Alaris®DS Docking Station
Technical Service Manual
This manual has been prepared for use by qualified service personnel
only.
Cardinal Health cannot accept any liability for any breakdown or
deterioration in performance of parts or equipment resulting from
unauthorised repair or modification.
t Cardinal Health, 1180 Rolle, Switzerland
Alaris®, Guardrails® and Asena® are registered trademarks of
Cardinal Health, Inc. or one of its subsidiaries.
All other trademarks belong to their respective owners.
© 2002-2007. Cardinal Health, Inc. or one of its subsidiaries. All rights reserved.
Alaris® DS Docking Station 2/31 1000SM00019 Issue 2
Contents
Page
Introduction ............................................................................................................. 4
General Precautions ................................................................................................ 4
Technical Feature Description ................................................................................ 5
Test Procedures ....................................................................................................... 5
Routine Maintenance .............................................................................................. 7
Trouble Shooting Guide .......................................................................................... 8
Spare Parts Replacement Procedures .................................................................... 9
Spare Parts Lists ...................................................................................................... 29
Service Contacts ...................................................................................................... 30
Document History ................................................................................................... 31
Alaris® DS Docking Station 3/31 1000SM00019 Issue 2
Introduction
The Alaris® DS Docking Station (herein after referred to as “Docking Station”) is designed as a modular system, containing
modules for the complete range of Alaris® Infusion Pumps family.
The Asena® brand name has been recently changed to the Alaris® brand name. This change in brand name has no effect
on the intended use or functionality of the product.
Familiarity
Ensure that you are fully familiar with this Docking Station by carefully studying the Directions for Use (DFU) prior to
attempting any repairs or servicing.
As part of a policy of continuous improvement, product enhancements and changes are introduced from time to time.
Purpose
This Technical Service Manual shows how to set up, test and maintain the Docking Station.
It is intended for use by personnel experienced in medical equipment testing and maintenance procedures .
Symbols
Wherever you see this symbol in the manual you will find a Hints & Tips note that we hope you will find useful.
These notes provide useful advice or information that may help you perform the task more effectively.
Wherever you see this symbol in the manual you will find a Toolbox note that highlights an aspect of test
or maintenance that is important for you to know about. A typical example is a software upgrade that you
should check has been installed.
General precautions
Please read the general Operating Precautions described in the Directions for Use carefully prior to
w
B
A
using the Docking Station.
This Docking Station contains static-sensitive components. Observe strict precautions for the
protection of static sensitive components when attempting to repair and service the Docking Station.
An explosion hazard exists if the Docking Station is used in the presence of flammable anaesthetics.
Exercise care to locate the Docking Station away from any such hazardous sources.
An electrical shock hazard exists if the Docking Stations casing is opened or removed. Refer all
servicing to qualified service personnel.
If the Docking Station is dropped, subjected to excessive moisture, humidity or high temperature,
or otherwise suspected to have been damaged, remove it from service for inspection by qualified
service personnel.
When connected to an external power source, a three-wire (Live, Neutral, Earth) supply must be used.
If the integrity of the external protective conductor in the installation or its arrangement is in doubt,
the Docking Station should be removed from service.
Use extreme caution when servicing equipment whilst it is connected to the AC mains.
Always visually inspect the tiles, power cord and plug for damage. If the power cord or plug are
damaged they should be replaced.
Alaris® DS Docking Station 4/31 1000SM00019 Issue 2
Technical Feature Description
The Docking Station provides the link of modularity between the Alaris® Syringe Pumps and Alaris® Volumetric Pumps. A
common docking interface provides the mains supply and easy mechanical mounting in one action, without the need for
cables. Only a single mains inlet is required. The power tile at the base of the Docking Station provides the AC Mains supply
and the Potential Equalisation connector.
The Docking Station has a unique, flexible mounting system - the Medical Device Interface (MDI) - mountable to a trolley
or any suitable horizontal rectangular bar.
The Docking Station is simple to set up with an adaptable modular design. The Docking Station has its own power
distribution circuit. The AC power is supplied via a standard IEC connector into the power tile. An illuminated isolator
mains switch shows when the power is on. There is a double fuse holder protecting the AC inlet. If the AC power switch
does not illuminate when the Docking Station is switched on, suspect that either the power supply fuse in the AC plug, or
the internal fuses have blown. First check the power supply fuse in the AC mains plug. If the AC power switch still does not
illuminate remove the equipment from service.
Test Procedures
Electrical Safety Checks
The following procedure is designed to test the electrical function and safety of the Docking Station. It should be
performed on all units after any maintenance, and at least once per year.
WARNING: The following procedures use MAINS VOLTAGE and HIGH TEST CURRENTS. Appropriate precautions
against electric shock should be taken at all times.
1. Connect the Docking Station to a mains supply. Move the power switch at the base of the Docking Station to the 'ON'
position and check that it lights up.
2. Connect a medical grade electrical safety tester, (e.g. Metron QA-90) to a mains supply. Calibrate the Enclosure Lead,
(see safety tester's operating instructions) and then connect it to the PE point of the Docking Station. Plug the mains
test lead from the safety tester into the mains inlet of the Docking Station.
3. Set up and perform a standard automatic electrical safety test to EN60601-1 Class I, using an Earth Continuity test
current of 25A. The tester may require an applied part 'Type' to be entered. If this is the case, 'Type B' should be
selected, but no applied parts should be specified. A hard copy of the test results should be printed. The required test
result limits are as follows:
Protective Earth Resistance (All test Points) < 200mΩ
Current Consumption < 300mA
Insulation Resistance > 200MΩ
Earth Leakage current:
Open Supply - (OS) < 1000µA
Normal Condition - (NC) < 500µA
Open Supply Reverse Mains - (OSRM) < 1000µA
Normal Condition Reverse Mains - (NCRM) < 500µA
Enclosure Leakage current:
Open Supply - (OS) < 500µA
Normal Condition - (NC) < 100µA
Open Earth - (OE) < 500µA
Open Supply Reverse Mains - (OSRM) < 500µA
Normal Condition Reverse Mains - (NCRM) < 100µA
Open Earth Reverse Mains - (OERM) < 500µA
Alaris® DS Docking Station 5/31 1000SM00019 Issue 2
Test Procedures (continued)
4. If the medical grade electrical safety tester does not include a suitable test probe to permit testing of the outlet earth
pin on each tile, a test lead may be constructed using the following equipment:
1) 6mm Ring Tag e.g. 150-272 (Farnell) 1 off
2) IEC Mains Lead (male, in-line) e.g. 257-813 (Farnell) 1 off
3) 3:1 Heatshrink Adhesive lined e.g. 304-7234 (Farnell) 30mm off
Ensure that the mains lead is cut as short as possible to minimise resistance.
1
N.B. Earth wire only
Test Lead
3
2
5. Disconnect the Enclosure Lead from the Docking Station and apply it to the ring tag on the test lead. Connect the test
lead to the mains outlet of each docking tile in turn and conduct an Earth Continuity test at 25A using the electrical
safety tester. In all cases, the resistance to earth from each tile outlet should not exceed 0.2Ω. If possible, the results of
these tests should be included on the hard copy output from the safety tester.
6. Disconnect the Enclosure Lead from the test lead. Attach a high current probe to the enclosure lead. Using the probe
and electrical safety tester, conduct Earth Continuity tests on one screw on every IEC Mains Outlet and one screw
on every tile plate. In all cases, the resistance to earth from each tile outlet should not exceed 0.2Ω. If possible, the
results of these tests should be included on the hard copy output from the safety tester.
Alaris® DS Docking Station 6/31 1000SM00019 Issue 2
Routine Maintenance
Routine Maintenance Procedures
To ensure that all parts of the Docking Station remain in good operating condition, it is important to keep it clean and
perform the routine maintenance procedures described below. All servicing should only be performed by a qualified
service engineer.
Interval Routine Maintenance Procedure
When turning ON Check that the ON/OFF switch is illuminated when in the ON position.
When loading pumps Check that each pump is properly located on its electrical connectors and is mechanically
locked into position.
When removing pumps Check that the red LED on the docking tile turns OFF when the pump is removed. If the LED
stays ON, the Docking Station should be serviced by a qualified service engineer.
As required Thoroughly clean external surfaces of the equipment before and after prolonged periods
of storage
After servicing On final assembly check that all connectors are correctly fitted and located, ensuring that
all earth cables are tightly secured to the extrusion and that there are no loose items within
the assembly. Check that all the labels are correctly located, that there are no scratches or
damage.
12 Monthly
If any item is dropped, damaged, subjected to excessive moisture or high temperature, take it out of
A
service immediately for examination by a qualified service engineer.
Inspect AC outlets, communication connectors and the AC inlet for damage.
Perform electrical safety checks (see ‘Test Procedures’). The complete unit leakage
current must be measured. If more than 500µA the equipment should not be used, but
should be serviced by a qualified service engineer.
Cleaning and Storage
Periodically during use, clean all exterior surfaces by wiping over with a lint-free cloth lightly dampened with warm water
and a standard disinfectant / detergent solution.
Before cleaning always switch OFF the Docking Station, disconnect from the AC power supply and
A
remove all pumps. Never allow liquid to enter the tiles or electrical contacts and avoid excess fluid buildup on the surface of the tiles. Do not use aggressive solvents or abrasive cleaning agents as these may
damage the exterior surface of the Docking Station.
Disposal
Information on Disposal for Users of Waste Electrical & Electronic Equipment
This U symbol on the product and/or accompanying documents means that used electrical and electronic products
should not be mixed with household waste.
If you wish to discard electrical and electronic equipment, please contact your Cardinal Health affiliate office or
distributor for further information.
Disposing of this product correctly will help to save valuable resources and prevent any potential negative effects on
human health and the environment which could otherwise arise from inappropriate waste handling.
Information on Disposal in Countries outside the European Union
This symbol is only valid in the European Union. The product should be disposed of taking environmental factors into
consideration. All components can be safely disposed of as per local regulations.
Alaris® DS Docking Station 7/31 1000SM00019 Issue 2
Trouble Shooting Guide
Docking Station has been dropped or damaged
If the equipment is damaged, the damaged parts should be identified and replaced before any further troubleshooting
is carried out.
During inspection, careful attention should be paid to the power tile and each docking tile, which may be damaged if
the Docking Station is dropped.
Docking Station has been exposed to fluids
Excessive fluid spills can lead to fluid ingress into the Docking Station. Even if the fluid dries out, deposits can be left
which cause the equipment to fail.
If fluid ingress is suspected the Docking Station should be inspected internally.
Clean and dry out the equipment.
Take care to ensure dried out deposits do not remain on the PCBs or other electrical components. Replace permanently
damaged tiles.
Docking Station will not power from AC mains
First check the function of the mains cable with another piece of working equipment.
Check that the mains is switched on at the wall outlet, if applicable.
Check that the power cord is seated properly in the mains inlet. Also check the fuse in the AC mains plug.
If the AC Power switch does not illuminate when the pump is connected to a live AC cable, check the mains fuses at the
mains inlet.
No power present at pump
Check that the Docking Station is switched on and has power.
Check that the pump is correctly seated on the tile.
Hold a magnet next to the Infra-Red communications port on the tile. If the Warning LED does not light up the tile must
be replaced. If the LED does light up, suspect a problem with the pump and remove from service to be examined by a
qualified service engineer.
Warning LED remains lit when pump is removed from tile
Remove and check that the tile relay body is not distorted by trapped cable loom(s). If relay body is distorting reposition
cable loom(s) away from the relay body.
Replace the complete tile, following the instructions in ‘Spare Parts Replacement Procedures’.
Alaris® DS Docking Station 8/31 1000SM00019 Issue 2
Spare Parts Replacement Procedures
Ensure the Docking Station is disconnected from the AC power supply and switched off before
attempting to service.
The Docking Station contains static-sensitive components and therefore strict ESD precautions should
be observed at all times.
Only use Cardinal Health recommended spare parts.
Following all spare part replacement and repair activities, testing must be performed in accordance
with the 'Routine Maintenance' section.
Power Tile
Replacement Procedure
Release the four M4x30 screws on the power tile and the four M4 screws on
1.
the adjacent pump tile.
Unscrew the two earth cables from the extrusion.
2.
Remove the 15V DC supply connector (PL5) from the adjacent pump tile. Also
3.
disconnect the Live and Neutral (SC1 and SC2) connectors from the adjacent
tile.
The complete power tile module can now be removed and replaced with the
4.
new power tile. Slide the new power tile into the extrusion. Reconnect the
15V DC supply, live and neutral to PL5, SC1 and SC2 on the adjacent pump
tile.
Refit the two earth cables to the extrusion.
5.
Check that all connectors are correctly fitted and located. Ensure that all earth
6.
cables are tightly secured to the extrusion.
Lower the pump tile into position in the extrusion and secure both the
7.
adjacent pump tile and the new power tile, using the M4 screws with loctite
243 on the screw threads and fastened to 40cNm.
Docking Tile
Replacement Procedure
1. Remove the four M4x10 screws on the tile.
2. Remove connectors PL5 and PL2. Disconnect Live and Neutral (SC1 and SC)
and the IEC Mains Outlet earth cable (PL3).
3. Fit the new tile. Ensure that the tile spacer is flush to the tile above.
4. Reconnect all cables.
5. Before fitting the four M4x10 screws ensure that screw threads have loctite
243 on, then fully fasten down to 100cNm,
Alaris® DS Docking Station 9/31 1000SM00019 Issue 2
Spare Parts Replacement Procedures (continued)
Bar Mounting Kit
Replacement Procedure
This instruction details the fitting of the bar mounting kit to a Docking Station to enable the Docking Station to be secured
to either a bar mounting wall or trolley mounting.
1. Place the Docking Station face down on a surface or bench, ensuring that the surface is clean and will not scratch or
damage the Docking Station. If the Docking Station is fitted with a horizontal section care must be taken not to rest the
weight of the Docking Station on the bag hooks. The bag holder should be either rotated so it is pointing upwards or
the Docking Station should be positioned so that the bag hooks overhang the end of the table or bench.
2. Disassemble the mounting kit and drop one of the two square nuts into each channel in the rear of the extrusion. See
below.
3. Using a tool, such as a screwdriver, slide the nuts along the channels so that they are parallel in the position required.
4. Fit the mounting blocks over the top of each of the square nuts and place the bar mount across the two blocks, ensuring
that the screw holes line up on each side.
5. Fit the two hex screws through the bar mounting and through the mounting blocks. Line up the end of the screws with
the thread of the square nuts, turn the screws until the threads engage and then screw up as normal.
6. Tighten up both screws ensuring that the mounting kit is level and secure.
7. Cut a section of sealing cord to a length suitable to fill the channel between the mounting kit and the end of the
extrusion.
8. Press one end of the cord into the channel at the end of the extrusion. Carefully stretch the cord and press it into place.
9. Repeat the operation for the remaining sections of channel.
Alaris® DS Docking Station 10/31 1000SM00019 Issue 2
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