062inches

SYRINGEEMPTYSWsignalgenerates thesyringe empty alarmandtheEMPTYSYRINGE
messageontheLCD.

Oninfuserswith finalassemblynumber-010and higher,theslideblockmovesdown on
theswitch, causingtheswitcharm toactivatethesyringeempty switch.

Note:Infuserswithfinalassemblynumber-010andhigherdonothaveasyringelow
switch.

SYRINGE EMPTY

BRACKET ARM

DIRECTION
OF TRAVEL

SYRINGE LOW

SYRINGE EMPTY

BRACKET ARM

SWITCH

SYRINGE LOW
SWITCH

94F14012

Figure4-3.SyringeLowand SyringeEmptyAlarmSystem (-008and Lower)

430-04502-003(Rev.4/99) 4-14 LifeCarePCAPlusandPlusIISeriesInfusers

SYRINGE EMPTY

SWITCH ARM

MECHANICSOVERVIEW

DIRECTION
OF TRAVEL

95F01036

Figure4-4. SyringeEmptyAlarmSystem (-010and Higher)

4.3.3

OCCLUSION PRESSUREALARMSYSTEM

TheOCCLUSIONalarmoccurswhenabackpressureof15±5psig(103.5±34.5kPa)is
exceeded.Backpressureissensedbytheocclusionpressuremicroswitchonthetopplate
oftheslideassembly(seeFigure4-5,OcclusionPressureAlarmSystem(-008andLower)
andFigure 4-6,OcclusionPressureAlarmSystem(-010 andHigher)).

Duringanormaldeliverycycle,rotationoftheleadscrewmovestheslideblockdownward,
whichmovesthecradleassemblydownwardandforcesfluidoutofthesyringe.Ifthere
isanocclusionintheadministrationset,backpressurebuildsupinthedeliverysystem
anddownward motionof theslideblockis restricted.

Alongitudinalslackintheleadscrewexistssothatwhenthedownwardmovementofthe
slideblockisrestricted,rotationoftheleadscrewforces theslide blockupwards against
acompressionspringbetweenthetopoftheleadscrew andthetopplate.Whenagiven
amountofpressureisappliedagainstthecompressionspring,theupperendofthelead
screwpressesagainsttheswitchactuatorandcauses ittopivotupward,thereby closing
theocclusionalarmswitch.Oninfuserswithfinalassemblynumber-010andhigher,the
switch opens.

Whentheocclusionalarmswitchcloses,the
PRESSURESWsignalisappliedtotheinputofdatabufferU8onthepowersupplysupply
PWA.WhenU8isgatedbythe
PWAreadsdatabitD0forocclusionpressurestatusandgeneratesanOCCLUSIONalarm.
Insetupmode,theOCCLUSIONalarmisclearedbyreleasingthecradleassembly.In
patientmode,theOCCLUSIONalarmisclearedbyopeningthefrontdoorandreleasing
thecradleassembly.The[SILENCE]touchswitchmaybepressedtomutetheocclusion
audiblealarmforoneminute.

TechnicalServiceManual 4-15 430-04502-003(Rev.4/99)

SWSTSELsignal,themicroprocessorontheCPU/Display

PRESSURESWsignalgoesactivelow.The

Section4MECHANICSOVERVIEW

OcclusionpressureisadjustedasdescribedinSection7.2.7,OcclusionAlarmSwitchTest

andAdjustment.

ADJUSTMENT

OCCLUSION

ALARM SWITCH

ADJUSTMENT

SET SCREW

(NOT SHOWN)

BRACKET
LOCKNUT

LOCKNUTS

TOP PLATE

SWITCH

ACTUATOR

SWITCH
BUTTON

COMPRESSION

SPRING

CRADLE

CLAMP

SPLIT NUTS

Figure4-5. OcclusionPressure AlarmSystem (-008and Lower)

DIRECTION OF
LEAD SCREW

LEFT
CLAMP LEVER

RIGHT
CLAMP LEVER

LEAD
SCREW

95F01037

430-04502-003(Rev.4/99) 4-16 LifeCarePCAPlusandPlusIISeriesInfusers

MECHANICSOVERVIEW

SWITCH

ACTUATOR

OCCLUSION ALARM

SWITCH

COMPRESSION SPRING

THUMB NUT

PIVOT POST

(BEHIND

LEAD SCREW)

LEAD SCREW

DIRECTION OF

LEAD SCREW

Figure4-6. OcclusionPressure AlarmSystem (-010and Higher)

NO. 0 PHILLIPS
SCREW

SLIDE CLAMP
RELEASE LEVER

95F01016

4.3.4

VIALANDINJECTORSENSORALARMSYSTEM

Thevialsensormicroswitchbetweenthecradleassemblyandslideblocksensesthe
presenceorabsenceofavialinthecradleassembly.Theinjectorsensorswitchbehind
theinjectorflangeclampsenses whether ornotthe vialinjectorflangeisproperlyseated
intheinjectorflangeclampwhenavialisclampedinthecradleassembly.Whenopen,
thevialsensor switchgenerates theCHECKVIAL alarm.

4.3.4.1

CHECKVIALALARM

Whenavialisproperlyseatedinthecradleassembly,thevialsensorrodisforcedtowards
therearoftheinfuserandpressesagainstthevialsensormicroswitchactuatorarm,
causing theswitchtoclose.Ifthevialisimproperlyseated(i.e.,thevialsensorrodisnot
forcedrearwardandtheswitchremainsopen)andtheinjectorflangeisproperlyseated,
anattempttostarttheinfusercauseslogiccircuitryonthepowersupplysupplyPWAto
sensethe
latchisset,theinfuserispreventedfromstarting,theaudiblealarmsounds,andthe
CHECKVIALmessageisdisplayedontheLCD.The[SILENCE]touchswitchhasnoeffect
onthisalarm;thealarmis cleared by properly seatingthevialinthecradle assembly.

VIALSWsignalandsettheON/OFFlatch(U14B,U14C).WhentheON/OFF

TechnicalServiceManual 4-17 430-04502-003(Rev.4/99)

Section4BATTERYOPERATIONOVERVIEW

4.3.4.2

CHECKINJECTORALARM

Whenavialismountedinthecradleassemblyandtheinjectorflangeisproperlyseated
intheinjectorflangeclamp,thevialsensorrodisforcedtowardstherearoftheinfuser
andpressesagainst theinjectorsensormicroswitch,whichcausestheswitchto close.If
avialisinstalledinthecradle,buttheinjectorflangeisimproperlyseated(i.e.,thevial
sensorrodisnotforced rearwardandtheswitchremainsopen),and anattemptismade
tostarttheinfuser,logiccircuitryonthepowersupplysupplyPWAsensesthestatusof
the

INJECTORSWsignalandsetstheON/OFFlatch(U14B,U14C).WhentheON/OFF
latchisset,theinfuserispreventedfromstarting,theaudiblealarmsounds,andthe
CHECKINJECTORmessageisdisplayedontheLCD.The[SILENCE]touchswitchhasno
effectonthisalarm;thealarmisclearedbyproperlyseatingtheinjectorflangeinthe
injectorflangeclamp.

4.3.4.3

CHECKSYRINGEALARM

Whennosyringeisinstalledintheinfuser,orwhenasyringeisinstalled,butboththe
vialandtheinjectorflangeareimproperlyseated,thevialsensorswitchandtheinjector
sensormicroswitchremainopen.Ifanattemptismadetostarttheinfuserunder these
conditions,logiccircuitryonthepowersupplysupplyPWAsensesthestatusofthe
INJECTORSWsignalandsetstheON/OFFlatch(U14B,U14C).WhentheON/OFFlatch
isset,theinfuserispreventedfromstarting,theaudiblealarmsounds,andtheCHECK
SYRINGEmessageisdisplayedonthe LCD.The[SILENCE]touchswitchhasnoeffecton
thisalarm;thealarmisclearedbyinstallingasyringesothatthevialisproperlyseated
inthecradleassemblyandtheinjectorflangeisproperlyseatedintheinjectorflange
clamp.

4.4

BATTERYOPERATION OVERVIEW

Theinfuserisintendedtooperateonbatterypoweronanexceptionbasisonly,suchas
emergencybackuportemporaryportableoperation.Examplesofemergencybackup
includeACpowerfailureorinadvertentdisconnectionoftheACpowercord.Temporary
portableoperationincludespatienttransfer fromonelocationtoanother.

TheinfusershouldbeconnectedtoACpowerwheneverpossibletoallowthebatteryto
remainfullycharged.Thebatteryindicatorilluminates whentheinfuser is operating on
batterypower.

Factorsthatmostcommonlyaffectbatterylifearethedepthandfrequencyofdischarge
andthelengthoftherechargeperiod.Asageneralrule,themoreoftenthebatteryis
dischargedandrecharged,thesooneritwillneedreplacement.Theprimarycauseof
damageisleavingthebatteryinalessthanfullychargedstateforanyperiodoftime.
Batterydamagecanoccurinamatterofhoursandcauseapermanentlossofbattery
capacity.Theamountoflostcapacitydependsonthedegreeofdischarge,thestorage
temperature, andthelength oftimethebatterywas stored ina discharged state.

Note:Apermanentlydamaged battery cannotberecharged tofullcapacity.

430-04502-003(Rev.4/99) 4-18 LifeCarePCAPlusandPlusIISeriesInfusers

BATTERYOPERATIONOVERVIEW

Whenthebatterydischargesbelowanacceptablelevelwhiletheinfuserisoperating,an
alarmsoundsandtheLOWBATTERYmessagedisplays.Althoughitisnotrecommended
to continueoperatingtheinfuseronbatterypoweratthispoint,thebatterywillcontinue
providingpoweruntildischarged;atthispoint,theinfuser enters thebatterydischarged
modeand operationceases.

CAUTION:AssoonastheLOWBATTERYalarmoccurs,connecttheinfusertoAC
power.

RechargingoccursanytimetheinfuserisconnectedtoACpower.Itisrecommendedthat
theinfuserbeconnectedto ACpowerwheneverpracticableto maximizeavailablebattery
chargeduringpatienttransportorambulation.Thepowerswitchdoesnothavetobeon
forthebatterytorecharge.Rechargingwhile theinfuseris operating israte dependent.

TechnicalServiceManual 4-19 430-04502-003(Rev.4/99)

Section4BATTERYOPERATIONOVERVIEW

Thispage intentionally leftblank

430-04502-003(Rev.4/99) 4-20 LifeCarePCAPlusandPlusIISeriesInfusers

Section5

MAINTENANCEANDSERVICE
TESTS

Thissectioncontainspreventivemaintenanceinformation,aperformanceverificationtest
(PVT),andbatterymaintenance informationforthePCAPlus andPlus II Series Infuser.

5.1

PREVENTIVE MAINTENANCE

Apreventivemaintenanceprogrampromoteslongevityandtrouble-freeoperationofthe
infuser.Suchaprogramshouldincludeperiodicinspectionoftheinfuser,exteriorcleaning
andsanitizing,andchecking forproperoperation oftheinfuserbyperformingthePVTin

Section5.2.

Asaminimumrequirement,cleantheinfuseraftereachuse.Establisharegularcleaning
scheduleduringuse.Inaddition,cleantheinfuserandperformthePVTaspartofany
scheduled serviceorafter anyrepair procedure.

5.1.1

INSPECTINGTHEINFUSER

Periodicallyinspecttheinfuserforsignsofdefectssuchaswornaccessories,broken
instrumentconnections,ordamagedcables.Suchaninspectionisalsoapplicableafter
repairing or duringcleaning. Replaceany damaged or defective externalparts.

Inspect thefollowingareasformissingordamagedparts andfor cosmeticdefects:

❏Labels
❏Cords
❏Switches andtouchswitches
❏Velcro
❏Externalscrews
❏Case
❏Poleclampand pads
❏Front panel
❏Security door
❏Accessories

®

straps

TechnicalServiceManual 5-1 430-04502-003(Rev.4/99)

Section5MAINTENANCEANDSERVICETESTS

5.1.2

CLEANING THEINFUSER

Thefollowingproceduresaredesignedtomaintaintheinfusionsystem,sustaininfuser
longevity,andpromotetrouble-free instrumentoperation.

Followhospitalprotocol forestablishingtheinfusercleaning schedule.

WARNING

DISCONNECTTHEINFUSERFROMACPOWERPRIORTOCLEANINGTHE
INSTRUMENT.FAILURETOCOMPLYWITHTHISWARNINGCOULDRESULTIN
ELECTRICALSHOCK.

CAUTION:Donotimmersetheinfuserinliquids.Immersioncoulddamagethe
instrument.Donotallowliquidstoentertheinfuserelectronicscompartment.

CAUTION:Donotspraycleaningsolutionstoward anyopenings intheinfuser.

CAUTION: Certaincleaningandsanitizingcompoundsmayslowly degrade
components madefrom someplastic materials.Usingabrasive cleanersorcleaning
solutionsnotrecommendedbyAbbottLaboratoriesmayresultinproductdamage
and,potentially,voidtheproductwarranty. Donotusecompoundscontaining
combinationsofisopropylalcoholanddimethylbenzylammonium chloride.

Cleantheexposedsurfacesoftheinfuserwithasoft,lint-freeclothdampenedwithoneof
thecleaningsolutionslistedinTable5-1,CleaningSolutions,oramildsolutionofsoapy
water.Removesoapresiduewithclearwater.Donotusesolventsthatareharmfulto
plastic, such as isopropylalcohol oracetone.Donot use abrasivecleaners.

CAUTION: Toavoidinfuserdamage,cleaningsolutionsshouldbeusedonlyas
directedinTable5-1.Thedisinfectingpropertiesofcleaningsolutionsvary;consult
themanufacturerforspecificinformation.

Table5-1.Cleaning Solutions

CleaningSolution Manufacturer Preparation

Vesphene
Manu-Klenz
FormulaC
Super Edisonite

®

IIse CalgonVestalLaboratories Per manufacturer’s recommendation

®

™

®

CalgonVestalLaboratories Per manufacturer’s recommendation
Diversey Corporation Per manufacturer’s recommendation
S.M. Edison ChemicalCo. Per manufacturer’s recommendation

Household bleach Various Per hospitalprocedures;do not

exceedonepart bleachin ten parts
water

LifeCare
Germicidal

®

Manufacturedfor Abbott
Laboratories

Per manufacturer’s
recommendations; use undiluted

Towelette

430-04502-003(Rev.4/99) 5-2 LifeCarePCAPlusandPlusIISeriesInfusers

PERFORMANCEVERIFICATIONTEST

5.1.3

SANITIZINGTHEINFUSER

Sanitizetheexternalsurfaces oftheinfuser usingacleaningsolutionlisted inTable5-1,

CleaningSolutions.

CAUTION:Donotsterilizetheinfuserusingheat,steam,ethyleneoxide(ETO),or
radiation; thesemethodsmaycausetheinstrumenttomalfunction.

Note:Notallcleaning solutionsare sanitizers. Checkproduct labeling.

5.2

PERFORMANCEVERIFICATIONTEST

As apart ofa preventive maintenance schedule,it is recommendedthattheperformance
verificationtest(PVT)beconductedperiodicallyperhospitalproceduresforcomplianceto
accreditationrequirements.

ThePVTisusedforoverallverificationofinfuserperformanceandasadiagnostictool
during infusertroubleshooting.The PVTcanbe usedfor diagnostic purposesduringthe
troubleshootingofamalfunctioninginfuser,andforverificationoftheoverallperformance
ofaninfuseraspartofapreventivemaintenanceschedule.Inaddition,thePVTshould
beusedforperformanceverificationbeforeaninfuserisreturnedtoserviceafterrepair.
IfanymalfunctionisdetectedasaresultofthePVT,refertoTable6-3,Troubleshooting

withthe PVT.

Note:ThePVTmustbeperformedexactlyasdescribedinthismanualtoassureeffective
andreliableproductevaluation information.

5.2.1

EQUIPMENTREQUIRED

Thefollowing equipment,or equivalent, isrequiredtoperform thePVT:

❏Door key
❏PCAvial,standard,ListNo.6021-03
❏PCAvial,empty,ListNo.6021, modified toonering
❏PCAset, ListNo.3559-01
❏Graduateormarkedtesttube, readable to0.2 mLincrementsor smaller
❏Three-waystopcock, ListNo.3233
❏Digitalpressuremeter (DPM),(0to50 psig),Bio-Tek

®

❏Safetyanalyzer,DynatechNevada
❏Butterfly,21-gauge, ListNo.4492
❏Testcable,fittedwithphonejackwithindividualbananaplugs(compatiblewith

patientcontrolconnector onrear ofinfuser)P/N561-88416-001

❏Parallelnetwork, P/N 561-88419-001
❏Digitalmultimeter (DMM)Fluke

231D

®

Model77

®

DPMII

TechnicalServiceManual 5-3 430-04502-003(Rev.4/99)

Section5MAINTENANCEANDSERVICETESTS

❏Silicone oil, DowCorning®No.360, P/N 743-35070-001
❏X-acto

®

knife

5.2.2

INSPECTION

InspecttheareaslistedinSection5.1.1,InspectingtheInfuser,formissingordamaged
parts andforanycosmetic defects.

5.2.3

INFUSERTESTSETUP

WARNING

DURINGTESTING, DONOTCONNECTTHEINFUSERTOA PATIENT.

Toset up theinfuser,proceedas follows:

1.Usingthedual-lock mechanism,securetheinfusertoanIVpole.
Note:Whenthesecuritydoorislocked,theinfuserlockstothepoleclampand

prevents itsremovalwithouta key.

2.Connect thesystem toACpower unlessotherwisespecified.

3.Connect theappropriateAbbottPCAset toanAbbott30 mLPCA vial/injector.

4.Primethevialandadministrationset. Holdthevialverticallywiththe
administrationsetextendingfromthetop.Slowly pushdownontheinjectoruntil
allairis cleared from thevialandadministration set.

CAUTION:Makecertainallcapsonthevialandtheadministrationsetare
removed andallclampsareopenwhenprimingsyringe.

5.2.4

SERVICETESTMODETEST

Table5-2,ServiceTests,andTable5-3,ServiceOptions,providealistof testsandoptions

availableintheservice test mode.Eachtestdisplays prompting information ontheLCD
screentoserveasaguidethroughthetest.Promptsanddescriptionsareshownin

Table5-2.

Note:Thepatientpendantmustbe connected totheinfusertocompletetheservicetest
modetest.

Toenter theservicetestmode, proceedas follows:

1.Confirm thattheACpower symbolonthefront panelisilluminated.

2.Turntheinfuseroffandenterthestoragemodebyopeningthesecuritydoorand
pressingthe[OFF/RECHG]touchswitchforapproximatelysixseconds.TheLCD
screen shoulddarken.

430-04502-003 (Rev. 4/99) 5 -4 LifeCarePCAPlusandPlusII SeriesInfusers

PERFORMANCEVERIFICATIONTEST

3.Pressandholdthe[YES/ENTER]touchswitchandthe[ON]touchswitch
simultaneouslyfor approximately threeseconds.

TheLCDscreendisplaysINTRAMTESTuntil**SERVICETEST**appears.TheLCD
screenalsodisplaysthecurrentsoftwareversionandthetotalelapseddayssincethe
infuserwasplacedinservice.

Note:Testsareself-prompting,givingtheoptionofrepeatingthetest,orgoingtothenext
test.

Table 5-2. ServiceTests

Test Description

Software version Infuser displays the software version toidentify the revisionlevelof

the infuserprogram stored inEPROM
Elapseddays Display reflectstotal days infuser has beeninoperation
InternalRAM Microcomputer RAMistested toassuredata can bereliablywritten

to and readfrom specific memory cells
ExternalRAMADRS Testisperformedto determine the integrity of the addresslines

usedtoselectspecificmemorylocations for data access
ExternalRAMcell Microcomputer RAMmemoryis tested
CPU Testroutine isperformedandthe testresultsare verifiedtoassure

that the microcomputer is executing instructions properly
ROM Checksum iscalculated andcomparedto a pre-storedand

pre-calculated valueto assure the operatingprogramresidingin

EPROMisintact
Real-time clock Real-timeclock istestedto verifyits accuracy
LED Pattern of1s through9s isdisplayedby the LEDsto verify operation
LCD Non-displayingtestpatternis writtento the LCD RAMand

comparedwitha stored patternto assure that the LCD screen can

accuratelydisplaydata
Keypad Stuckkey testdetermines if any of the keysarepermanently

shorted. Pressindividualkeysto determine if the key operatesand

the microcomputer recognizes the correct key.Testpatient

pendantpushbutton
Indicator Testverifies battery andACsymbolsare turnedonand off when

the powercord isconnectedand disconnected
Alarm Audiblealarmsignalis generated to verify the alarm circuitry
Motor rotation Motor isrotated a given amount andthe shaft sensor signalis

checkedbythe motorcontrolcircuitry

TechnicalServiceManual 5 -5 430-04502-003 (Rev. 4/99)

Section5MAINTENANCEANDSERVICETESTS

Table 5-2. ServiceTests

Test Description

Security door Testverifies the microcomputer recognizes whenthe securitydoor

islockedor unlocked

Syringetest Testverifies the microcomputer can detect the presenceandproper

positioning of the vialand injectorinthe syringedriver mechanism
Emptysyringe Testverifies the microcomputer detects an empty syringe
Low syringe Testverifies the microcomputer detects a lowsyringe(PCAPlus

only)

Table 5-3. ServiceOptions

Option Description

Patient pendant tone
selection

12 hourclock
selection (PCAPlus
only);12/24hour
clock selection(PCA
Plus IISeries)

Select RX
concentration
(3.1 software and
higher)

Selection provides one of the following options:

1.Tonewith successfulPCAdose only(default)

2.Toneon allattempted PCAdoses (placebo)
Selection provides one of the following options:

1. Clock format: 12 hour

2. Clock format: 24 hour

Selection provides one of the following options:

1.Milligramsonly

2.Milligramsand micrograms

3.Drugs, milligrams, andmicrograms

5.2.5

DELIVERYACCURACYTEST

Toperform thedelivery accuracytest,proceedas follows:

1.UsingaPCAvial/syringewithaprimedPCAadministrationsetanda21-gauge
butterfly, insertthevialintotheinfuservialholderandinjector cradle.

2.Purgetheinfuseratstartup,thensetuptheinfuserfor1mg/mL.Placethe
butterfly inthegraduate.Initiate twoloading doses of10 mL each.

3.Verify theinfuserdelivers 20

±1 mLinthegraduate.

430-04502-003 (Rev. 4/99) 5 -6 LifeCarePCAPlusandPlusII SeriesInfusers

PERFORMANCEVERIFICATIONTEST

5.2.6

OCCLUSIONTEST

Toperform theocclusiontest,proceedas follows:

1.Removetheplungerfromthesyringe.UsinganX-actoknife,cutthetwotopribs
offthesyringeplunger,asshowninFigure5-1,ModificationofSyringePlunger.
Makecertainthatnoroughmaterialis looseontheplunger.

2.Applyalightcoatingofsiliconeoiltotheremainingrib.Replacetheplungerinthe
syringe.

3.Insertthewater-filledmodifiedvialwiththeprimedPCAadministrationsetintothe
cradle assembly. Lubricatethevialwithsilicone oilbefore each use.

4.AttachtheDPMtothedistalendoftheadministrationsetthroughthethree-way
stopcock.

5.Allowtheinfuserselftesttocomplete.WhentheLCDscreendisplaysPURGETHE
SYSTEMNOW?,pressthe[SILENCE/NO]touchswitch.

6.WhentheLCDscreendisplaysDRUG:RxMORPHINE1MG/ML?YESORNO,
pressthe[YES/ENTER]touchswitch.

7.WhentheLCDscreendisplaysADMINISTERLOADINGDOSENOW?,pressthe
[YES/ENTER]touchswitch.

8.Selectloadingdoseof5mg.Pressthe[YES/ENTER]touchswitch,thenpressthe
[LOADINGDOSE]touchswitch.

9.Observefluid discharge attheend ofthestopcock, thenclose thestopcock.

10.VerifytheinfusersoundsanalarmandflashestheOCCLUSIONmessagewhenthe
pressuregauge indicatesthefollowing:

-008and lower:14.0 to19.0 psig (96.6to131.1kPa)

-010and higher:12.5 to17.5 psig(86.25 to120.75 kPa)

11.Openthestopcock toclear theOCCLUSIONalarm.

12.Pressthe[HISTORY]touchswitchandcheckforcorrecttime;ifincorrect,referto
thesystem operating manualfor informationonresettingthetime.

13.Clearalldosehistorydatafrommemorybyholdingdownthe[OFF/RECHG]
touchswitchuntil theLCDscreen, includingthebacklightedgrid,goes blank.

REMOVE
AND DISCARD
TOP TWO RIBS

CUT HERE

95F01015

Figure5-1. Modificationof Syringe Plunger

TechnicalServiceManual 5 -7 430-04502-003 (Rev. 4/99)

Section5MAINTENANCEANDSERVICETESTS

5.2.7

PCA+CONTINUOUSTEST

Toperform thePCA+ CONTINUOUStest,proceedas follows:

1.Removethemodifiedvialfromthecradleassemblyandsetupastandardwater-filled
vialwitha 21-gauge butterflyonthedistalend oftheset.

CAUTION:Donotremovetheprotectivecoverfromthebutterflyneedle.

2.Insert thevialintothecradleassembly.

3.WhentheLCDscreendisplaysPURGETHESYSTEMNOW?,pressthe
[SILENCE/NO]touchswitch.

4.WhentheLCDscreendisplaysDRUG:RxMORPHINE1MG/ML?YESORNO,
pressthe[YES/ENTER]touchswitch.

5.WhentheLCDscreendisplaysADMINISTERLOADINGDOSENOW?,pressthe
[YES/ENTER]touchswitch.

6.Selectloadingdoseof1mg.Pressthe[YES/ENTER]touchswitch,thenpressthe
[LOADINGDOSE]touchswitch.

7.WhentheLCDscreendisplaysSELECTMODEPCAONLY?,pressthe
[SILENCE/NO]touchswitch.

8.WhentheLCDscreendisplaysSELECTMODECONTINUOUS?,pressthe
[SILENCE/NO]touchswitch.

9.WhentheLCDscreendisplaysSELECTMODEPCA+CONTINUOUS?,pressthe
[YES/ENTER]touchswitch.SetPCAdose of 1 mg.Press[YES/ENTER].

10.Selecta lockoutinterval offive minutes, thenpress[YES/ENTER].

11.Selecta continuousrateof 20 mg/hr,then press[YES/ENTER].

12.When theLCDscreen displays 4 HOURDOSELIMIT SET?, press[YES/ENTER].

13.Selecta 4 HOURDOSELIMIT of1.5 mg, thenpress[YES/ENTER].

14.Pressthe[HISTORY]touchswitchtoconfirmthattheinfusersettingsareas
specified.Closeandlockthesecuritydoor;thedisplayshouldread:DOORLOCKED

-TOTALDELIVERED1 mg.

15.Pressthe[RESET/START]touchswitch.Verifythatthewalkingbarappearsinthe
LEDwindow,indicatingCONTINUOUSmodedelivery.Verifythatthreeasterisks
appear intheupper leftcorner.The asterisks indicatePCAdosingis available.

16.PressthepatientpendantpushbuttontodeliveraPCAdose;verifythatabeep
soundsandPCA+CONTINUOUSdisplays.Verifythewalkingbarappearsinthe
LEDwindow.

17.Afterapproximatelytwominutes,verifythefourhourdoselimithasbeenreached
andtheKVOrate has begun.Verify theTOTALDELIVEREDdisplays2.5 mg.

Note:Ifdeliveredpriortosetup,the loadingdose isnotincluded inthefourhour
dose limit.

18.Pressthepatientpendantpushbuttonthreetimes;theinfusershouldnotrespond.

19.Unlockthesecuritydoorandremovetheinjectorfromtheholder;verifythatthe
CHECKINJECTORmessageflashes.ReseatinjectorandverifythattheCHECK
INJECTORmessagedisappears.

430-04502-003 (Rev. 4/99) 5 -8 LifeCarePCAPlusandPlusII SeriesInfusers

PERFORMANCEVERIFICATIONTEST

20.Withthesecuritydoorunlocked,pullthetopofthevialaway fromthevialholder;
verifythattheCHECKVIALmessage flashes.Reinsertthevialandverifythatthe
CHECKVIAL messagedisappears.

21.Removethevialfromthecradle.Clearalldosehistorydatafrommemorybyholding
downthe[OFF/RECHG]touchswitchuntiltheLCDscreen,includingthe
backlighted grid,goes blank.

5.2.8

PATIENTCONTROLJACKTEST

Toperform thepatientcontrol jacktest, proceed asfollows:

1.Disconnectthepatientpendantcablefromthepatientcontroljackonthebackof
theinfuser.

2.Connectthetestcablephonejacktothepatientcontrolconnector;connectthe
leadsontheotherendofthecabletotheterminalsoftheDMMasappropriate.Set
theDMM to10voltDCscale.

3.TurnontheinfuserandverifyaDMMreadingofgreaterthanorequalto4.5VDC.
Removethetestcable from theinfuser.

5.2.9

PATIENTPENDANTASSEMBLYTEST

Toperform thepatientpendantassembly test,proceedas follows:

1.Disconnectthepatientpendantfromthepatientcontroljackonthebackofthe
infuser.

2.Unscrew theshieldfromthepatientpendantphonoplug.

3.SettheDMMtomeasurecontinuity,thenattachaDMMtestleadtoeachpatient
pendantphoneplugconnection(polarityisnotcritical).

4.Pressandholdthepatientpendantswitch.VerifytheDMMdisplayscontinuity
(0ohm)andthecontinuity beepersounds.

Note:Avalueofupto3ohmsmaybeindicatedduetopatientpendantcable
assembly internalresistance.

5.Pressandholdthepatientpendantswitch. Graspthepatientpendantcable
approximately4inches(10cm)abovethepatientpendantswitchandrotatethe
cablethreetofourtimeswhilebendingitapproximately30degrees.VerifytheDMM
continuestodisplaycontinuity.

6.Pressandholdthepatientpendantswitch. Graspthepatientpendantcable
approximately4inches(10cm)abovethephoneplugandrotatethecablethreeto
fourtimeswhilebendingitapproximately30degrees.VerifytheDMMcontinues
todisplay continuity.

7.Releasethepatientpendantswitch.VerifytheDMMdisplaysinfinity(maximum
resistance).

8.Connectthepatientpendantcabletothepatientcontroljack.Securethelocking
nut(ifapplicable).

TechnicalServiceManual 5 -9 430-04502-003 (Rev. 4/99)

Section5MAINTENANCEANDSERVICETESTS

5.2.10

BATTERYCHARGERTEST

Toperform thebattery charger test,proceedas follows:

1.Disconnect theinfuserfromACpower.

2.Remove thebatterycoveranddisconnect thebattery.

3.Connect theparallelnetworktothecharging circuitconnector.

4.ConnecttheinfusertoACpower.Powerontheinfuser.Measurevoltageacross
thenetwork;theDMMshouldread9.4
boostchargerPWA).

Note:The infusermustbepowered onbeforeobtaining theDMMreading.

Note: SeeSection4.2.3,BatteryBoostChargerPWA,toidentifyinfuser

configurations witha battery boostcharger PWA.

5.Removetheparallelnetwork.Reconnectandre-installthebattery;makecertain
thebatterywires are notpinched.Re-installthebattery cover.

±0.15VDC(14.5±2VDCwithabattery

5.2.11

ELECTRICALSAFETYTEST

Toperform theelectricalsafety test,proceedas follows:

1.ConnecttheACpowercordtoanapprovedsafetyanalyzer.Leakagecurrentmust
notexceed50microamperes,butmustbegreaterthan2microamperes(open
ground).

2.Usingthesafetyanalyzer,measuretheresistancebetweenthegroundlugoftheAC
connectorandexposedmetalparts,suchasthedoorkeylock,patientpendant
connector,ortheexposedscrewheadsonthepoleclamp.Notethatthedoorhinge
isnotgrounded.Resistanceshould notexceed0.1 ohm.

Note:Exposedmetalontheinfuserisisolated from ground.

430-04502-003(Rev.4/99) 5-10 LifeCarePCAPlusandPlusIISeriesInfusers

PERFORMANCEVERIFICATIONTEST

5.2.12

PRINTERTEST

Toperform theprintertest,proceedas follows:

1.Connect theinfusertoACpower.

2.Connecttheprintercable(Centronicsinterface)totheprinterportlocatedonthe
back oftheinfuser.

3.Power ontheprinter and verify itis online.

4.Opentheinfusersecuritydoor,theninsertthesyringeintothecradleassembly.
Verifytheinfuserbegins theselftest.

5.Aftertheselftestcompletes,thePURGESYSTEMNOW?promptdisplays.Pressthe
[PRINT]touchswitch.

6.ConfirmENDOFRECORDisprintedonthehistoryandeventlogprintout.Itmay
benecessary totakethe printer offline,thenformfeed thelastpartialpageofthe
printoutfromtheprinter.

7.ComparetheprintouttoFigure5-2,SamplePrinterTest.Date,time,andparameters
willvary.

Note:Depending ontheinfuserconfigurationor thesoftware revisionlevel, the printout
maynothavean HOUR-BY-HOUR:entry.

TechnicalServiceManual 5-11 430-04502-003(Rev.4/99)

Section5MAINTENANCEANDSERVICETESTS

*********************
* LIFECARE4100 *
* PATIENTRECORD *
*********************

PATIENTNAME:

_____________________

PATIENTID:

_____________________

DRUGADMINISTERED:

_____________________

10:41 NOV1794

MODENOTSET

SETTINGS:

CONCNOTSET

DELIVERED:

LOADING 0.0MG
TOTAL 0.0MG

LAST1 HOUR

PCADEMANDS 0
PCAINJECTED 0
PCAPARTIAL 0

LOADING 0.0MG
DOSEDEL 0.0MG
TOTAL 0.0MG

LAST24HOURS

PCADEMANDS 0
PCAINJECTED 0
PCAPARTIAL 0

LOADING 0.0MG
DOSEDEL 0.0MG
TOTAL 0.0MG

HOUR-BY-HOUR:

EVENTLOG:

10:41 PRINTOUT
10:41 ON

*********************
VERIFIEDBY:
*********************

*********************
* ENDOFRECORD *
*********************

Figure5-2. SamplePrinterTest

5.2.13

ENDOF PERFORMANCEVERIFICATIONTEST

AttheendofthePVT,clearalldosehistorydatafrommemorybyholdingdownthe
[OFF/RECHG]touchswitchuntilthedisplaygoesblank.Ifalltestshavebeensuccessful,
returntheinfusertoservice.Ifanyofthetestsfail,refertothetroubleshootinginformation
inSection 6,Troubleshooting, or contactAbbottLaboratories.

430-04502-003 (Rev. 4/99) 5- 12 LifeCarePCAPlusandPlusII SeriesInfusers

PVTDATAFORM

5.3

PVT DATAFORM

ListNumber: __________________SerialNumber: ____________________

Inspection

1.Verify thatalllabelsare ontheinfuser. Pass___Fail___

2.Inspect theelectricalcord for damage orforeignmaterial. Pass___Fail___

3.Verify thatthecontrolpanelswitcheshave nocracksor other
damage.

4.Verify thatthetwoVelcro straps are presentand not damaged. Pass___Fail___

5.Verify thatallscrewsare securedand tight. Pass___Fail___

6.Inspect thecasefor cracksorstains. Pass___Fail___

7.Inspect thepole clampand pads fordamage. Pass___Fail___

8.Verify thatthefrontpanelhas nocracksorcosmetic defects. Pass___Fail___

9.Verify thatthetwobottom pressurepadsare present anddo not
showexcessivewear.

10.Inspect thesecurity doorforany cracksorotherdamage. Pass___Fail___

11.Inspect thepatientpendantforcracked connector housingor
cable damage.

Pass___Fail___

Pass___Fail___

Pass___Fail___

ServiceTestMode

1.Record softwareversion_________

2.Alltestsinservicemode pass successfully. Pass___Fail___

DeliveryAccuracyTest

1.Setup PCAfor a concentrationof1 mg/mL.Delivertwoloading
doses of10.0 mL (Total =20.0 mL)andverify delivery accuracy.
Record___________ mL(specification=19.0 to21.0 mL)

OcclusionTest

1.Initiate 5 mg loadingdose and verifyocclusionalarmand
flashingOCCLUSION message.
Record__________ psig
Specification:

-008 andbelow:14.0 to19.0 psig (96.6to131.1 kPa)

-010 andabove: 12.4 to17.5 psig (86.25 to120.75kPa)

PCA+ContinuousTest

1.Verify thewalking bar isdisplayed duringcontinuous mode
delivery.

2.Verify thatthree asterisks appearintheupperleftcorner,
indicating PCAdosingavailable.

3.Verify a beepoccurs andPCA +CONTINUOUSis displayed
whenthependantispressed.

4.Approximately twominutesafter pressingthepatientpendant,
verifythat4 HRLIMREACHEDis displayed,KVOrate begins,
andTOTALDELIVEREDdisplayreads2.5 mg.

5.Verify thatafter pressing patient pendantthree more times,
thereis noresponsefromtheinfuser.

6.Verify thatby pullingthesyringe vialawayfromtheholder,a
check vialalarmoccurs.

7.Verify thatby pullingthesyringe injectoraway fromtheinjector
holder, thecheck injector alarmoccurs.

Pass___Fail___

Pass___Fail___

Pass___Fail___
Pass___Fail___
Pass___Fail___
Pass___Fail___

Pass___Fail___
Pass___Fail___
Pass___Fail___

TechnicalServiceManual 5-13 430-04502-003(Rev.4/99)

Section5MAINTENANCEANDSERVICETESTS

PatientControlJackTest

1.Verify thatthepatientcontrolinput measuresgreater thanor

Pass___Fail___

equalto4.50 VDC.

PatientPendant AssemblyTest

1.Connect DMMtopatient pendantphoneplugconnections.Set

Pass___Fail___
DMM tomeasurecontinuity. Pressandhold thepatient
pendantswitchandverify theDMM displayscontinuity.

2.Pressand hold thepatientpendantswitch while rotatingthe

Pass___Fail___
controlcable. Verify theDMM displayscontinuity.

3.Pressand hold thepatientpendantswitch while rotatingthe

Pass___Fail___
controlcable. Verify theDMM displayscontinuity.

4.Release patient pendantswitch.Verify DMMdisplays infinity. Pass___Fail___

BatteryChargerTest

1.Connect theparallelnetworkandmeasurethecharger voltage

Pass___Fail___
across thenetwork. Record___________VDC
Specification:

9.4±0.15 VDCwithoutbattery boostcircuit

14.5±2.0 VDCwithbattery boostcircuit

ElectricalSafetyTest

1.Record leakage current.____________

Pass___Fail___
Acceptable result50µA.

2.Record ground lugresistance. __________

Pass___Fail___
Acceptable result0.1 ohms.

PrinterTest

1.Confirm ENDOFRECORDisprintedonthehistory andevent

Pass___Fail___
log printout.

2.Compare theprintouttoFigure 5-2,SamplePrinter Test. Pass___Fail___

PerformanceVerificationTestperformedby__________________________Date:_____________
Test Equipment:
PressureMeter # _______________
SafetyAnalyzer# _______________
DMM # ______________________

430-04502-003 (Rev. 4/99) 5- 14 LifeCarePCAPlusandPlusII SeriesInfusers

Section6

TROUBLESHOOTING

ThissectioncontainsinformationonobtainingtechnicalassistancefromAbbott

LaboratoriesTechnicalSupportOperations,audiblealarmandalarmmessages,alarm

code history, andtroubleshootingtheinfuser.

6.1

TECHNICAL ASSISTANCE

Fortechnicalassistance,productreturnauthorization,andtoorderparts,accessories,or
manualswithintheUnitedStates,contactAbbottLaboratoriesTechnicalSupport

Operations.

1-800-241-4002

Sendallauthorized,prepaid returns tothefollowingaddress:

AbbottLaboratories

TechnicalSupportOperations

755 Jarvis Drive

Morgan Hill, California 95037
FromoutsidetheUnited States, contactthenearest AbbottLaboratoriesrepresentative.
ContacttheAbbottLaboratoriesprofessionalhospitalrepresentativeorAbbott

LaboratoriesTechnicalSupportOperationsforinformationabouttheAbbottLaboratories

Extended WarrantyProgram for thePCAPlusand PlusIISeriesInfuser.

6.2

DIAGNOSTICMODE

Note:A printer must be connectedtotheinfuserwhenusing thediagnostic mode.
ThePCAPlusIISeriesInfuserwith3.1softwareandabovehasadiagnosticmodethat

allowsretrievalofthelast200eventsandmalfunctioncodes.Thisinformationisretained
indefinitely ina battery-backedRAM ontheCPU/displayPWA.

Toaccessdiagnosticinformation,theinfusermustbeinstoragemode(cold-startcondition)

(see Section4.1.1.2,Cold-StartSequence).

Simultaneouslypressandholdthe[PURGESYSTEM]and[ON]touchswitchesfor
approximatelythreeseconds;theLCDscreenfirstdisplaysINTRAMTEST,then
DIAGNOSTICMODE.TheLCDscreenalsodisplaysthesoftwarerevisionandthetotal
elapsed days since theinfuserwas placed intoservice.

TechnicalServiceManual 6 -1 430-04502-003 (Rev. 4/99)

Section6TROUBLESHOOTING

Pressthe[YES/ENTER]touchswitch,thenpress[PRINT]toprintouttheeventlog,orpress
[SILENCE/NO]tocontinuetothemalfunctionlogscreen.

Thediagnosticmodeeventlogliststhelast200events.Themalfunctionlogliststhelast
200 malfunctioncodes(see Figure6-1,SampleEvent LogandMalfunctionLog).

********************
**DIAGNOSTIC MODE **
********************
S.W. VERSION: 3.13

ELAPSE DAYS: Ø

PM 12:Ø1 NOV 12 94

***************

EVENT LOG

***************
AM Ø8:28 OFF
AM Ø9:19 4 HR LIMIT NOT SELECTED
AM Ø9:19 LOCKOUT 5 MIN
AM Ø9:19 PCA DOSE 5.Ø MG
NOV Ø7 94 NEW DATE *
PM 12:16 OFF
PM 12:15 CHK SYR ALM
PM 12:15 INJECTR ALM
PM 12:14 CHK SYR ALM
PM 12:14 VIAL ALM
********************
VERIFIED BY:
********************

********************
**DIAGNOSTIC MODE **
********************
S.W. VERSION: 3.13

ELAPSE DAYS: Ø

PM 12:Ø6 NOV 12 94

***************
MALFUNCTION LOG

***************
/ML ØØ ØØ MALF. 1A
/ML Ø9 14 MALF. 2B
/ML Ø9 1Ø MALF. 3A
/ML Ø9 Ø9 MALF. 4F
********************
VERIFIED BY:
********************

********************
* END OF RECORD *
********************

********************
* END OF RECORD *
********************

Figure6-1. SampleEvent LogandMalfunction Log

95F01011

6.3

ALARM ANDDISPLAY MESSAGE OVERVIEW

Undermostalarmconditions,theinfuserstopsoperating,generatesanaudiblealarm,
anddisplaysan alarmmessageontheLCDscreen.

CAUTION:Forthosepatientswhoarelikelytobeadverselyaffectedbyunintended
operationsandfailures,includinginterruptedmedicationorfluiddeliveryfromthe
device,closesupervisionandprovisionforimmediatecorrectiveactionshouldbe
provided.

CAUTION:Donotreturntheinfusertoserviceafteranalarmormalfunctionwithout
determining andcorrectingthecauseofthealarmormalfunction.

430-04502-003(Rev.4/99) 6-2 LifeCarePCAPlusandPlusIISeriesInfusers

ALARM AND DISPLAYMESSAGEOVERVIEW

6.3.1

AUDIBLEALARMS

Theinfusersoundsanalarmintheeventofanyabnormalcondition.Thealarmvolume
canbe set toLOW,MEDIUM,or HIGHby a three-wayswitchonthebackoftheinfuser.

Theinfuserproducesfive differenttones,as follows:

1.A single, shorttone indicatestheinfusersensesa touchswitchbeingpressed.

2.Twoshorttonesindicate thestartof apower-up sequence.

3.Threeshorttonesindicatethatatouchswitchwaspressedthatisinvalidforthe
infuser’scurrentstateofoperationorisnotanallowableresponsetoaprompton
theLCDscreen.

4.Twoshort-tone,long-tonesequences,repeatingeveryfewseconds,indicatean
alarmcondition. TheLCDscreen displays thetype ofalarminflashingletters.

5.Acontinuoustone indicatesaninfuser malfunction.TheLCDscreenmayormay
not displayfurtherinformation,dependingonthemalfunction.

6.3.2

ALARMCAUSESANDACTIONS

Theinfuserwillstopdelivery whenany ofthefollowingalarms occur:

❏CHECKVIAL
❏CHECKINJECTOR
❏CHECKSYRINGE
❏EMPTY SYRINGE
❏OCCLUSION
❏MALFUNCTION

Thesealarms,theirpossiblecauses,andcorrectiveactionsaredetailedinTable6-2,Infuser

Troubleshooting.

6.3.3

MALFUNCTIONCODES

Table6-1,MalfunctionCodes,describesthemalfunctioncodesastheyappearwhenan

alarmsoundsand MALFUNCTIONappearsontheLCDscreen.

TechnicalServiceManual 6 -3 430-04502-003 (Rev. 4/99)

Section6TROUBLESHOOTING

Table6-1. MalfunctionCodes

Code Malfunction Corrective Action

1A MALF line went lowand couldnot

ReplaceCPU/display PWA

returnto normal

1B MALF line went lowand couldnot

ReplaceCPU/display PWA

returnto normal

1C MALF line didnot go low soonenough

ReplaceCPU/display PWA

after power-up
1D Malfunctionlinewent hightoo soon ReplaceCPU/display PWA
1E Watchdog circuit failureduring

ReplaceCPU/display PWA

real-timeoperation
2A Power-updiagnosticfailed ReplaceCPU/display PWA
2B Nonvolatile RAMchecksum testfailed ReplaceCPU/display PWA
3A Motorfailed to rotate Lubricateleadscrew

ReplacepowersupplyPWA
Replacemotor assembly

3B MOTORBADsignal from motor driver

ReplacepowersupplyPWA

circuitry

Replacemotor assembly
4A LCD timeouterror ReplaceCPU/display PWA
4B LCD datareadbackerror ReplaceCPU/display PWA
4C Nonvolatile RAMtestfailed ReplaceCPU/display PWA
4D EPROMchecksum testfailed ReplaceCPU/display PWA
4E Not used
4F LED segment defective ReplaceCPU/display PWA
4G Real-timeclock stopped ReplaceCPU/display PWA
4H Touchswitchstuckon front panel Replacefront panel

ReplaceCPU/display PWA
4I Not used
4J Not used
4K LED error ReplaceCPU/display PWA

430-04502-003(Rev.4/99) 6-4 LifeCarePCAPlusandPlusIISeriesInfusers

INFUSERTROUBLESHOOTING

Table6-1. MalfunctionCodes

Code Malfunction Corrective Action

4L Voltage error Replace powersupplyPWA
4M Not used
4N Error intimerT1 Replace CPU/display PWA
4O Error intimerT2 Replace CPU/display PWA
4P Programerror Replace CPU/display PWA
4Q CPU stackerror Replace CPU/display PWA
4R Analog-to-digitalconvertererror Replace CPU/display PWA
5A Undeterminederror ContactAbbott Laboratories

6.4

INFUSER TROUBLESHOOTING

Table6-2,InfuserTroubleshooting,showsfailuresymptomsandprobablecauses.
Table6-2is organized by thealarmmessagesthatappear ontheinfuserLCDscreen.

Beforetroubleshooting,turntheinfuserpoweroff,thenon.Allowtheselftesttocomplete.
If an alarmor malfunction persists,carefully inspecttheinfuserfordamageasdescribed
inSection5.1.1,InspectingtheInfuser. Ifalarmormalfunctionpersists,performthe
corrective action specified inTable 6-2,or contactAbbottLaboratories.

Table 6-2.InfuserTroubleshooting

Alarm Message/

FaultSymptom

CHECKVIAL Vialis improperly installed

ormissing

Possible

Cause

Corrective

Action

Properly insertvialinthe vial
cradle

(see systemoperating

manual)

Adjustvialsensorswitch

(see Section 7.2.4)

CHECKINJECTOR Injectorisimproperly

installed or missing

TechnicalServiceManual 6 -5 430-04502-003 (Rev. 4/99)

Properly insertinjector inthe
driver/retainer assembly(see
systemoperatingmanual)

Adjustinjector sensor switch

(see Section 7.2.3)

Section6TROUBLESHOOTING

Table 6-2.InfuserTroubleshooting

Alarm Message/

FaultSymptom

Possible

Cause

CHECKSYRINGE Syringe (vialand injector)

improperly installedor
missing

LOWSYRINGE
(PCAPlus only)

Approximately5 mL of
solutionremainingin
syringe

Messageoccurs too soon
ortoo late

EMPTYSYRINGE Syringe empty

(approximately 1 mL may
remain)

Corrective

Action

Properly insertsyringeinthe
cradle(see systemoperating
manual)

Replace injector sensor
switch
or vial sensorswitch

(see Section 7.3.27)

(see

Section 7.3.22)

Note alarm and press
[SILENCE/NO]touchswitch
to silence alarm

Adjustsyringelowswitch

(see Section 7.2.5)

Press [SILENCE/NO]
touchswitchto silence alarm.
Unlockandopensecurity
door,remove empty syringe
andturn infuseroff.Prepare
andinsertvial/injector.
Complete setup

(see system

operatingmanual)

Alarmoccurs too soonor
too late

CHECKSETTINGS Securitydoorclosedand

locked beforesetup was
complete

CHECK4-HR LIMIT Four-hour doselimit is set

lessthan PCAdose

DOOROPEN Securitydoorhas beenleft

openfor morethan two
minutes withouta
touchswitchbeing pressed

Infuser doesnot sense
doorclosure

Adjustsyringeempty switch

(see Section 7.2.6)

Open securitydoorand
assuresettings areproperly
entered

ConfirmPCAdoseis less
thanor equaltofour-hour
doselimit

Closeandlocksecurity door
after allparametersare
entered

Adjustdoor latchmechanism
Replace doorlockswitch

(see Section 7.3.41)

430-04502-003 (Rev. 4/99) 6 -6 LifeCarePCAPlusandPlusII SeriesInfusers

Table6-2. Infuser Troubleshooting

INFUSERTROUBLESHOOTING

Alarm Message/

FaultSymptom

Possible

Cause

OCCLUSION Kinkedor otherwise

occluded tubing, occluded
venipuncture device, or
closedslide clamp

Occlusion pressureout of
calibration

INFUSER INRESET

[RESET/START]

touchswitch pressedwhen
Note:INFUSERIN
RESET messagealso
appearsafter an alarm
conditionhas been

security doorlocked(in

CONTINUOUSor PCA+

CONTINUOUSmode)and

deliveryin progress
cleared. Press the
[RESET/START]
touchswitch to resume
delivery

Corrective

Action

Open security doorif closed.
Relievebackpressureby
squeezing and releasing the
cradlereleasehandles

Adjust occlusionpressure

(see Section 7.2.7.3

or

Section 7.2.7.4)

Replaceocclusionpressure
switch

(see Section 7.3.26)

Press the [RESET/START]
touchswitch to resume
delivery

LOWBATTERY(flashing
battery symbol)

No battery operation or
short operating timeto
LOWBATTERYalarm

Battery isneardischarge

level

Battery pack not fully

charged

Battery pack isdefective or

hasexceededuseful life

Connectinfuser to ACpower
Note:See

Section 4.4,

BatteryOperationOverview,

for detailedinformation about
battery-powered operation

Recharge battery pack for16
hours

Test battery chargingcircuit

(see Section 5.2.10).

If test
passes, replacebattery pack

(

see Section 7.3.5)

. If test
fails, replacepowersupply
PWA

(see Section 7.3.15)

Replacebattery pack(

see

Section 7.3.5)

TechnicalServiceManual 6-7 430-04502-003(Rev.2/99)

Section6TROUBLESHOOTING

Table 6-2.InfuserTroubleshooting

Alarm Message/

FaultSymptom

No ACor battery operation Fuse blown Replace fuse

Defectivepowersupply
PWA

MALFUNCTIONXX
(Error codedisplayedin

placeof XX)

No audiblealarm or
audiblealarm levelcontrol

Infuser self-testprograms
havedetected an internal
failure

Defectiveaudiblelevel
switch

Possible

Cause

Corrective

7.3.6)

MeasureACvoltage
betweenJ3 pins2 and3.If
voltage is between11and 17
VAC,replace power supply
PWA

(see Section 7.3.15)

voltage is not between11
and17 VAC,contactAbbott

Laboratories

Note malfunctioncode
displayed.Press
[OFF/RECHG]touchswitchto
silencealarm;turn infuser
off.Remove infuser from
serviceandrefer to

Replace audiblelevelswitch

(see Section 7.3.36)

Action

(see Section

. If

Table 6-1

Defectivepowersupply
PWA

Replace powersupplyPWA

(see Section 7.3.15)

6.5

PVTTROUBLESHOOTING

Table6-3,TroubleshootingwiththePVT,describesfailuresthatmaybedetectedduringthe

PVT(seeSection5.2).Ifanerrorcodedisplays,seeSection6.3,AlarmandDisplayMessage

Overview.

Table 6-3.Troubleshootingwiththe PVT

PVTTest Failure PossibleCause Corrective Action

Servicetestmode test

Section 5.2.4

Infuser not incoldstart Hold [OFF/RECHG]for six

seconds

Defectivetouchswitch Replace front panel

Section 7.3.40)

(see

DefectiveCPU/displayPWA Replace CPU/display PWA

(see Section 7.3.16)

430-04502-003 (Rev. 4/99) 6 -8 LifeCarePCAPlusandPlusII SeriesInfusers

PVTTROUBLESHOOTING

Table 6-3.Troubleshootingwiththe PVT

PVTTest Failure PossibleCause Corrective Action

Software version Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

Elapsed days Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

InternalRAM Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

External RAMADRS Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

External RAMcell Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

CPU Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

ROM Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

Real time clock Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

LED Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

LCD Defective CPU/displayPWA ReplaceCPU/display PWA

(see Section 7.3.16)

Keypad Looseconnection/damaged

ribboncable

Check ribbon cable from
touchswitch to J13 on
CPU/display PWA.Replace
front panelif necessary

(see

Section 7.3.40)

Check ribbon cable from J12
onCPU/displayPWAto J7 on
powersupplyPWA.Replace
ribbon cable if necessary

Section 7.3.19)

Defective touchswitch Replacefront panel

(see Section 7.3.40)

(see

Defective CPU/display PWA ReplaceCPU/display PWA

(see Section 7.3.16)

TechnicalServiceManual 6-9 430-04502-003(Rev.4/99)

Section6TROUBLESHOOTING

Table 6-3.Troubleshootingwiththe PVT

PVTTest Failure PossibleCause Corrective Action

Indicator Looseconnection/defective

ribbon cable

DefectiveCPU/displayPWA Replace CPU/display PWA

DefectivepowersupplyPWA Replace powersupplyPWA

Alarm Looseconnection/defective

ribbon cable

Defectivealarmvolume switch Replace alarm volumeswitch

Check ribbon cable from J12
onCPU/displayPWAto J7on
powersupplyPWA

Replace ribbon cable if
necessary

(see Section

7.3.19)

(see Section 7.3.16)

(see Section 7.3.15)

Check connection at J8 on
powersupplyPWA

Inspect interconnect PWA
cable for damage,replace if
necessary

(see Section

7.3.38)

or interconnect PWA

(see Section 7.3.36

or

Section 7.3.37)

Defectivepiezoelectricalarm Replace piezoelectric alarm

DefectivepowersupplyPWA Replace powersupplyPWA

DefectiveCPU/displayPWA Replace CPU/display PWA

Motor rotation Leadscrew dirtyor needs

lubrication
Looseconnection Check connectorJ5 on power

DefectivepowersupplyPWA Replace powersupplyPWA

Defectivemotor assembly Replace motor assembly

or interconnect PWA

(see Section 7.3.34
Section 7.3.37)

(see Section 7.3.15)

(see Section 7.3.16)

Lubricate lead screw

Section 7.2.11)

supply PWA

(see Section 7.3.15)

(see Section 7.3.28
Section 7.3.29)

or

(see

or

430-04502-003 (Rev. 4/99) 6- 10 LifeCarePCAPlusandPlusII SeriesInfusers

PVTTROUBLESHOOTING

Table 6-3.Troubleshootingwiththe PVT

PVTTest Failure PossibleCause Corrective Action

Security door Looseconnection Check connectorJ8 andJ7

onpower supply PWA

Doorlock switchout of
adjustment or defective

Adjustor replace doorlock
switch

(see Section 7.3.41)

DefectivepowersupplyPWA Replace powersupplyPWA

(see Section 7.3.15)

Syringetest Looseconnection Check connectorJ6 or J4 on

powersupplyPWA

Injectorsensorswitch
defective

Vialsensor switch out of
adjustment or defective

Replace injector sensorswitch

(see Section 7.3.27)

Adjustor replace vialsensor
switch

(see Section 7.3.22)

DefectivepowersupplyPWA Replace powersupplyPWA

(see Section 7.3.15)

Low/empty syringe Looseconnection Check connectorJ4 on power

supply PWA

Syringelowsensorswitch out
of adjustmentor defective

Adjustor replace syringelow
switch

(see Section 7.3.25)

(PCAonly)

Patient pendent tone
selection

12/24hour clock
selection (PCAPlus)

Select RX
concentration (3.1
software andhigher)

Syringeempty sensorswitch
out of adjustmentor defective

Adjustor replace syringe
empty switch

(see

Section 7.3.25)

DefectivepowersupplyPWA Replace powersupplyPWA

(see Section 7.3.15)

DefectiveCPU/displayPWA ReplaceCPU/displayPWA

(see Section 7.3.16)

DefectiveCPU/displayPWA ReplaceCPU/displayPWA

(see Section 7.3.16)

Incorrect software revision Verify software is3.1 or higher

TechnicalServiceManual 6- 11 430-04502-003 (Rev. 4/99)

Section6TROUBLESHOOTING

Table 6-3.Troubleshootingwiththe PVT

PVTTest Failure PossibleCause Corrective Action

Delivery accuracy test

Section 5.2.5

Occlusion test

Section 5.2.6

PCA+continuous test

Section 5.2.7

PCAsetnot primed properly Primeset/checkclamps
DefectivepowersupplyPWA Replace powersupplyPWA

(see Section 7.3.15)

Defectivemotor assembly Replace motor assembly

(see Section 7.3.28

or

Section 7.3.29)

Syringenot modifiedproperly Check modification ofsyringe

plunger

Setnot installed or primed

Primeset

properly
Occlusion pressureswitch out

of adjustmentor defective

Adjustor replace occlusion
pressureswitch

7.2.7.3

and

or

Section 7.3.26)

(see Section

Section 7.2.7.4

DefectivepowersupplyPWA Replace powersupplyPWA

(see Section 7.3.15)

Setnot installed or not primed
properly

Check installationand prime
set

Infuser not set up properly Check infuser settings

Patient controljack test

Section 5.2.8

Patient pendant
assemblytest

Section 5.2.9

Looseconnection Check connectorJ8 on the

powersupplyPWA

Defectiveinterconnect PWA
cable

Replace interconnect PWA
cable

(see Section 7.3.38)

Defectivepatientpendantjack Replace patientpendant jack

or interconnect PWA

(see Section 7.3.35

or

Section 7.3.37)

Defectivepatientpendant
assembly

Replace patientpendant
assembly

430-04502-003 (Rev. 4/99) 6- 12 LifeCarePCAPlusandPlusII SeriesInfusers

PVTTROUBLESHOOTING

Table 6-3.Troubleshootingwiththe PVT

PVTTest Failure PossibleCause Corrective Action

Batterychargertest

Section 5.2.10

Electrical safetytest

Section 5.2.11

Looseconnection Check connectorJ3 on the

powersupplyPWA
Check connectorP1 and P2

onboost chargerPWA

Defective boost chargerPWA Replaceboost charger PWA

(see Section 7.3.39)

Defective powersupply PWA ReplacepowersupplyPWA

(see Section 7.3.15)

Insufficient earth connection Check for adequate earth

connection

Defective ACpowercord plug ReplaceACpowercordplug

(see Section 7.3.13)

Defective ACpowercord ReplaceACpowercord

(see Section 7.3.12)

TechnicalServiceManual 6-13 430-04502-003(Rev.4/99)

Section6TROUBLESHOOTING

Thispage intentionally leftblank.

430-04502-003(Rev.4/99) 6-14 LifeCarePCAPlusandPlusIISeriesInfusers

Section7

REPLACEABLE PARTS AND
REPAIRS

Thissectionitemizesallpartsandsubassembliesoftheinfuserthatarerepairablewithin
thescopeofthismanual.Inaddition,thissectiondescribesreplacementprocedures for
alllistedparts.

WARNING

POSSIBLEEXPLOSIONHAZARDIFTHEINFUSERISSERVICED INTHEPRESENCE
OFFLAMMABLEANESTHETICS.

WARNING

UNLESSOTHERWISEINDICATED,DISCONNECTINFUSERFROMACPOWER
BEFORE PERFORMINGADJUSTMENTOR REPLACEMENTPROCEDURES.

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbag beforeplacingitonanysurface.

7.1

REPLACEABLEPARTSLIST

Replaceablepartsfortheinfuserareitemizedinthesparepartspricelistandareidentified
inFigure9-1,IPBfortheInfuser.Table9-2,IPBfortheInfuser,identifieseachinfuserpart
by anindex number thatcorrelates toFigure 9-1.

Torequestacopyofthecurrentsparepartspricelist,contactAbbottLaboratories.For
convenientreference,inserta copyof thespare parts pricelist here.

TechnicalServiceManual 7 -1 430-04502-003 (Rev. 4/99)

Section7REPLACEABLEPARTSANDREPAIRS

Thispage intentionally leftblank.

430-04502-003(Rev.4/99) 7-2 LifeCarePCAPlusandPlusIISeriesInfusers

ADJUSTMENTPROCEDURES

7.2

ADJUSTMENTPROCEDURES

Unlessotherwiseindicated,thefollowingproceduresrequireanemptysyringetobe
installedinthecradle.

WARNING

UNLESSOTHERWISEINDICATED,DISCONNECTINFUSERFROMACPOWER
BEFORE PERFORMINGADJUSTMENTPROCEDURES.

7.2.1

REQUIREDTOOLSANDMATERIALS

Thefollowingstandardhandtools,specialtools,andmaterials,orequivalents,arerequired
fortheadjustmentproceduresinthissection.Thetoolsandmaterialsrequiredforaspecific
adjustment procedureare listedatthebeginningofeach procedure.

❏SetofAllen wrenches
❏Setofnutdrivers
❏Setofopenend wrenches
❏Flatblade screwdriver
❏No.0 Phillipsscrewdriver
❏No.2 Phillipsscrewdriver
❏X-acto knife
❏Digitalpressuremeter (DPM),Bio-TekDPMII
❏RedGLPTinsulating varnish
❏Water-filled syringe
❏Empty syringe
❏Modified syringe
❏Three-waystopcock
❏IV administrationset
❏Permanentmarker
❏Syringe limitgauge
❏Trimpottool
❏Silicone oil, DowCorning
❏Grease, Braycote
❏Needlenose pliers
❏Electro-Wash 2000
❏Lint-free clothorcottonswabs
❏Smallbrush

®

®

360 Mineral Fluid

804

®

orisopropylalcohol

TechnicalServiceManual 7-3 430-04502-003(Rev.4/99)

Section7REPLACEABLEPARTSANDREPAIRS

7.2.2

SEPARATING FRONTANDREARCASEASSEMBLIES

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbagbeforeplacingitonanysurface.

Theinfuserfrontandrearcaseassembliesmustbeseparatedbeforeperformingany
adjustment procedure.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,
1/4inchnutdriver, 5/16 inchnutdriver, and permanentmarker.

Toseparatetheinfuserfrontandrearcaseassemblies,refertoFigure7-1,SeparatingFront

andRear CaseAssemblies,thenproceedas follows:

1.Disconnect theinfuserfromACpower.

2.Settheinfuseruprightona flatsurface.Confirmthesecurity dooris unlocked.

3.UsingaNo.2Phillipsscrewdriver,removetheACpowercordretainingplateby
removingthescrewthatattachestheretaining platetotheback oftheinfuser.

4.UsingaNo.2Phillipsscrewdriver,removethelongflat-headPhillipsscrewsfrom
eachcorner oftheinfuserrearcaseassembly.

5.Separate thefrontcaseassembly from therear caseassembly.

6.Disconnect the28 pin,2 rowconnectorfromJ8 onthepower supply PWA.

Note:Priortodisconnectingaconnector,verifyitisnumbered.Iftheconnector
containsnoidentifier,number itwitha permanentmarker.

7.Disconnect the16 pinconnectorfromJ9 onthepower supply PWA.

8.Disconnect the4 pinconnector from J3onthepower supplyPWA.

9.3.1Seriesonly:Disconnectthe4pinand6pinribboncablesfromJ1andJ2on
thebatteryboostcharger PWAattheback of therear caseassembly.

Note:Ribboncablesarehard-wiredtothepowersupplyPWA.Donotdamagethe
cables whendisconnectingthem.

10.Place thefrontassemblyonthework surface.

11.Usinga5/16inchnutdriver,removethenutandstarlockwashersecuringthe
ground wire (greenwithyellow stripe)tothemotor gear case.

12.Usinga5/16 inchnutdriver, removethe nut securing the groundwire(green with
yellowstripe)tothefrontpanel. Thenutmaybehiddenbytheribboncable
connectingthebottom ofthetwoPWAs.

13.DisconnectconnectorsJ4,J5, J6,and J7onthepower supplyPWA.

14.Re-assemble theinfuserintheexactreverse order ofdisassembly.

15.Closeandlockthesecurity door.

Toverifysuccessfulseparationandre-assemblyoftheinfuserfrontandrearcase
assemblies, perform thePVT as described inSection 5.2.

430-04502-003(Rev.4/99) 7-4 LifeCarePCAPlusandPlusIISeriesInfusers

ADJUSTMENTPROCEDURES

REAR COVER

ATTACHMENT

CASE

SCREW (4)

REAR VIEW

Figure7-1. Separating FrontandRearCase Assemblies

FRONT VIEW

FRONT COVER

95F01005

7.2.3

INJECTORSENSORSWITCHADJUSTMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbagbeforeplacingitonanysurface.

TheinjectorsensorswitchisadjustableonmostPCAPlusSeriesInfuserswithfinal
assemblies850-04250-002through850-04250-008.PCAPlusIISeriesInfuserswithfinal
assemblies850-04250-010andhigherdonotcontainaninjectorsensorswitchbracket;
therefore,theinjectorswitchisnotadjustable.SomeconfigurationsofPCAPlusSeries
Infuserswithfinalassemblynumbers850-04250-006through850-04250-008maynot
containaninjector sensorswitchbracket.

Recommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,1/4inch
nutdriver, 3/16 inchnutdriver, 5/16 inchnutdriver, and red GLPTinsulatingvarnish.

Toadjusttheinjectorsensorswitch,refer toFigure7-2,InjectorSensorSwitch(-008and

Lower)orFigure 7-3,InjectorSensorSwitch(-010andHigher), thenproceedas follows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

TechnicalServiceManual 7-5 430-04502-003(Rev.4/99)

Section7REPLACEABLEPARTSANDREPAIRS

3.Usinga3/16inchnutdriver,loosenthetwoswitchmountingscrewsuntiltheswitch
holdercanbeeasilymoved;donotloosenthescrewssomuchthattheswitch
bracket rocks from side toside.

4.Positiontheswitchbracketparalleltothesurfaceand1/32inchfromtheinfuser
case; tightenthescrews.

5.Apply red GLPTinsulating varnishtothescrew heads.

6.Re-assemble infuserinexactreverse order ofdisassembly.

7.Closeandlock securitydoor.

Toverifysuccessfuladjustmentoftheinjectorsensorswitch,performthePVTasdescribed
inSection 5.2.

MOTOR ASSEMBLY

INJECTOR

SENSOR
SWITCH

BRACKET

INFUSER
FRONT CASE

Figure7-2. InjectorSensor Switch (-008and Lower)

SWITCH MOUNTING
SCREW (2)

95F01010

430-04502-003(Rev.4/99) 7-6 LifeCarePCAPlusandPlusIISeriesInfusers

ADJUSTMENTPROCEDURES

MOTOR ASSEMBLY

SWITCH MOUNTING
SCREW (2)

INFUSER
FRONT CASE

95F01023

Figure 7-3. Injector Sensor Switch(-010and Higher)

7.2.4

VIALSENSORSWITCHADJUSTMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbag beforeplacingitonanysurface.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,
1/4inchnutdriver,3/16inchnutdriver,5/16inchnutdriver,andredGLPTinsulating
varnish.

Toadjustthevialsensorswitch,refertoFigure7-4,VialSensorSwitchandSyringeLow

Switch(-008andLower),thenproceedas follows:

Note:Infuserswithfinalassemblynumber-010andhigherdonothaveavialsensor
switchbracket(seeFigure7-5,VialSensorSwitch(-010andHigher).Noadjustmentis
required oninfusers withfinalassembly number -010 and higher.

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

3.Loosenthetwovialsensorswitchadjustmentscrewswitha3/16inchnutdriver
untiltheswitchholdercanbeeasilymoved;donotloosenthescrewssomuchthat
theswitch bracket rocksfromside toside.

4.Placetheswitchbracketupright.Movetheswitchupslowlyuntilitclicksoff,then
movetheswitchdownslowlyuntilitclickson. Movetheswitchdownfurther

TechnicalServiceManual 7 -7 430-04502-003 (Rev. 4/99)

Section7REPLACEABLEPARTSANDREPAIRS

(approximately1/16inch)toverifytheswitchdetectsavial.Tightenthescrews
whilekeeping theswitchbracketlevel.

5.Apply red GLPTinsulating varnishtothescrew heads.

6.Re-assemble theinfuserintheexactreverse order ofdisassembly.

7.Closeandlock thesecuritydoor.

Toverifysuccessfuladjustmentofthevialsensorswitch,performthePVTasdescribedin

Section5.2.

VIAL SENSOR

ROD

VIAL SENSOR

SWITCH

ACTUATOR ARM

ADJUSTMENT SCREWS

FOR VIAL SENSOR SWITCH

Figure 7-4. VialSensor Switch and Syringe LowSwitch (-008and Lower)

VIAL SENSOR
SWITCH
BRACKET

SYRINGE LOW
SWITCH

SYRINGE EMPTY
SWITCH

95F01012

430-04502-003 (Rev. 4/99) 7 -8 LifeCarePCAPlusandPlusII SeriesInfusers

VIAL SENSOR ROD

VIAL SENSOR SWITCH

ACTUATOR ARM

ADJUSTMENTPROCEDURES

VIAL SENSOR
SWITCH

95F01013

Figure 7-5. VialSensor Switch(-010andHigher)

7.2.5

SYRINGELOWSWITCHADJUSTMENT(PCAPLUS ONLY)

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbag beforeplacingitonanysurface.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,
1/4inchnutdriver,3/16inchnutdriver,5/16inchnutdriver,syringelimitgauge,and
red GLPTinsulating varnish.

Toadjustthesyringelowswitch,refertoFigure7-4,VialSensorSwitchandSyringeLow

Switch(-008andLower),thenproceed asfollows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

3.Installthesyringelimitgaugeinthecradle.Squeezethecradleclampsandmove
thecradleuptothelimitallowedbythegauge.Verifythatthegaugedialreads
approximately0.05inch (0.127cm).

4.Starttheinfuserusinganydrug/concentrationsetting.Purgethesystemuntilthe
gauge dialreadsapproximately 0.1 inch.

TechnicalServiceManual 7 -9 430-04502-003 (Rev. 4/99)

Section7REPLACEABLEPARTSANDREPAIRS

5.Usinga3/16inchnutdriver,loosenthetwoscrewssecuringthesyringelowswitch
bracket. Movetheswitchbracket untiltheswitchclickson.Tightenthescrews.

6.Movethecradleuptothelimitallowedbythegauge.Programtheinfuserfornormal
operationandverifythatthesyringelowalarmoccurswhenthegaugedialreads
between0.05 inchand 0.15 inch.

7.Apply red GLPTinsulating varnishtothescrew heads.

8.IfSection7.2.6,SyringeEmptySwitchAdjustment,isnotperformed,re-assemble
theinfuserintheexact reverseorderofdisassembly.

9.Closeandlock thesecuritydoor.

Toverifysuccessfuladjustmentofthesyringelowswitch,performthePVTasdescribed
inSection 5.2.

7.2.6

SYRINGEEMPTYSWITCHADJUSTMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbag beforeplacingitonanysurface.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,
1/4inchnutdriver,3/16inchnutdriver,5/16inchnutdriver,syringelimitgauge,and
red GLPTinsulating varnish.

Toadjustthesyringeemptyswitch,refertoFigure7-6,SyringeEmptySwitch(-008and

Lower)orFigure 7-7,SyringeEmpty Switch(-010 andHigher),then proceedas follows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

3.Installthesyringelimitgaugeinthecradle.Squeezethecradleclampsandmove
thecradleuntilthedialreadsapproximately0.3inch. WhentheLCDscreen
displaysPURGETHESYSTEMNOW?,pressthe[YES/ENTER]touchswitch.Purge
thesystemuntilthegaugereadsapproximately0.39inch.Iftheemptysyringe
alarmisactivatedbeforethesystemispurged,loosenthesyringeemptyadjustment
screwsandmovetheswitchbracketupuntiltheswitchclicksoffandthealarm
stops.

4.Loosentheadjustmentscrewsasnecessary.Movetheswitchbracketdownslowly
untiltheswitchclicks on.Tighten thescrews.

5.Adjustthecradleuntilthegaugedialreadsapproximately0.3inch.Settheinfuser
forPCAonlymodedelivery.WhentheLCDscreendisplaysSELECTMODEPCA
ONLY?,pressthe[YES/ENTER]touchswitch.

6.Seta PCAdoseof5 mg.

7.Closeandlock thesecuritydoor.

8.Whenthreeasterisks(***)appearontheLCDscreen,pressthepatientpendant
pushbutton.

9.Verifytheemptysyringealarmoccurswhenthedialreadsbetween0.39and

0.41inch.Ifthealarmdoesnotoccurwithintheseparameters,returntoStep3
andvary thesettingtoless thanor greater than0.39 inch,asappropriate.

10.Tighten thescrews.Applyred GLPTinsulatingvarnishtothescrewheads.

430-04502-003 (Rev. 4/99) 7- 10 LifeCarePCAPlusandPlusII SeriesInfusers

ADJUSTMENTPROCEDURES

11.Re-assemble theinfuserintheexactreverse order ofdisassembly.

12.Closeandlockthesecurity door.

Toverifysuccessfuladjustmentofthesyringeemptyswitch,performthePVTasdescribed
inSection 5.2.

SYRINGE EMPTY

BRACKET ARM

DIRECTION
OF TRAVEL

SYRINGE EMPTY

SWITCH ARM

Figure7-6.SyringeEmpty Switch (-008and Lower)

SYRINGE LOW
BRACKET ARM

SYRINGE LOW
SWITCH ARM

95F01014

TechnicalServiceManual 7-11 430-04502-003(Rev.4/99)

Section7REPLACEABLEPARTSANDREPAIRS

SYRINGE EMPTY

SWITCH ARM

DIRECTION
OF TRAVEL

95F01036

Figure7-7. SyringeEmptySwitch (-010and Higher)

7.2.7

OCCLUSION ALARMSWITCHTESTAND ADJUSTMENT

Therecommendedtoolsforthisprocedureareasfollows:No.0Phillipsscrewdriver,No.2
Phillipsscrewdriver,1/4inchnutdriver,3/16inchnutdriver,5/16inchnutdriver,two
9/32inchopenendwrenches,5/64inchAllenwrench,X-actoknife,redGLPTinsulating
varnish, water-filled syringe,DPM,three-waystopcock,and IV administrationset.

Note:Thefollowingprocedurerequiresamodifiedsyringetoassurethatthefriction
betweenthesyringeplungerandtheinsidesurfaceofthevialwillnotcausefalseocclusion
pressurereadings.

7.2.7.1

MODIFYING THESYRINGE

Tomodifythesyringe,refertoFigure7-8,ModificationofSyringePlunger,thenproceedas
follows:

1.Removetheplungerfromthesyringe.UsinganX-actoknife,cutthetwotopribs
offthesyringeplunger,asshowninFigure7-8.Makecertainthatnoroughmaterial
islooseontheplunger.

2.Applyalightcoatingofsiliconeoiltotheremainingrib.Replacetheplungerinthe
syringe.

430-04502-003(Rev.4/99) 7-12 LifeCarePCAPlusandPlusIISeriesInfusers

CUT HERE

Figure7-8. Modificationof Syringe Plunger

7.2.7.2

OCCLUSIONALARMSWITCHTEST

ADJUSTMENTPROCEDURES

REMOVE
AND DISCARD
TOP TWO RIBS

95F01015

Toperformtheocclusionalarmswitchtest,refertoFigure7-9,OcclusionAlarmTestSetup,
then proceedas follows:

1.Disconnect theinfuserfromACpower.

2.Usinga three-waystopcock,attachtheDPMtotheend ofthepatientline.

3.Installawater-filledsyringewithmodifiedplungerandanIVadministrationset
intotheinfuser.

4.Purgethesetuntilwaterflowsoutofthestopcockvalve.Closethevalve.When
theLCDscreendisplaysDRUG:RxMORPHINE1MG/ML?YESORNO,press
[YES/ENTER].

5.Programaloadingdoseof10mg.Lettheinfuseroperateuntilanocclusionalarm
sounds.

6.Notethereadingonthemeterwhentheocclusionalarmoccurs.Ifthereadingis
notbetween14and19psig(96.6and131.1kPa)for-008andloweror12.5and

17.5psig(86.25and120.75kPa)for-010andhigher,performtheocclusionalarm
adjustmentprocedureinSection7.2.7.3,OcclusionAlarmSwitchandPressure

Adjustment(-008andLower)or7.2.7.4,OcclusionAlarmSwitchandPressure
Adjustment (-010 and Higher).

Ifthereadingisbetweenthespecifiedparameters,performthePVTasdescribedin

Section5.2.

TechnicalServiceManual 7- 13 430-04502-003 (Rev. 4/99)

Section7REPLACEABLEPARTSANDREPAIRS

WATER-FILLED

VIAL

STOPCOCK

DPM

UNIVERSAL

PRESSURE METER

0.00

cm OF H O

INCHES OF H O

2

2

-13.5 TO 15

mmHg

OFF

PRESSURE INPUT

-13.5 TO 75

PSI

PURGE
SYSTEM

LOAD
DOSE

ON

OFF

RECHG

YES

ENTER

REVIEW
CHANGE

SILENCE

NO

RESET
START

Abbott

LIFECARE

PRINT

HISTORY

PCA PLUS

4100

DRAIN

95F01003

Figure7-9. OcclusionAlarmTest Setup

7.2.7.3

OCCLUSIONALARMSWITCHANDPRESSUREADJUSTMENT (-008ANDLOWER)

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbagbeforeplacingitonanysurface.

Toadjusttheocclusionalarmswitchandpressure,refertoFigure7-10,OcclusionAlarm

PressureAdjustment (-008 and Lower),thenproceedas follows:

1.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

2.Examinethepositionoftheocclusionalarmswitch.Iftheswitchbuttonisin
contactwiththeswitchactuator,proceedtoStep5.Iftheswitchbuttonisnot
makingcontactwiththeswitchactuator,loosenthebracketlocknutatthetopof
thebracket, usingan11/32 inchopenend wrench.

3.Usinga9/32inchAllenwrench,adjustthesetscrewsotheswitchbuttonmakes
contact with theswitch actuator,but does notopentheswitch.

4.Retightenthebracketlocknut,usingthe11/32inchopenendwrench,andapply
red GLPTinsulating varnishtoprevent theset screw from turning.

430-04502-003(Rev.4/99) 7-14 LifeCarePCAPlusandPlusIISeriesInfusers

ADJUSTMENTPROCEDURES

5.Usinga5/16inchopenendwrench,loosenthelowerlocknutbelowthecompression
spring.

6.ConnectthecablesfromtherearcaseassemblytothePWAsandslideassemblyto
allowtheinfusertooperatewiththecaseopen.Supportthefrontcaseassembly
tokeepituprightfortheadjustmentprocedure.

7.Installawater-filledsyringewithamodifiedplungerintotheinfuser;connectanIV
administrationset, DPM,andstopcock.Openthestopcock valve.

8.Purgethesystemuntilwaterflowsoutofthestopcockvalve.Closethevalve.When
theLCDscreendisplaysDRUG:RxMORPHINE1MG/ML?YESORNO,press
[YES/ENTER].Programaloadingdoseof10mg.Lettheinfuseroperateuntilan
occlusionalarm soundsorthepressure reaches19 psig(131.1 kPa).

9.Iftheocclusionalarmsoundsbeforethepressurereaches14psig(96.6kPa),relieve
thefluidpressurebyopeningthestopcockvalve. Tightentheupperlocknut
one-halfturnagainst thecompressionspring.RepeatStep7.

10.Iftheocclusionalarmdoesnotsoundat19psig(131.1kPa),relievethefluid
pressure,loosen theupperlocknutone-half turn.RepeatStep 7.

11.Whentheinfuseroccludesatbetween14and19psig(96.6and131.1kPa),retighten
thelowerlocknutagainsttheupperlocknut;useone5/16inchopenendwrench
toholdtheupperlocknutandanother5/16inchopenendwrenchtotightenthe
lower locknutagainsttheupper locknut.

12.Closeandlockthesecurity door.

Toverifysuccessfuladjustmentoftheocclusionalarmswitchandpressure,performthe
PVT as describedinSection5.2.

ADJUSTMENT

OCCLUSION

ALARM SWITCH

ADJUSTMENT

SET SCREW

(NOT SHOWN)

BRACKET
LOCKNUT

LOCKNUTS

TOP PLATE

LEFT

SWITCH

CLAMP LEVER

ACTUATOR

SWITCH
BUTTON

COMPRESSION

SPRING

CRADLE

CLAMP

SPLIT NUTS

RIGHT
CLAMP LEVER

LEAD

DIRECTION OF

SCREW

LEAD SCREW

95F01037

Figure7-10. OcclusionAlarmPressure Adjustment(-008and Lower)

TechnicalServiceManual 7-15 430-04502-003(Rev.4/99)

Section7REPLACEABLEPARTSANDREPAIRS

7.2.7.4

OCCLUSIONALARMSWITCHANDPRESSUREADJUSTMENT (-010ANDHIGHER)

Toadjusttheocclusionalarmswitchandpressure,refertoFigure7-11,OcclusionAlarm

PressureAdjustment (-010 and Higher),thenproceedas follows:

1.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

2.Examinethepositionoftheocclusionalarmswitch.Iftheswitchactuatorisin
contactwiththeswitchbutton,proceedtoStep3.Iftheswitchactuatorisnot
makingcontactwiththeswitchbutton,useaNo.0Phillipsscrewdrivertoloosen
thescrewontheswitchactuator. Adjustthescrewuntiltheswitchactuator
contacts theswitchbutton,butdoesnot triptheswitch.

3.ConnectthecablesfromtherearcaseassemblytothePWAsandslideassemblyto
allowtheinfusertooperatewiththecaseopen.Supportthefrontcaseassembly
tokeepituprightfortheadjustmentprocedure.

4.Installawater-filledsyringewithmodifiedplungerintotheinfuser;connectanIV
administrationset, DPM,andstopcock.Openthestopcock valve.

5.Purgethesystemuntilwaterflowsoutofthestopcockvalve.Closethevalve.When
theLCDscreendisplaysDRUG:RxMORPHINE1MG/ML?YESORNO,press
[YES/ENTER].Setandinitiatealoadingdoseof10mg.Allowtheinfusertooperate
untilanocclusion alarmsoundsor thepressurereaches17.5 psig (120.75 kPa).

6.Iftheocclusionalarmsoundsbeforethepressurereaches12.5psig(86.25kPa),
relievethefluidpressurebyopeningthestopcockvalve.Loosenthesetscrewon
thethumb nutandturnthethumb nutclockwisetotighten.RepeatStep4.

7.Iftheocclusionalarmdoesnotsoundatorbefore17.5psig(120.75kPa),relieve
thefluidpressurebyopeningthestopcockvalve.Loosenthesetscrewonthethumb
nutandturnthethumbnutcounterclockwise toloosen.RepeatStep 4.

8.Whentheinfuser occludesat between12.5and 17.5psig (86.25and 120.75kPa),
retightentheset screwonthethumb nut.

9.Closeandlock thesecuritydoor.

Toverifysuccessfuladjustmentoftheocclusionswitchandpressure,performthePVTas
describedinSection 5.2.

430-04502-003(Rev.4/99) 7-16 LifeCarePCAPlusandPlusIISeriesInfusers

ADJUSTMENTPROCEDURES

SWITCH

ACTUATOR

NO. 0 PHILLIPS
SCREW

OCCLUSION ALARM

SWITCH

COMPRESSION SPRING

SLIDE CLAMP
RELEASE LEVER

THUMB NUT

PIVOT POST

(BEHIND

LEAD SCREW)

LEAD SCREW

DIRECTION OF

LEAD SCREW

Figure 7-11. OcclusionAlarm Pressure Adjustment(-010and Higher)

95F01016

7.2.8

LCDINTENSITYADJUSTMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbag beforeplacingitonanysurface.

Therecommendedtoolfor this procedureisa trimpottool.
ToadjusttheLCDintensity,refertoFigure7-12,CPU/DisplayPWA,LED,andLCD

Assembly.

1.RemovethepowersupplyPWAasdescribedinSection7.3.15,PowerSupplyPWA

Replacement.

2.Remove thefourspacersfrom theCPU/display PWA.

3.LifttheCPU/displayPWAfromthefrontenclosure.Removetheflexiblecircuitcable
fromJ13 ontheCPU/displayPWA.

4.PositionthepowersupplyPWAandtheCPU/displayPWAsotheresistorR19
adjustmentscrewis accessible. ConnectP3of the power cableto J3on thepower
supplyPWA.Connect the40 pinribboncable toJ7 onthepowersupply PWA.

CAUTION:AssurethepowersupplyPWAandtheCPU/displayPWAremain
separatedduringtheadjustmentprocedure.

5.ConnecttheinfusertoACpower.Usingthetrimpottool,adjustresistorR19so
theLCDscreen can be readfroma distanceofapproximately three feet.

6.DisconnecttheinfuserfromACpower.ConnecttheflexiblecircuitcabletoJ13.
InserttheCPU/displayPWA inthefront enclosure;replace thefour spacers.

TechnicalServiceManual 7- 17 430-04502-003 (Rev. 4/99)

Section7REPLACEABLEPARTSANDREPAIRS

7.Replace thepowersupply PWAintheexactreverse order of itsremoval.

ToverifysuccessfuladjustmentoftheLCDintensity,performthePVTasdescribedin

Section5.2.

ADHESIVE-BACKED
PLASTIC INSULATOR

LCD DISPLAY ASSEMBLY

STANDOFF (4)

LED

J14

SOCKET

LCD RIBBON
CABLE

40 PIN
RIBBON CABLE

J15

R19

ADJUSTMENT SCREW

CPU/DISPLAY PWA

J13

J12

Figure7-12. CPU/DisplayPWA,LED,and LCDAssembly

TO POWER
SUPPLY PWA

7.2.9

SETTINGTHEREALTIMECLOCK(PCAPLUSII)

95F01020

Notools arerequired forthisprocedure.
ThePCAPlusIISeriesInfuserreal-timeclocktrackstime.Infuseroperationsrequirethat

thereal-timeclockbeoperatingproperly.Thereal-timeclockmustbesetunderthe
followingcircumstances:

❏Initialinstallation
❏Timechange
❏Followingcompletebattery discharge

Atstartup,aftersuccessfulcompletionoftheselftest,thetimeanddatearedisplayedon
theLCDscreen. To reset thereal timeclock,proceedas follows:

430-04502-003(Rev.4/99) 7-18 LifeCarePCAPlusandPlusIISeriesInfusers

ADJUSTMENTPROCEDURES

1.Pressthe[NO] touchswitchtoadvancebeyondtheCLEAR?screen.

2.Pressthe[NO] touchswitchtoadvancebeyondthePURGESYSTEMNOWscreen.

3.Pressthe[YES/ENTER]touchswitchtoselect thefirstavailabledrug screen.

4.Pressthe[NO]touchswitchtoadvancebeyondtheADMINISTERLOADINGDOSE
screen.

5.Pressthe[YES/ENTER]touchswitchtoselect PCAONLYmode.

6.Pressthe[YES/ENTER]touchswitchtoselect thedisplayed PCAdose.

7.Pressthe [YES/ENTER] touchswitchto selectthe displayedLOCKOUTINTERVAL.

8.Pressthe[NO] touchswitchtoadvancebeyondthe4 HOURDOSELIMIT.

9.Pressthe[REVIEWCHANGE]touchswitchtoadvancebeyondthePCASETTINGS
screen.

10.Pressthe[NO]touchswitchtoadvancebeyondtheCHANGE?ANY
SETTINGS:/MODEscreen.

11.Pressthe[YES/ENTER]touchswitchtoselecttheCHANGE?screentoresettime
anddate.

Note:Ifthefieldsstopflashingbefore the correct timeanddate are set, pressthe
[NO]touchswitchtorestart theflashing.

12.Pressthe[⇑]or [⇓]touchswitchtoenterthecorrect value.

13.Pressthe[REVIEWCHANGE]touchswitch toadvancethe flashingfieldto thenext
field tobechanged.

14.Whenallfieldshavebeenset,theLCDscreendisplaysACCEPT?.Pressthe
[YES/ENTER]touchswitchtoacceptthevalues.

Settingtherealtimeclockisaroutinemaintenanceprocedureandnoverification
procedureisnormallyrequired.However,iftheinfusermayhavebeendamagedduring
this procedure,perform thePVT as describedinSection5.2.

7.2.10

DOORLOCKSWITCHADJUSTMENT

Therecommendedtoolfor this procedureisneedle nosepliers.
Toadjustthedoorlockswitch,proceed asfollows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfusercaseassembliesasdescribedinSection7.2.2,SeparatingFront

andRear CaseAssemblies.

3.Pressthedoor lockactuator arm and listen forswitchactuation.

4.Closeandlockthesecuritydoorandconfirmthedoorhookandthedoorlock
actuator hold thedoor closed.

5.Withthesecuritydoorclosed,turnthekeytotheunlockedandlockedpositions
whilelisteningforswitchactuation.Ifthedoorlockswitchisadjustedproperly,
switchactuationshouldbe heardeachtime thedoorislockedorunlocked.Ifthe
doorlockswitchdoes notrequire adjustment, proceed toStep7.

6.Usingneedlenosepliers,carefullybendthedoorlockactuatorortheswitchactuator
arm (asapplicable)until properadjustmentis achieved.Becareful notto damage
theswitch.

TechnicalServiceManual 7-19 430-04502-003(Rev.4/99)

Section7REPLACEABLEPARTSANDREPAIRS

7.Re-assemble theinfuserintheexactreverse order ofdisassembly.

8.Closeandlock thesecuritydoor.

Toverifysuccessfuladjustmentofthedoorlockswitch,performthePVTasdescribedin

Section5.2.

7.2.11

LEADSCREWLUBRICATION

Recommendedtoolsforthisprocedureareasfollows:Electro-Wash2000orisopropyl
alcohol,lint-free clothor cottonswabs,grease, and a smallbrush.

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfusercaseassembliesasdescribedinSection7.2.2,SeparatingFront

andRear CaseAssemblies.

3.UsingElectro-Wash2000 orisopropylalcoholandasmallbrushorcottonswabs,
remove allold greaseand residue fromthelead screw.

Note:IsopropylalcoholmaybesubstitutedforElectro-Wash2000;however,if
usingisopropylalcohol,useextracaretoassurethatallresiduallubricantis
removed.

4.Applyathincoatingofgreaseandworkitintothethreadsalongthelengthofthe
shaft.Donotfillthethreads.Movetheslideclampasnecessarytocleanand
lubricate thelengthofthelead screw.

5.Re-assembletheinfusercaseassembliesintheexactreverseorderofdisassembly.

Toverify successfulleadscrewlubrication,perform thePVTas describedinSection5.2.

7.3

REPLACEMENT PROCEDURES

Thissectioncontainssafetyandequipmentprecautions,requiredtoolsandmaterials,and
step-by-stepreplacementproceduresfortheinfuser.Unlessotherwisestated,always
perform thePVT after replacementprocedures.

7.3.1

SAFETYANDEQUIPMENTPRECAUTIONS

Beforeopeningthefrontenclosureoftheinfuser,takeallnecessaryprecautionsfor
working onhigh-voltageequipment.

WARNING

UNLESSOTHERWISEINDICATED,DISCONNECTTHEINFUSERFROMACPOWER
BEFORE PERFORMINGANYREPLACEMENTPROCEDURE.

430-04502-003(Rev.4/99) 7-20 LifeCarePCAPlusandPlusIISeriesInfusers

REPLACEMENTPROCEDURES

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbagbeforeplacingitonanysurface.

7.3.2

REQUIREDTOOLSANDMATERIALS

Thefollowingtoolsandmaterials,orequivalents,arerequiredforthereplacement
proceduresinthissection.Inaddition,atthebeginningofeachprocedureisalistoftools
andmaterialsrequired forthatspecific procedure.

❏SetofAllen wrenches
❏Setofnutdrivers
❏7/8inchopenendwrench
❏Setofboxwrenches(3/16 inch to1/4 inch)
❏Smallflatblade screwdriver
❏Standard flatbladescrewdriver
❏No.0 Phillipsscrewdriver
❏No.1 Phillipsscrewdriver
❏No.2 Phillipsscrewdriver
❏Electriciansknife
❏X-acto knife
❏Wire cutters
❏Wire strippers
❏Solderingiron
❏Solder, tin/lead,Sn63/Pb37,RMAtypeonly
❏Shrinktubing, 1/8 inch
❏Smalltiewraps
❏Isopropylalcohol
❏Grease, Braycote804
❏Heatgun(optional)

7.3.3

SEPARATING FRONTANDREARCASEASSEMBLIES FOR REPLACEMENTPROCEDURES

Several of the replacement proceduresin this sectionrequireseparatingtheinfuserfront
andrearcaseassemblies. RefertoSection7.2.2,SeparatingFrontandRearCase

Assemblies,asindicated inthefollowing procedures.

7.3.4

BATTERYPACKCOVERREPLACEMENT

Therecommendedtoolfor this procedureisa 1/4 inchnutdriver.

TechnicalServiceManual 7-21 430-04502-003(Rev.4/99)

Section7REPLACEABLEPARTSANDREPAIRS

Toreplacethebatterypackcover,refertoFigure7-13,BatteryPackReplacement,then
proceed asfollows:

1.Disconnect theinfuserfromACpower.

2.Place theinfuserfacedownona softsurface. Usinga 1/4 inchnutdriver, remove
thetwo6-32 hexhead screwsfromthebottomcover.

3.Remove thebatterypackcover andinstallthereplacement battery pack cover.

4.Replace thetwoscrewsremovedinStep2.

Replacementofthebatterypackcoverisaroutinemaintenanceprocedureandno
verificationprocedureisnormallyrequired. However,iftheinfusermayhavebeen
damaged duringthis procedure,perform thePVT as described inSection 5.2.

BATTERY

COVER

6-32 X 1/2

HEX HEAD WITH WASHER

BATTERY

INFUSER REAR CASE

INFUSER FRONT CASE

6-32 X 5/16

HEX HEAD WITH WASHER

RUBBER
FOOT PAD (2)

95F01018

Figure7-13. BatteryPack Replacement

7.3.5

BATTERYPACKREPLACEMENT

Therecommendedtoolfor this procedureisa 1/4 inchnutdriver.
To replacethe battery pack,refertoFigure 7-13,Battery PackReplacement,thenproceed

as follows:

1.Disconnect theinfuserfromACpower.

2.Place theinfuserfacedownona softsurface. Usinga 1/4 inchnutdriver, remove
thetwo6-32 hexhead screwsfromthebottomcover.

430-04502-003(Rev.4/99) 7-22 LifeCarePCAPlusandPlusIISeriesInfusers

REPLACEMENTPROCEDURES

3.Remove thebatterypackcover.

4.Separatethebatterypackcablefromthechargercircuitcable.Removethebattery
anddispose ofitinaccordancewithlocalbatterydisposalpractices.

5.Connecttheleadsofthenewbatterypacktothebatteryconnector;makecertain
that theconnectionis tight.

6.Installthereplacementbatterypackintothehousingsothatthebottomsofbatteries
arevisible;makecertainthatthewiresarenotkinkedorcrushedunderthe
batteries.

7.Replace thebottom cover; make certainthebattery leads are tucked inside.

8.Replace thetwoscrewsremovedinStep2.

9.PCAPlusIIonly:ResettherealtimeclockasdescribedinSection7.2.9,Settingthe

Real TimeClock(PCAPlus II).

Toverifysuccessfulreplacementofthebatterypack,pressthe[ON]touchswitchwith the
infuserdisconnected from ACpower.Verify thefrontpanelbattery symbolilluminates.

Replacementofthebatterypackisaroutinemaintenanceprocedureandnoadditional
verificationprocedureisnormallyrequired. However,iftheinfusermayhavebeen
damaged duringthis procedure,perform thePVT as described inSection 5.2.

7.3.6

FUSEREPLACEMENT

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriverand
smallflatblade screwdriver.

Toreplacethefuses,refertoFigure7-14,ReplaceablePartsonBackofInfuser,thenproceed
as follows:

1.Disconnect theinfuserfromACpower.

2.Placetheinfuserfacedownonasoftsurfaceandremovethe6-32x1/4inchflat
headPhillipsscrewthatattachestheACpowercordretainingplatetotheinfuser
rear case.

3.Toaccessthefuses, remove theAC powercord from itsreceptacle by graspingthe
plug.Donotpullonthecord.

4.LocatetheplasticfuseholderdirectlyabovetheACpowerreceptacle.Insertasmall
flatbladescrewdriverbetweenthelockingtabatoneendthefuseholderandthe
infuserhousing.Pressthetabtowardthecenterofthefuseholdertoreleaseit.The
fuseholderwillmove slightlyoutwardwhenreleasedfromtheoneside.

5.RepeatStep4toreleasetheotherlockingtab.Thespring-loadedfuseholderwill
releaseandmoveoutwards.Graspbothlockingtabsandremovethefuseholder
fromthereceptacle.

6.Removefusesandreplacewithapprovedfusesonly(seeSection8,Specifications).
Donotuseanyother fusetypes.

7.Insertthefuseholderintothereceptacle,thenpressthefuseholderagainstthe
lockingtabs untilitclicks intoposition.

8.Replace theACpowercord by connecting ittotheinfuserACpower receptacle.

9.Re-installtheACpowercord retaining platewiththescrewremovedinStep2.

Toverifysuccessfulreplacementofthefuses,performthePVTasdescribedinSection5.2.

TechnicalServiceManual 7-23 430-04502-003(Rev.4/99)

Section7REPLACEABLEPARTSANDREPAIRS

AUDIBLE LEVEL

SWITCH

PATIENT PENDANT

JACK

PATIENT PENDANT

VELCRO STRAP

RETAINING PLATE

POLE CLAMP

ASSEMBLY

8-32 X 5/8

MOUNTING

SCREWS (4)

CASE ATTACHMENT

BOLT (4)

PRINTER/DATAWAY
CONNECTOR

6-32 X 1/4
MOUNTING
SCREWS (4)

AC CORD
VELCRO STRAP
RETAINING PLATE

FINAL ASSEMBLY
NUMBER

TEST CONNECTOR

FUSEHOLDER

AC POWER CORD
RETAINING PLATE

MOUNTING SCREW

AC POWER CORD

95F01019

Figure7-14.Replaceable Parts onBackof Infuser

7.3.7

POLECLAMPASSEMBLYREPLACEMENT

Therecommendedtoolfor this procedureisa No.2 Phillipsscrewdriver.
Toreplacethepoleclampassembly,refertoFigure7-14,ReplaceablePartsonBackof

Infuser,thenproceed asfollows:

1.Place theinfuserfacedownona softsurface.

2.Remove thefour5/8 inch Phillipsmountingscrewsandassociated lockwashers.

3.Removethepoleclampassemblyandinstallthereplacementpoleclampassembly
using thescrewsand lockwashersremovedinStep2.

Replacementofthepoleclampassemblyisaroutinemaintenanceprocedureandno
verificationprocedureisnormallyrequired. However,iftheinfusermayhavebeen
damaged duringthis procedure,perform thePVT as described inSection 5.2.

430-04502-003(Rev.4/99) 7-24 LifeCarePCAPlusandPlusIISeriesInfusers

REPLACEMENTPROCEDURES

7.3.8

VELCROSTRAPANDRETAINERPLATE REPLACEMENT

Velcrostrapsandretainerplatesontherearoftheinfusersecurethepatientpendantand
theACpowercord.ThisproceduredetailsthereplacementoftheVelcrostrapandretainer
plateinbothlocations.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriverand
X-acto knife.

ToreplacetheVelcrostrapandretainerplate,refertoFigure7-14,ReplaceablePartson

Backof Infuser,thenproceedas follows:

1.RemovethetwoscrewsthatattachtheVelcrostrapandretainerplatetotheback
oftheinfuser. Remove theretainerplateandstrap. Donotdiscard thestrap.

Note:ThereplacementVelcrostrapdoesnothaveholesformountingscrews.The
holes must be cut atthetimeofinstallation.

2.PlacethereplacementVelcrostrap,withfuzzysidedown,ontheworksurface.Place
theretainerplateonthestrapintheexactlocationasontheoldstrap.Usethe
retainerplateas a templatetomark hole locationsonthestrap.

3.Using an X-actoknife,cut holesin thereplacementstrapatthemarkedlocations.

4.Replace theretainerplateifdamaged.

5.Installthereplacementstrapandretainerplateusingthetwoscrewsremovedin
Step1.

ReplacementoftheVelcrostrapandretainerplateisaroutinemaintenanceprocedure
andnoverificationprocedureisnormallyrequired.However,iftheinfusermayhavebeen
damaged duringthis procedure,perform thePVT as described inSection 5.2.

7.3.9

SECURITYDOORREPLACEMENT

Therecommendedtoolfor this procedureisa No.2 Phillipsscrewdriver.
Toreplacethesecuritydoor,proceedas follows:

1.Unlock and openthesecurity door.

2.Openthedoorcompletely(approximately270degrees)torevealfourroundhead,
Phillipsmountingscrews.

3.Usinga Phillipsscrewdriver,remove thefourscrewsand remove thedoor.

4.AttachthereplacementdoorusingthescrewsremovedinStep3.

5.Closeandlockthesecuritydoor.Verifythatthedooralignswiththedoorlatch
assembly andthatthedoor islocked.

Replacementofthesecuritydoorisaroutinemaintenanceprocedure andnoverification
procedureisnormallyrequired.However,iftheinfusermayhavebeendamagedduring
this procedure,perform thePVT as describedinSection5.2.

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Section7REPLACEABLEPARTSANDREPAIRS

7.3.10

SECURITYDOORLATCHREPLACEMENT

Therecommendedtoolfor this procedureisa No.2 Phillipsscrewdriver.
Toreplacethesecuritydoorlatch,proceed asfollows:

1.Unlock and openthesecurity door.

2.Frominsideofthedoor,removetheflatheadPhillipsscrewthatattachesthelatch
tothedoor.

3.Fromthefrontofthedoor,peel back thenameplatelabelandremovethelatch.

4.Installthereplacementlatchandre-attachitfrominsidethedoorusingthe
attachmentscrewthatwas removedinStep2.

5.Pressthenameplatelabelbackinplace.

6.Closeandlock thesecuritydoor.

Replacementofthesecuritydoorlatchisaroutinemaintenanceprocedureandno
verificationprocedureisnormallyrequired. However,iftheinfusermayhavebeen
damaged duringthis procedure,perform thePVT as described inSection 5.2.

7.3.11

PATIENTPENDANTCONTROLCABLE REPLACEMENT

Toreplacethepatientpendantcontrolcable,disconnectthecablefromthePATIENT
CONTROL jackontherear of theinfuserandconnect thenew cable.

Replacementofthepatientpendantcontrolcableisaroutinemaintenanceprocedureand
noverificationprocedureisnormallyrequired.However,iftheinfusermayhavebeen
damaged duringthis procedure,perform thePVT as described inSection 5.2.

7.3.12

ACPOWERCORDREPLACEMENT

Therecommendedtoolfor this procedureisa No.2 Phillipsscrewdriver.
ToreplacetheACpowercord,RefertoFigure7-14,ReplaceablePartsonBackofInfuser,

then proceedas follows:

1.UsingaNo.2Phillipsscrewdriver,removethescrewthatattachestheACpower
cord retainingplatetotherear oftheinfuser.

2DisconnecttheACpowercordbygraspingtheplug.Donotpullonthepowercord.

3.Replace theACpowercord by connecting ittotheinfuserACpower receptacle.

4.Re-installthepowercord retainingplate withthescrewremovedinStep1.

430-04502-003(Rev.4/99) 7-26 LifeCarePCAPlusandPlusIISeriesInfusers

REPLACEMENTPROCEDURES

Replacementof the ACpowercordisaroutinemaintenanceprocedureandno additional
verificationprocedureisnormallyrequired. However,iftheinfusermayhavebeen
damaged duringthis procedure,perform thePVT as described inSection 5.2.

7.3.13

ACPOWERCORDPLUGREPLACEMENT

IntheeventthattheACpowercordplugbecomesdamaged,obtainahospital-grade
replacementplug.Theexactprocedureforreplacingtheplugdependsuponthe
constructionofthereplacementplug.Thefollowingprocedureisintendedonlyasaguide,
andnotas a specific methodforplugreplacement.

Therecommendedtoolsforthisprocedureareasfollows:wirecutters,screwdriver,and
electricians knife.

ToreplacetheACpowercord plug,proceedas follows:

1.Remove thedamaged plugby cutting thecord near theplug.

2.Disassemblethereplacementplugtoaccesstheplugterminalsandtoestimatethe
amount ofinsulationthatneeds tobe removedfromtheACpower cord.

3.Usinganelectriciansknife,removetheappropriateamountofouterinsulationfrom
theendof thepowercordtoexposethethreewiresinthecable.Notethatthetwo
ACwiresareblackandwhiteandthegroundwireisgreen.Usingwirestrippers,
removesufficientinsulation(approximately1/4inch)fromthesewirestopermit
connectionofbareconnectors tothereplacement plug.

4.Connectthewirestothereplacementplug,asappropriate;assurethattheground
wireisconnectedtothegroundlugontheplug.

5.Re-assemble thereplacement plug.

6.Conducttheelectricalsafety testinSection5.2.11,ElectricalSafetyTest.

ToverifysuccessfulreplacementoftheACpowercordplug,performthePVTasdescribed
inSection 5.2.

7.3.14

GASKETSEALREPLACEMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbagbeforeplacingitonanysurface.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,
1/4inchnutdriver, 5/16 inchnutdriver, and isopropylalcohol.

Toreplacethegasket seal,proceedas follows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFrontandRearCaseAssemblies.Donotdisconnectribboncablesas

partofthisprocedure.

3.Settheinfuserrearcaseassembly uprightwiththesecuritydoor open.

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Section7REPLACEABLEPARTSANDREPAIRS

4.Remove thegasket seal andinstallthereplacement gasket seal.

5.Wipethereplacementgasket seal withisopropylalcohol.

6.Re-assembletheinfusercaseassembliesintheexactreverseorderofdisassembly.

7.Closeandlock thesecuritydoor.

Toverifysuccessfulreplacementofthegasketseal,performthePVTasdescribedinSection

5.2.

7.3.15

POWERSUPPLYPWAREPLACEMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbagbeforeplacingitonanysurface.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,
1/4inchnutdriver,5/16inchnutdriver,1/4inchopenendwrench,andAllenwrenches.

ToreplacethepowersupplyPWA,refertoFigure7-15,PowerSupplyPWAandCPU/Display

PWA,thenproceedas follows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

3.Usinga1/4inchnutdriver,removethefourhexheadscrewssecuringthepower
supplyPWA tothespacers.Ifnecessary,holdthepowersupplyPWAspacerswith
a1/4 inchopen endwrenchwhile removingthescrews.

4.Liftthepower supply PWAfrom thespacers.

5.Installthereplacement power supplyPWAintheexact reverseorder ofremoval.

6.Re-assembletheinfusercaseassembliesintheexactreverseorderofdisassembly.

7.Closeandlock thesecuritydoor.

Toverify successfulreplacementofthepower supply PWA, perform the PVTasdescribed
inSection 5.2.

430-04502-003(Rev.4/99) 7-28 LifeCarePCAPlusandPlusIISeriesInfusers

REPLACEMENTPROCEDURES

FLEXIBLE CIRCUIT CABLE

CPU/DISPLAY PWA

NYLON WASHER (4)

SPACER (4)

POWER SUPPLY PWA

HEX HEAD SCREW (4)

J7

40 PIN RIBBON CABLE

95F01026

Figure7-15.Power SupplyPWAand CPUDisplay PWA

7.3.16

CPU/DISPLAYPWAREPLACEMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbagbeforeplacingitonanysurface.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,
1/4inchnutdriver,5/16inchnutdriver,1/4inchopenendwrench,andAllenwrenches.

ToreplacetheCPU/displayPWA,refertoFigure7-15,PowerSupplyPWAandCPU/Display

PWA,thenproceedas follows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

3.RemovethepowersupplyPWAasdescribedinSection7.3.15,PowerSupplyPWA

Replacement.

4.Usinga1/4inchnutdriver,removethefourCPU/displayPWAspacers.Setthe
nylonwashers aside forre-assembly.

5.PivottheCPU/display PWAonitsrightedgetoaccesstheflexible circuitcable.

6.Loosentheflexible circuitcable from J13 ontheCPU/displayPWA.

7.Remove the40 pinribboncable fromJ12 ontheCPU/display PWA.

8.Remove theCPU/display PWAfrom thefront panelassembly.

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Section7REPLACEABLEPARTSANDREPAIRS

9.Reconnect P3 ofthepower cable toJ3 ofthepowersupply PWA.

10.Usinga5/16 inchnutdriver, reconnectthegroundwire tothemotorgear case.

11.ReconnecttheinfusertoACpowerandpressthe[ON]touchswitch.VerifytheLCD
screencanbereadfromadistanceofapproximatelythreefeet.Ifnecessary,adjust
theLCDintensity(see Section7.2.8,LCDIntensity Adjustment).

12.Disconnecttheinfuserfrom ACpower.

13.Re-assemble theinfuserintheexactreverse order ofdisassembly.

14.Closeandlockthesecurity door.

ToverifysuccessfulreplacementoftheCPU/displayPWA,performthePVTasdescribed
inSection 5.2.

7.3.17

LEDREPLACEMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbagbeforeplacingitonanysurface.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,
1/4inchnutdriver,5/16inchnutdriver,1/4inchopenendwrench,andAllenwrenches.

ToreplaceanyoftheLEDsontheCPU/displayPWA,refertoFigure7-12,CPU/Display

PWA,LED,andLCDAssembly,thenproceedas follows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

3.RemovethepowersupplyPWAasdescribedinSection7.3.15,PowerSupplyPWA

Replacement,andtheCPU/displayPWAasdescribedinSection7.3.16,
CPU/DisplayPWA Replacement.

4.RemovetheLEDandinstallthereplacementLED.TheLEDsaresocketedandmay
initiallybe difficult toremove;use carenottobend theconnector pins.

Note:Toassureproperalignmentwhenreplacingaseven-segmentLED(DS2,DS3,
DS4, DS5, or DS7),makecertainthedecimalpoint isinthelower rightcorner.

5.Re-installthepowersupply PWAand theCPU/display PWA.

6.Re-assembletheinfusercaseassembliesintheexactreverseorderofdisassembly.

7.Closeandlock thesecuritydoor.

ToverifysuccessfulreplacementoftheLED,performthePVTasdescribedinSection5.2.

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REPLACEMENTPROCEDURES

7.3.18

LCDASSEMBLYREPLACEMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbag beforeplacingitonanysurface.

Therecommendedtoolsforthisprocedureareasfollows:No.0Phillipsscrewdriver,No.2
Phillipsscrewdriver,1/4 inch nutdriver,and5/16 inchnutdriver.

ToreplacetheLCDassembly,refertoFigure7-12,CPU/DisplayPWA,LED,andLCD

Assembly,thenproceedas follows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

3.RemovethepowersupplyPWAasdescribedinSection7.3.15,PowerSupplyPWA

Replacement,andtheCPU/displayPWAasdescribedinSection7.3.16,
CPU/DisplayPWA Replacement.

4.Disconnect theLCDribboncable from J15ontheCPU/display PWA.

5.Pulltheadhesive-backedplasticinsulatorfromtheLCDwindow.

6.Using aNo. 0Phillipsscrewdriver,removethescrewsfromeachcorneroftheLCD
assembly.

7.GrasptheCPU/displayPWAandcarefullyremovetheLCDassemblyoutofthe
connector J14 socket.Donotbend theconnector pins.

8.Mounttheadhesive-backedplasticinsulatoronthereplacementLCD;centerthe
insulatorwindowontheLCDsotheinsulatorcoverstheedgesofthemetalbracket.

9.Re-installtheLCDassembly, power supplyPWA,andCPU/display PWA.

10.Re-assembletheinfusercaseassembliesintheexactreverseorderofdisassembly.

11.Closeandlockthesecurity door.

ToverifysuccessfulreplacementoftheLCDassembly,performthePVTasdescribedin

Section5.2.

7.3.19

40PINRIBBONCABLEREPLACEMENT

CAUTION:UseproperESDgroundingtechniqueswhenhandlingcomponents.Wear
anantistaticwriststrapanduseanESD-protectedworkstation.StorethePWAinan
antistaticbag beforeplacingitonanysurface.

Therecommendedtoolsforthisprocedureareasfollows:No.2Phillipsscrewdriver,
1/4inchnutdriver,5/16inchnutdriver,1/4inchopenendwrench,andAllenwrenches.

Toreplacethe40pinribboncable,refertoFigure7-15,PowerSupplyPWAandCPU/Display

PWA,thenproceedas follows:

1.Disconnect theinfuserfromACpower.

2.SeparatetheinfuserfrontandrearcaseassembliesasdescribedinSection7.2.2,

SeparatingFront and RearCaseAssemblies.

TechnicalServiceManual 7- 31 430-04502-003 (Rev. 4/99)