Alaris PC Unit 8000, PC Unit 8015, Pump Module 8100 User manual

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Page 1

Technical Service Manual

Alaris® PC Unit, Models 8000 and 8015

Alaris

Pump Module, Model 8100

Supports: Guardrails® Suite (v7)

Guardrails

Suite MX (v8)

December 2010

RATE(mL/h)

SILENCE

OPTIONS

CLEAR

CHANNEL

SELECT

SYSTEM

ENTER

CANCEL

SILENCE

OPTIONS

CLEAR

SYSTEM

ENTER

CANCEL

PAUSE

CHANNEL

OFF

RESTART

Model 8015 Model 8100Model 8000

Alaris® Products

Page 2

CareFusion San Diego, California carefusion.com/alaris

General Contact Information

Customer Advocacy - North America

Clinical and technical feedback.

Phone: 888.876.4287

E-Mail: CustomerFeedback@carefusion.com

Technical Support - North America

Maintenance and service information support; troubleshooting.

United States:

Phone:

888.876.4287

Instrument return, service assistance, and order placement.

United States:

Phone: 888.876.4287

Canada:

Phone:

800.387.8309

Customer Care - North America

Canada:

Phone: 800.387.8309

Alaris® and Guardrails® are registered trademarks of CareFusion Corporation or one of its subsidiaries. Microstream® is a trademark of Oridion Medical 1987 Ltd. All other trademarks belong to their respective owners.

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Page 3

TABLE OF CONTENTS

Chapter 1 - General Information

1.1 Introduction ....................................................................................................................................................................................... 1-1

1.2 Alarms and Messages

1.3 Battery Management System

1.3.1 Battery and Charging Process

1.3.2 System On/Off

................................................................................................................................................................................ 1-3

1.3.3 Real Time Clock (RTC) with NVRam Control Lithium Battery-Backed RTC

1.3.4 Battery Maintenance

1.4 Battery Capacity Information

1.5 Pole Clamp Feature

1.6 Memory

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

Chapter 2 - Checkout and Configuration

2.1 Introduction ....................................................................................................................................................................................... 2-1

2.2 New Instrument Checkout

2.3 Configuration Options and Setup - General

2.3.1 Configuration Notes

2.3.2 Configuration Setup Notes

2.4 Configuration Setup - PC Unit

2.4.1 Access System Configuration Options

2.4.2 Alarm audio

2.4.3 Anesthesia Mode

2.4.4 Battery meter

2.4.5 Clock setup

2.4.6 Key click audio

2.4.7 Max Pt. weight

2.4.8 Patient ID Entry

2.4.9 PM reminder

2.4.10 Profiles

2.4.11 Tamper resist

2.5 Configuration Setup - Pump Module

2.5.1 Access System Configuration Options

2.5.2 Accumulated air

2.5.3 Air-in-line settings

2.5.4 Auto-restart attempts

2.5.5 KVO rate adjust

2.5.6 Max rate

...................................................................................................................................................................................... 2-3

................................................................................................................................................................................... 2-3

....................................................................................................................................................................................... 2-4

................................................................................................................................................................................ 2-5

..................................................................................................................................................................................... 2-6

................................................................................................................................................................................................. 2-6

................................................................................................................................................................................... 2-7

.............................................................................................................................................................................................. 2-10

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

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

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

.......................................... 1-3

................................................................................................................................................................... 1-4

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

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

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

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

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

..................................................................................................................................................... 2-2

.............................................................................................................................................. 2-2

........................................................................................................................... 2-2

.......................................................................................................................................................................... 2-3

.............................................................................................................................................................................. 2-6

................................................................................................................................ 2-7

........................................................................................................................... 2-7

............................................................................................................................................................................. 2-8

......................................................................................................................................................................... 2-8

................................................................................................................................................................. 2-8

.............................................................................................................................................................................. 2-9

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

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TABLE OF CONTENTS

Chapter 2 - Checkout and Configuration (Continued)

2.5.7 Max VTBI ........................................................................................................................................................................................... 2-10

2.5.8 Pressure mode

2.5.9 SEC-PRI alert

2.5.10 Secondary

2.6 Configuration Setup - Shared Infusion

2.6.1 Access System Configuration Options

2.6.2 Delay Options

2.6.3 Drug Calculation

2.6.4 Multidose

2.6.5 Pressure dynamic

2.6.6 Volume/Duration

............................................................................................................................................................................... 2-11

................................................................................................................................................................................. 2-12

......................................................................................................................................................................................... 2-13

............................................................................................................................ 2-13

........................................................................................................................... 2-13

.................................................................................................................................................................................. 2-13

............................................................................................................................................................................ 2-14

............................................................................................................................................................................................ 2-15

......................................................................................................................................................................... 2-16

............................................................................................................................................................................ 2-16

Chapter 3 - Preventive Maintenance

3.1 Introduction ....................................................................................................................................................................................... 3-1

3.2 Cleaning

.............................................................................................................................................................................................. 3-1

Chapter 4 - Principles of Operation

4.1 Introduction ....................................................................................................................................................................................... 4-1

4.2 PC Unit

4.2.1 Logic Board Assembly - Model 8000

4.2.2 Logic Board Assembly - Model 8015

4.2.3 Power Supply Board Assembly

4.2.4 Power Requirements

4.2.5 Mechanical

4.3 Pump Module

4.3.1 Display Board Assembly

4.3.2 Logic Board Assembly

4.3.3 Motor Controller Board Assembly

4.3.4 Mechanical

4.4 Power Control Circuit

4.5 Inter-Unit Communications Circuit and Connections

4.5.1 Software

4.5.2 Unit Detection and Identification Circuitry

4.5.3 IUI

4.5.4 Module Detection and Logical Designation

4.5.5 Unit ID Assignment at System On

4.5.6 Module Attachment After System On

................................................................................................................................................................................................ 4-1

............................................................................................................................... 4-1

............................................................................................................................... 4-3

........................................................................................................................................... 4-4

.................................................................................................................................................................. 4-5

........................................................................................................................................................................................ 4-6

.................................................................................................................................................................................. 4-7

.......................................................................................................................................................... 4-8

............................................................................................................................................................... 4-9

...................................................................................................................................... 4-12

........................................................................................................................................................................................ 4-12

................................................................................................................................................................. 4-13

............................................................................................. 4-13

............................................................................................................................................................................................. 4-14

.................................................................................................................... 4-14

........................................................................................................................................................................................................... 4-15

................................................................................................................. 4-16

..................................................................................................................................... 4-16

.............................................................................................................................. 4-18

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

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TABLE OF CONTENTS

Chapter 4 - Principles of Operation (Continued)

4.5.7 Module Detachment .................................................................................................................................................................... 4-18

4.5.8 Communications Time-Out

.................................................................................................................................................... 4-18

Chapter 5 - Corrective Maintenance

5.1 Introduction ....................................................................................................................................................................................... 5-1

5.2 Disassembly / Reassembly

5.3 PC Unit

................................................................................................................................................................................................ 5-3

5.3.1 Battery Pack Assembly

5.3.2 Latch Assembly

5.3.3 Power Cord

.............................................................................................................................................................................. 5-4

....................................................................................................................................................................................... 5-5

5.3.4 Pole Clamp Assembly

5.3.5 Rear Panel (Model 8000) and Rear Panel Assembly

5.3.6 Rear Panel Assembly Parts

5.3.7 Model 8000: CI Board Accessory (Model 8012)

5.3.8 Model 8015: Wireless Network Card Assembly

5.3.9 Model 8000: Nurse Call Accessory (Model 8010)

5.3.10 Model 8000: Nurse Call / CI Board Accessory

5.3.11 Handle

.................................................................................................................................................................................................. 5-17

5.3.12 Front and Rear Case Separation

5.3.13 Model 8000: Display and Retainer

5.3.14 Model 8015: Display, Retainers, and Inverter Board

5.3.15 IUI Connectors

............................................................................................................................................................................... 5-22

5.3.16 Rear Case Assembly Parts

5.3.17 Model 8015: Memory Card

5.3.18 Chassis Assembly Parts

5.4 Pump Module

.................................................................................................................................................................................. 5-28

5.4.1 Latch Assembly and Feet

5.4.2 IUI Connectors and Rear Case

5.4.3 Door/Display Board Assembly

5.4.4 Display Board Assembly

5.4.5 Door Latch Assembly

5.4.6 Platen Assembly

............................................................................................................................................................................ 5-33

5.4.7 Logic and Motor Controller Board Assemblies

5.4.8 Motor, Air-in-Line (AIL) Sensor Assembly, and Bezel Assembly

5.4.9 Membrane Frame Assembly and Pressure Sensors

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

............................................................................................................................................................. 5-3

................................................................................................................................................................ 5-6

............................................................................................ 5-7

................................................................................................................................................... 5-8

....................................................................................................... 5-10

........................................................................................................ 5-11

................................................................................................... 5-13

.......................................................................................................... 5-16

........................................................................................................................................ 5-18

.................................................................................................................................... 5-19

.............................................................................................. 5-20

.................................................................................................................................................... 5-23

..................................................................................................................................................... 5-25

.......................................................................................................................................................... 5-26

........................................................................................................................................................ 5-28

............................................................................................................................................ 5-29

............................................................................................................................................. 5-30

.......................................................................................................................................................... 5-31

................................................................................................................................................................. 5-32

.......................................................................................................... 5-34

.................................................................... 5-36

............................................................................................. 5-38

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

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Page 6

TABLE OF CONTENTS

Chapter 6 - Troubleshooting

6.1 Introduction ....................................................................................................................................................................................... 6-1

6.2 Errors

6.2.1 Error Numbering Scheme

6.3 Maintenance Mode

6.3.1 External Communications

6.3.2 Calibration Parameters

6.3.3 Clock Setup

6.3.4 Battery Conditioning Test

6.3.5 Keypad Test

6.3.6 Display Test

6.3.7 Display Error Log

6.3.8 Display Contrast

....................................................................................................................................................... 6-2

...................................................................................................................................................................... 6-2

....................................................................................................................................................... 6-3

............................................................................................................................................................. 6-3

...................................................................................................................................................................................... 6-4

........................................................................................................................................................ 6-5

...................................................................................................................................................................................... 6-6

.......................................................................................................................................................................... 6-7

............................................................................................................................................................................ 6-8

Chapter 7 - Illustrated Part Breakdown

7.1 Introduction ....................................................................................................................................................................................... 7-1

7.2 Illustrations

7.3 Parts List

7.4 Ordering Parts

........................................................................................................................................................................................ 7-1

............................................................................................................................................................................................ 7-1

................................................................................................................................................................................ 7-2

Figures

4-1 Block Diagram - Models 8000 and 8015 ....................................................................................................................... 4-20

4-2 Block Diagram - Model 8100 7-1 Models 8000 and 8015 - Chassis Assembly 7-2 Model 8015 - Memory Card 7-3 Models 8000 and 8015 - Rear Case Assembly 7-4 Models 8000 and 8015 - IUI Connectors and Backup Speaker 7-5 Model 8000 - LED Display Assembly 7-6 Model 8015 - LED Display Assembly 7-7 Models 8000 and 8015 - Front to Rear Case Assembly 7-8 Models 8000 and 8015 - Handle Assembly 7-9 Models 8000 and 8015 - Rear Panel Assembly 7-10 Model 8000 - Rear Plate Assembly 7-11 Model 8015 - Wireless Network Assembly 7-12 Model 8000 - Model 8010 Nurse Call Accessory 7-13 Model 8000 - Model 8012 Communications Interface Accessory 7-14 Model 8000 - Communications Interface Board / Nurse Call Accessory 7-15 Models 8000 and 8015 - Pole Clamp Assembly

................................................................................................................................................. 4-21

............................................................................................................... 7-9

................................................................................................................................................... 7-10

......................................................................................................... 7-11

..................................................................... 7-13

.............................................................................................................................. 7-14

............................................................................................................................... 7-15

...................................................................................... 7-17

................................................................................................................. 7-18

........................................................................................................ 7-19

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

................................................................................................................... 7-23

.................................................................................................... 7-24

................................................................ 7-25

................................................. 7-26

....................................................................................................... 7-27

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Pump Module

Alaris

Technical Service Manual

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TABLE OF CONTENTS

Figures (Continued)

7-16 Models 8000 and 8015 - Power Cord Assembly and Labels ........................................................................... 7-28

7-17 Models 8000 and 8015 - Latch Assembly 7-18 Models 8000 and 8015 - Battery Pack Assembly 7-19 Model 8015 - Communications Board 7-20 Model 8015 - Inverter Board

.................................................................................................................................................. 7-32

7-21 Models 8000 and 8015 - Isolated RS-232 Board 7-22 Models 8000 and 8015 - IUI Boards 7-23 Model 8000 - Logic Board 7-24 Model 8015 - Logic Board

....................................................................................................................................................... 7-35

....................................................................................................................................................... 7-36

7-25 Models 8000 and 8015 - Power Supply Board 7-26 Model 8100 - Membrane to Bezel Assembly 7-27 Model 8100 - Motor and AIL Sensor Assembly 7-28 Model 8100 - Logic Board and Motor Controller Board Assembly 7-29 Model 8100 - Platen Assembly

............................................................................................................................................ 7-44

7-30 Model 8100 - Door and Display Board Assembly 7-31 Model 8100 - Rear Case and IUI Connectors 7-32 Model 8100 - Latch and Feet Assembly 7-33 Model 8100 - Label Locations 7-34 Model 8100 - AIL Board 7-35 Model 8100 - Display Board 7-36 Model 8100 - Logic Board

.............................................................................................................................................. 7-49

............................................................................................................................................................ 7-50

................................................................................................................................................... 7-51

....................................................................................................................................................... 7-52

7-37 Model 8100 - Motor controller Board

..................................................................................................................... 7-29

.................................................................................................... 7-30

............................................................................................................................. 7-31

..................................................................................................... 7-33

................................................................................................................................. 7-34

.......................................................................................................... 7-37

.............................................................................................................. 7-41

......................................................................................................... 7-42

................................................................ 7-43

.................................................................................................... 7-45

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

......................................................................................................................... 7-48

................................................................................................................................ 7-53

Tables

1-1 Defined Terms ................................................................................................................................................................................ 1-2

1-2 Battery Trip Points 1-3 Abbreviations, Acronyms, Symbols 4-1 Power Sources 4-2 Power Supply Board Voltages 4-3 IUI Logic 4-4 IUI Signals

.............................................................................................................................................................................................. 4-17

......................................................................................................................................................................................... 4-17

5-1 Required Materials, Supplies and Tools 5-2 Torque Values - Models 8000 and 8015 5-3 Torque Values - Model 8100 5-4 Level of Testing Guidelines - Models 8000 and 8015 5-5 Level of Testing Guidelines - Model 8100 6-1 Technical Troubleshooting Guide

........................................................................................................................................................................ 1-4

.................................................................................................................................. 1-7

............................................................................................................................................................................... 4-5

.............................................................................................................................................. 4-6

......................................................................................................................... 5-2

........................................................................................................................ 5-39

.................................................................................................................................................. 5-40

........................................................................................... 5-41

..................................................................................................................... 5-42

....................................................................................................................................... 6-9

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

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TABLE OF CONTENTS

List of Tables (Continued)

6-2 Subsystem Codes ........................................................................................................................................................................ 6-18

6-3 Failure Codes 6-4 Error Codes 7-1 Parts List - Models 8000 and 8015 7-2 Parts List - Model 8100

.................................................................................................................................................................................. 6-19

...................................................................................................................................................................................... 6-22

................................................................................................................................... 7-3

............................................................................................................................................................. 7-38

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Page 9

Chapter 1 – GENERAL INFORMATION

CAUTION

To avoid damaging the keypad, do not use sharp objects (such as, pens, pencils) to activate switches.

CAUTION

Any attempt to service this product by anyone other than an authorized CareFusion Service Representative, while the product is under warranty, may invalidate the warranty.

1.1 INTRODUCTION

This manual describes how to service the

PC Unit (Models 8000 and 8015) and

Pump Module (Model

8100). It is used in

conjunction with the following Alaris documents and software:

• Alaris

System Directions for Use (DFU)

• Maintenance software and user manual This manual is intended for personnel

experienced in analysis, troubleshooting and repair of analog/digital microprocessorbased electronic equipment.

Reference the Alaris

System DFU for a product introduction, detailed setup and operation procedures, deﬁ nitions (including precaution deﬁ nitions), speciﬁ cations, and other information related to the use of the

Alaris

System.

If the PC Unit or Pump Module requires service while under warranty, it must be serviced only by CareFusion authorized service personnel. Reference the "Warranty" and "Service Information" sections in the Alaris

Important: The

System DFU.

SYSTEM ON key becomes

the "Power Off" key anytime the Alaris System is in a watchdog state. The watchdog state is identified by:

System

• constant loud audio tone that cannot be

silenced

• nonresponsive keypad

• flashing red arrow above

Alaris® PC Unit

Alaris

Technical Service Manual

SYSTEM ON key

Pump Module

1-1

Page 10

GENERAL INFORMATION

Table 1-1. Defined Terms

The following table identifies the defined terms used throughout this document for certain trademarked products and product features.

Product / Feature Defined Term

Alaris® Auto-ID module Auto-ID Module

Alaris

EtCO2 module EtCO2 Module

Alaris

PCA module PCA Module

Alaris

PC point-of-care unit PC Unit

Alaris

PC unit PC Unit

Alaris

Pump module Pump Module

Alaris

SpO2 module SpO2 Module

Alaris

Syringe module Syringe Module

Guardrails

data set Data Set

1.2 ALARMS AND MESSAGES

Alarm messages are displayed on the scrolling Message Display bar. Reference

the Alaris

System DFU for detailed

information. An audio alarm and the Alarm Status

Indicator flash red when an alarm limit is met or exceeded. All alarms can be temporarily silenced by pressing the

SILENCE key on the

PC Unit.

1.3 BATTERY MANAGEMENT SYSTEM

This section contains general information on the battery management system. Included is information on how the power supply processor monitors and maintains the battery, controls the system on/off for the rest of the instrument and provides support functions for the main processor.

The battery management system consists of the power supply processor

IC and various

sensors and signal processing circuits.

The power supply processor performs the following functions:

• Controls battery charger.

• Provides a battery status "battery gauge".

• Monitors battery voltage and temperature.

• Controls instrument power source (on/off

function).

The power supply processor communicates with the main processor via a serial data channel. The main processor issues commands to the battery manager which then responds with status information and data using this channel.

1.3.1 Battery and Charging Process

The battery pack is a

10-cell (1.2V per cell),

high capacity nickel metal hydride ( type, rated at a minimum of

12 volts and 4 amp-hours (with

500 charge cycles). It has a

built-in temperature sensor which allows the battery manager to monitor battery temperature.

NiMH)

1-2

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Page 11

GENERAL INFORMATION

1.3 BATTERY MANAGEMENT SYSTEM

(Continued)

1.3.1 Battery and Charging Process (Continued)

• Self-resetting thermal fuse at 70° C.

• Self-resetting current limit sense at

5A.

The battery charge circuit charges the battery with a constant current of

whenever the power supply processor turns the charger on. The power supply processor regulates average charge current by turning the charger on and off with the appropriate duty ratio. The battery charge cycle consists of

4 modes: fast charge, float charge,

terminates charge, and top-up charge.

• Fast Charge: Fast charge is initiated whenever the battery is between and

27° C, and has been discharged by

more than

200 amp-seconds through

10° C

actual use or self discharge. Leaving the instrument unplugged for a day would cause about

200 amp-seconds of

self discharge. The charge current is a continuous

2A. The end of a fast charge

is detected when the temperature of the battery is at least a rate of

0.7° C/min. (or 1.4A depending

on system load at

30° C and increases at

0.6° C/min.) above its

temperature at start of charge, or when the battery voltage declines by

50 mV

below its peak value, or total charge time exceeds

2.6 hours.

• Float Charge: The float charge phase begins at the end of the top-up phase and helps maintain a fully charged battery. This phase charges at an average rate of

225 mA and 1 second per minute.

• Terminates Charge: The power supply processor does not allow charging to begin unless the temperature is The power supply processor terminates charge if battery temperature drops below

10° C or rises above 55° C.

1.3.2 System On/Off

The power supply processor provides the interface between system on/off switch and the main processor. When the instrument is off, the power supply processor interprets either power switch as a turn on command and applies power to the rest of the instrument, informing the main processor the switch was pressed. Once power is on, further presses of a power switch are passed on to the main processor which determines the appropriate response under the existing conditions. If the response is to turn the power off, the main processor requests that the power supply processor remove power from the rest of the instrument.

If an error has been detected which causes the watchdog to be in alarm, a push of either power switch will immediately cause the power to be turned off, without intervention by the power supply processor.

10 - 40° C.

• Top-Up Charge: The top-up charge phase begins at the end of the fast charge phase and finishes adding the last few percent of charge to the battery and balances individual cell charges. This phase charges at an average rate of

0.4A.

1.3.3 Real Time Clock (

RTC) with NVRam

Control Lithium Battery-Backed RTC

RTC switches SRAM voltage to prevent

memory loss during a power loss.

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

1-3

Page 12

GENERAL INFORMATION

1.3 BATTERY MANAGEMENT SYSTEM

(Continued)

1.3.4 Battery Maintenance

CAUTION

Use only batteries approved by CareFusion, due to battery manager requirements and the thermostat contained in the battery assembly. If the instrument has been in storage, connect it to

AC power before

turning it on. One refresh cycle is usually sufficient to restore battery capacity. If necessary, repeat the procedure at intervals,

2 or 3 times, to increase capacity.

24-hour

Several features are included in the battery manager to help properly maintain the battery.

• A battery capacity measurement is available in diagnostic mode.

• A special circuit removes all load from battery when voltage falls too low, preventing damage from over-discharge due to long-term storage.

NiMH batteries can be stored no more than 6 months (3 months in instrument) with no

load but will self-discharge from a charged state in about

100 days. This does not

damage the battery as it would if it were a lead-acid type battery. Connect the instrument to

AC to recharge batteries.

Disposal

There are no federal, state or local laws managing the disposal of

NiMH batteries are recyclable. To learn

about recycling batteries at

NiMH batteries.

INMETCO, visit

their website at http://www.inmetco.com.

Table 1-2. Battery Trip Points

Battery Voltage Instrument Response

• 30 minutes left on gauge

Couloumb Control (I.t)

11.20V

11.0V

10.8V disconnect battery

1-4

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

• instrument continues to function

• warning tone activated

• low battery warning

• instrument does not pump

• constant alarm

• low battery alarm (depletion)

• 1 minute or longer (nominal 5 minutes) after low battery alarm

• backup speaker activated

• instrument shutdown (5 minutes after alarm)

Page 13

GENERAL INFORMATION

1.4 BATTERY CAPACITY INFORMATION

All batteries have specific conditions under which they are guaranteed to meet their published specifications. Deviations from these conditions typically result in a reduction of available capacity. Manufacturers of

NiMH batteries rate

capacities, usually expressed in Ah (Ampere-hours), based on a specified "ideal" charge and discharge condition as well as the use of a new battery.

An ideal charge cycle starts with a fully discharged battery charged at

C/10 (C is

rated capacity in Ah) constant current for

15 hours while at room temperature. For

example, a for

15 hours at 180 mA constant current with

a room temperature of

1.8 Ah battery would be charged 23° C.

The ideal discharge starts with a fully charged battery under a

C/5 constant current

load at room temperature, discharging to a cell voltage of

0.9V . The rated capacity

is then calculated as the time to discharge divided by discharged at not reach

5. A 1.8 Ah cell would be 360 mA constant current and

0.9V for at least 5 hours. A given

battery type has different capacities based on the load. For example, a battery rated at

1.8 Ah at a 360 mA load may have only

1.6 Ah at a 1600 mA load.

There are many conditions which can affect the battery capacity. The following conditions have the most practical impact on battery capacity delivered in this instrument.

• Battery Alarm Voltage: The battery alarm voltage is the voltage at which the instrument stops operating and generates an alarm indicating the instrument needs to be connected to perfect conditions, a battery of

AC power. Under

10 cells

connected in series reaches the end

of discharge at

9.0V; however, cells

are not perfectly matched so some will reach

0.9V before others. The problem

occurs when a cell in series with other cells can go below

0.9V and actually go

into cell reversal, which permanently damages the particular cell. On the other hand, increasing the alarm voltage to compensate for imperfectly matched cells results in reduced run times with available capacity. The user sees this as premature low battery warnings and alarms. The instrument deals with this by increasing the alarm voltage to guarantee the battery is not damaged and reduce the assumed capacity to below that printed on the battery. The battery gauge is intended to show the minimum run time left on the battery taking all these factors into account.

• Charge Rate: The ideal charge rate requires

15 hours to get to full charge,

which is undesirable from the user’s perspective. The instrument provides a multiphase charge cycle which results in about

80% capacity in the first 2 hours

after fast charge. The next charge phase, top-up, is designed to finish the charge and to bring all individual cells to the fully charged state, essentially rematching them. See the "Battery and Charging Process" section in this chapter for "Fast Charge" and "Top-Up Charge" information. If the top-up charge is not completed, the cell mismatch is not reduced and the cumulative capacity reduction occurs. Top-up is a

3-hour

charge but the elapsed time to complete it may be over

5 hours, as the charger is

turned on and off to keep the battery cool during that time.

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

1-5

Page 14

GENERAL INFORMATION

1.4 BATTERY CAPACITY INFORMATION

(Continued)

• Cycle Life and Aging: Batteries wear out as they get older and go through many charge/discharge cycles; the chemicals and materials used to construct the cell break down. The instrument deals with this by assuming that a battery will continually reduce capacity at a rate equivalent to

4 years and continually reduce capacity

at a rate equivalent to

30% per 200 full

30% over

charge cycles. These calculated values are used to reduce the run time displayed on the battery gauge.

• Partial Discharge/Recharge: When a battery is partially discharged and then charged for less than the full time, differences between individual cell capacities result in cells completing charge at different times. If the full charge sequence is not completed, the cell mismatch becomes progressively greater. This is viewed by the user as low apparent run times and premature low battery warning and alarms. The problem is cumulative in that the mismatch increases for every partial cycle. The lowered capacity is not permanent but may require

2-3 full discharge/charge

cycles to recover. The instrument deals with this by reducing the run time displayed based on a limited history of partial cycles.

• Temperature During Charge: As the effective ambient temperature of the battery increases, the amount of charge that the battery will accept decreases. At an ambient temperature of

35° C, an

enclosed battery will temporarily accept only about otherwise accept at

90% of the charge it would

23° C.

1.5 POLE CLAMP FEATURE

The PC Unit’s pole clamp adapts to a wide variety of surfaces, to provide versatility. The pole clamp features include:

• Ergonomically designed knob.

• Accommodates diameters from

/8 inches (15.9 to 34.9 mm).

• Vertical or horizontal orientation, allowing it to adapt to both

IV poles and bed rails.

If pole-mounted, the system should be mounted in an upright position during operation, to provide maximum stability and display readability.

1.6 MEMORY Model 8000:

• Flash

4.5 MB (nonvolatile): It stores boot

and application codes for the PC Unit.

•

RAM 4 MB (volatile): It stores the Data

Set,

CQI logs, event logs, error logs,

battery logs, and patient data. It is volatile but has a lithium battery on the Logic Board to maintain memory when no other power is applied.

Model 8015:

• Flash

16 MB (nonvolatile): It stores boot

and application codes for the PC Unit,

CQI logs, event logs, error logs, and

battery logs.

• CF Flash

64 MB (nonvolatile): It

stores audio tones, the Data Set, and "restorable" patient data.

•

SDRAM 128 MB (volatile): It executes

transferred application code from flash. It stores patient-specific program and instantaneous information.

/8 to

1-6

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Page 15

GENERAL INFORMATION

Table 1-3. Abbreviations, Acronyms, Symbols

Various abbreviations, acronyms and symbols are used throughout this manual. This table defines those that are not commonly known or easily recognized.

* "active low" logic signal / not - true when signal is low

AIL air-in-line AKB PC Unit keypad processor

DFU Directions for Use DS display

FDSA Fluid Delivery Subassembly IUI inter-unit interface NMD nonmaskable interrupt PSP power supply processor

PWN pulse width N (where "N" is width of pulse) SEC-PRI secondary-to-primary TH thermistor UCS upper chip-select VDAC voltage DAC

VEE voltage emitter VRAW voltage raw (unregulated voltage)

WDI watchdog input WDO watchdog output

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Pump Module

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Technical Service Manual

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GENERAL INFORMATION

THIS PAGE

INTENTIONALLY

LEFT BLANK

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Chapter 2 – CHECKOUT AND CONFIGURATION

CAUTIONS

• Should an instrument be dropped or severely jarred, remove it from use immediately. It

should be thoroughly tested and inspected by qualified service personnel to ensure proper function prior to reuse.

• Keep the Pump Module door closed when the instrument is not in use.

NOTE: The PC Unit does not feature a learn/teach function or a default drug list.

2.1 INTRODUCTION

This chapter describes PC Unit and Pump Module initial setup and configuration. Due to product changes over time, configurations described in this chapter may differ from the instrument being serviced.

2.2 NEW INSTRUMENT CHECKOUT

Prior to placing a new instrument in use, perform a check-in procedure using the applicable maintenance software.

When powering up the instrument, verify the instrument beeps and all display segments flash. This confirms that the instrument has performed its self test and is operating correctly. During operation, the instrument continually performs a self test, and alarms and displays a message if it detects an internal malfunction.

Contact CareFusion authorized service personnel if the instrument has physical damage, fails to satisfactorily pass the startup sequence, fails a self test, or continues to alarm.

LED

2.3 CONFIGURATION OPTIONS AND SETUP - GENERAL

Reference the Alaris

System DFU for the

following information:

• System Settings

• Pump Module Settings

2.3.1 Configuration Notes

• Changes to factory default values are retained after a power cycle.

• If Factory Default is Yes, then all configuration settings are set to their factory default.

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Pump Module

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CHECKOUT AND CONFIGURATION

2.3 CONFIGURATION OPTIONS AND

SETUP - GENERAL (Continued)

2.3.1 Configuration Notes (Continued)

• If Factory Default is No, then 1 or more of the configuration settings has been changed. If desired, Factory Default can be selected and set to Yes, which will set all configuration settings to their factory default.

• With Profiles feature enabled, settings are configured independently for each profile. A hospital-defined, best-practice Data Set must be loaded to enable Profiles feature. Date and Time is a system setting and is the same in all profiles.

• If Guardrails

software is being used to load Data Sets into PC Unit, leave configuration settings at factory defaults. When a Data Set is loaded, it overrides configuration settings because each profile has its own individual configuration settings.

- displays next option setting screen (if applicable) or returns display to System Config screen

• Pressing PC Unit’s CANCEL key while in a System Configuration option screen:

- leaves setting unchanged

- returns display to System Config

screen

2.4 CONFIGURATION SETUP - PC UNIT

2.4.1 Access System Configuration Options

1. Hold

OPTIONS key at power up.

System Configuration - Module

Factory default:

Shared Infusion Settings

PC Unit

Pump Module

SPO2 Module

>Select an Option

or EXIT

EXIT

PAGE

DOWN

2.3.2 Configuration Setup Notes

• Disabling Profiles option disables loaded Data Set and allows a configuration option to be changed.

• Pressing

EXIT soft key while in a

System Configuration - Module screen

immediately powers system down, with no "Powering Down" display.

• Pressing

EXIT soft key while in a System

Config screen returns display to main System Configuration - Module screen.

• Pressing

CONFIRM soft key while in a

System Configuration option screen:

- accepts existing setting or setting

change

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2. Press PC Unit soft key. To view additional options, press

PAGE DOWN

soft key.

System Config - PCU 1 of 2

Alarm audio:

Anesthesia Mode: Disabled

Battery meter:

Clock setup:

Key click audio:

>Select an Option or EXIT

EXIT

-- Continued Next Page --

Profile 1

Disabled

09:00

Enabled

PAGE

DOWN

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CHECKOUT AND CONFIGURATION

2.4 CONFIGURATION SETUP - PC UNIT

(Continued)

2.4.1 Access System Configuration Options (Continued)

System Config - PCU 2 of 2

Max . weight:Pt

Patient ID Entry:

PM reminder:

Profiles: Disabled

Tamper resist:

>Select an Option or EXIT

PAGE

EXIT

500 kg

Disabled

2.4.2 Alarm audio

There are 3 different alarm profiles that can be selected to help differentiate between audio alarms in certain hospital environments.

Audio alert patterns (

±5%):

2. To change profile selection, press soft key next to desired profile. To hear a sample of selected audio alarm, press Test soft key.

3. To accept setting, press Confirm soft key.

2.4.3 Anesthesia Mode

The Anesthesia Mode allows access to additional drugs in each profile that is appropriate to anesthesiology. This mode also features permanent pause and the ability to set higher air-in-line settings.

1. After accessing System Config - PCU options display, press Anesthesia Mode soft key.

System Configuration - PCU

Anesthesia Mode

Allows use of the Anesthesia Mode feature.

Enable

Disable

Profile

1: 500 ms ON, 1500 ms OFF,

500 ms ON

Profile 2: 100 ms ON, 500 ms OFF,

400 ms ON

Profile 3: 400 ms ON, 500 ms OFF,

400 ms ON

1. After accessing System Config - PCU options display, press Alarm audio soft key.

System Configuration - PCU

Profile

Alarm audio profile selection

Select the desired alarm audio patterns. Press Test to hear a sample of the selected profile.

Profile

Confirm

Test

2. To change setting, press soft key next to applicable option (Enable or Disable).

2.4.4 Battery meter

When Enable is selected, the approximate time remaining on the battery is displayed (in a numeric value). The run time depends on the battery charge/condition and the load on the battery at the time. Run time may also be affected by the operating mode, rate, monitoring options and back pressure. The battery meter reading may take up

5 minutes after starting an infusion to

to stabilize.

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CHECKOUT AND CONFIGURATION

2.4 CONFIGURATION SETUP - PC UNIT

(Continued)

2.4.4 Battery meter (Continued)

1. After accessing System Config - PCU options display, press Battery meter soft key.

System Configuration - PCU

Battery meter

Allows the pump to display remaining battery run time to the user.

Enable

Disable

2. To change setting, press soft key next to applicable option (Enable or Disable).

2. To change time: a. Press Change Time soft key.

System Configuration - PCU

Clock setup

Current time:

__:__

Current date:

1998-12-15

>Enter Time-of-Day

Change

Time

Change

Date

b. Enter time.

System Configuration - PCU

Clock setup

Current time:

09:30

Current date:

1998-12-15

Change

Time

Change

Date

2.4.5 Clock setup

This option is used to set the time and date.

1. After accessing System Config - PCU options display, press Clock setup soft key.

System Configuration - PCU

Clock setup

CONFIRM

Change

Time

Change

Date

Current time:

09:00

Current date:

1998-12-15

>Confirm Time-of-Day and Date

>Press CONFIRM

CONFIRM

3. To change date: a. Press Change Date soft key.

System Configuration - PCU

Clock setup

CONFIRM

Change

Time

Change

Date

Current time:

09:30

Current date:

yyyy-mm-dd

>Enter Current Date

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CHECKOUT AND CONFIGURATION

2.4 CONFIGURATION SETUP - PC UNIT

(Continued)

2.4.5 Clock setup (Continued)

b. Enter date.

System Configuration - PCU

Clock setup

CONFIRM

Change

Time

Change

Date

CONFIRM soft

Current time:

09:30

Current date:

2001-01-29

>Press CONFIRM

4. To accept settings, press key.

2.4.6 Key click audio

This option is used to Enable or Disable the keypress audio feedback.

1. After accessing System Config - PCU options display, press Key click audio soft key.

2.4.7 Max Pt. weight

This option is used to set the maximum patient weight.

1. After accessing System Config - PCU options display, page

2, press Max Pt.

weight soft key.

System Configuration - PCU

Maximum patient weight adjustment

Maximum weight:

500 kg

Change

value

Confirm

2. To change maximum weight: a. Press Change value soft key.

System Configuration - PCU

Maximum patient weight adjustment

Maximum weight:

____kg

Change

value

System Configuration - PCU

Key click audio

Provides an audible sound with each keypress.

Enable

Disable

2. To change setting, press soft key next to applicable option (Enable or Disable).

b. Enter new weight.

System Configuration - PCU

Maximum patient weight adjustment

Maximum weight:

_100 kg

Alaris® PC Unit

Alaris

Technical Service Manual

Change

value

Confirm

Pump Module

2-5

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CHECKOUT AND CONFIGURATION

2.4 CONFIGURATION SETUP - PC UNIT

(Continued)

2.4.7 Max Pt. weight (Continued)

3. To accept setting, press Confirm soft key.

2.4.8 Patient ID Entry

Enabling the Patient ID feature allows an alphanumeric patient identifier to be entered in the Patient ID Entry screen that displays after responding Yes to New Patient?. When the Patient ID feature is disabled, the Patient ID Entry screen can only be accessed through the Systems Options menu.

1. After accessing System Config - PCU options display, page

2, press Patient

ID Entry soft key.

System Configuration - PCU

Patient ID Entry

Allows the patient ID to be assigned at system start up.

Enable

Disable

1. After accessing System Config - PCU options display, page

2, press PM

reminder soft key.

System Configuration - PCU

Preventive Maintenance reminder

Notifies user at power on when modules are due for routine preventive maintenance.

Enable

Disable

2. To change setting, press soft key next to applicable option (Enable or Disable).

2.4.10 Profiles

A profile is a unique set of system configuration settings and best-practice guidelines for a specific patient population or patient type. Profile settings are established prior to system implementation. The Profiles option can be enabled only when a Data Set is loaded. Disabling the Profiles option disables the loaded Data Set.

2. To change setting, press soft key next to applicable option (Enable or Disable).

2.4.9 PM reminder

Enabling the PM reminder feature allows

MAINTENANCE REMINDER message

a to appear when the PC Unit or attached module is due for routine scheduled preventive maintenance.

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1. After accessing System Config - PCU options display, page

2, press Profiles

soft key.

System Configuration - PCU

Profiles

Allow the user to select from an institution defined list of Profiles

Enable

Disable

2. To change setting, press soft key next to applicable option (Enable or Disable).

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CHECKOUT AND CONFIGURATION

2.4 CONFIGURATION SETUP - PC UNIT

(Continued)

2.4.11 Tamper resist

When Enable is selected, this mode can be activated or deactivated by pressing and holding the Tamper Resist Switch on the back of the PC Unit for Reference the Alaris

3 to 4 seconds.

System DFU for more

detailed information. Prior to accessing the Tamper resist mode,

all modules that are to be operating must be set up.

System Configuration - PCU

Tamper resistant mode

Allows use of the tamper Resistant Mode feature.

Enable

Disable

Auth

user

Change override

System Configuration - Module

Factory default:

Shared Infusion Settings

PC Unit

Pump Module

SPO2 Module

>Select an Option

or EXIT

EXIT

PAGE

DOWN

2. Press Pump Module soft key. To view additional options, press

PAGE DOWN

soft key.

System Config - Pump 1 of 2

Accumulated air:

Air-in-line settings:

Auto-restart attempts:

KVO rate adjust:

Max rate:

>Select an Option or EXIT

EXIT

Enabled

micro-

liter

1 mL/h

999 mL/h

PAGE

DOWN

1. After accessing System Config - options display, page

2, press Tamper

PCU

resist soft key.

2. To change setting, press soft key next to applicable option (Enable or Disable).

2.5 CONFIGURATION SETUP - PUMP MODULE

2.5.1 Access System Configuration Options

1. Hold

OPTIONS key at power up.

System Config - Pump 2 of 2

Max VTBI:

Pressure mode:

SEC-PRI alert:

Secondary:

>Select an Option or EXIT

PAGE

EXIT

9999 mL

Pump

Enabled

Disabled

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Pump Module

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CHECKOUT AND CONFIGURATION

2.5 CONFIGURATION SETUP - PUMP MODULE (Continued)

2.5.2 Accumulated air

When Disable is selected, the air-in-line system detects a bolus size of »

50, 75 or 250

microliters only. When Enable is selected, the air-in-line system detects a bolus size of »

50, 75 or 250 microliters and a number of

small boluses of a predetermined number, depending on the bolus size selected in the Air-in-line settings option.

1. After accessing System Config - Pump options display, press Accumulated air soft key.

System Configuration - Pump

Accumulated Air-in-line

Detects the presence of multiple small air bubbles.

Enable

Disable

System Configuration - Pump

Air-in-line detection threshold (in microliters)

Sets the upper limit for a single bolus of air to pass without alarm

250

2. To change setting, press soft key next to applicable option.

2.5.4 Auto-restart attempts

This setting determines the number of attempts (

0 to 9) the instrument will make

to restart the infusion (following detection of a patient-side occlusion) before it alarms "Occlusion".

1. After accessing System Config - Pump options display, press Auto-restart attempts soft key.

2. To change setting, press soft key next to applicable option (Enable or Disable).

2.5.3 Air-in-line settings

There are settings that can be selected;

3 different air-in-line bolus

50, 75 or 250

microliters. This is the amount of air allowed to pass through the detector before an air-inline alarm sounds.

1. After accessing System Config -

Pump options display, press Air-in-line settings soft key.

System Configuration - Pump

Auto-Restart Mode

Attempts:

Determines the number of attempts to restart the infusion following detection of a patient side occlusion before the pump will alarm.

Increase

Decrease

Confirm

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CHECKOUT AND CONFIGURATION

2.5 CONFIGURATION SETUP - PUMP

MODULE (Continued)

2.5.4 Auto-restart attempts (Continued)

2. To set number of attempts, press Increase or Decrease soft key.

• When the maximum number of

attempts is selected, Increase is grayed-out (disabled).

System Configuration - Pump

Auto-Restart Mode

Attempts:

Determines the number of attempts to restart the infusion following detection of a patient side occlusion before the pump will alarm.

Increase

Decrease

Confirm

3. To accept setting, press Confirm soft key.

2. To change

KVO rate:

a. Press Change

System Configuration - Pump

KVO rate adjustment

KVO rate:

b. Enter desired rate.

System Configuration - Pump

KVO rate adjustment

KVO rate:

mL/h

KVO rate soft key.

Change

KVO rate

Change

KVO rate

Confirm

2.5.5 KVO rate adjust

This option is used to select the (Keep Vein Open) rate (

0.1 to 20 mL/h).

KVO

This determines the rate of fluid flow after "Infusion Complete" has occurred.

1. After accessing System Config - Pump options display, press

KVO rate adjust

soft key.

System Configuration - Pump

KVO rate adjustment

KVO rate:

mL/h

Change

KVO rate

Confirm

3. To accept setting, press Confirm soft key.

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Pump Module

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CHECKOUT AND CONFIGURATION

2.5 CONFIGURATION SETUP - PUMP

MODULE (Continued)

2.5.6 Max rate

This option is used to select the maximum rate (

0.1 to 999 mL/h).

1. After accessing System Config - Pump options display, press Change value soft key.

System Configuration - Pump

Maximum rate adjustment

Maximum rate:

999

mL/h

Change

value

Confirm

2. To change rate:

b. Enter desired rate.

System Configuration - Pump

Maximum rate

adjustment

Change

Maximum rate:

99.9

mL/h

Change

value

Confirm

3. To accept setting, press Confirm soft key.

2.5.7 Max VTBI

This option is used to select the maximum

VTBI adjustment rate (0.1 to 9999 mL).

1. After accessing System Config - Pump options display, page

2, press Max VTBI

soft key.

a. Press Change value soft key.

System Configuration - Pump

Maximum rate adjustment

Maximum rate:

___

mL/h

Change

value

System Configuration - Pump

Maximum VTBI adjustment

Maximum VTBI:

9999

Change

value

Confirm

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CHECKOUT AND CONFIGURATION

2.5 CONFIGURATION SETUP - PUMP

MODULE (Continued)

2.5.7 Max VTBI (Continued)

2. To change rate: a. Press Change value soft key.

System Configuration - Pump

Maximum VTBI adjustment

Maximum VTBI:

____ mL

Change

value

b. Enter desired rate.

System Configuration - Pump

Maximum VTBI adjustment

Maximum VTBI:

999.9

Change

value

Confirm

Selectable: Occlusion limit of

50 to 525 mmHg (approximately 1 to 10.2 psi), in 25 mmHg increments, can be selected.

1. After accessing System Config - Pump

options display, page

2, press Pressure

mode soft key.

System Configuration - Pump

Pressure mode selection

Pressure mode:

Pump

Lock status:

Unlocked

Selectable

Lock Status

CONFIRM

Pump

Change

2. To change setting:

a. Ensure lock status is Unlocked. b. Press soft key next to applicable

option (Pump or Selectable).

• If Selectable mode is selected, following screen displays.

3. To accept setting, press Confirm soft key.

2.5.8 Pressure mode

There are

2 pressure modes available that

determine the patient-side occlusion limit. The selected mode can be Unlocked or

Locked after being confirmed. Pump: Instrument will occlude at

approximately

10 psi pressure.

System Configuration

Selectable Max Pressure:

525 mmHg

Selectable Default Pressure:

300 mmHg

CONFIRM

Alaris® PC Unit

Alaris

Technical Service Manual

Down

Pump Module

2-11

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CHECKOUT AND CONFIGURATION

2.5 CONFIGURATION SETUP - PUMP

MODULE (Continued)

2.5.8 Pressure mode (Continued)

3. To change pressure setting: a. Press Up or Down soft key next to

applicable option.

•

When maximum pressure setting is selected, Up is grayed-out (disabled). When minimum pressure setting is selected, Down is grayed-out (disabled).

System Configuration

Selectable Max Pressure:

400 mmHg

Selectable Default Pressure:

350 mmHg

Down

CONFIRM

c. To lock selection, press Change

Lock Status soft key.

System Configuration - Pump

Pressure mode selection

Pressure mode:

Selectable

mmHg

350

Lock status:

Locked

4. To accept setting, press

Selectable

Lock Status

CONFIRM

Pump

Change

CONFIRM soft

key.

2.5.9 SEC-PRI alert

When Enable is selected, an alarm sounds when the instrument switches from Secondary to Primary mode.

1. After accessing System Config - Pump options display, page

2, press SEC-PRI

alert soft key.

2-1 2

b. To accept setting, press CONFIRM

soft key.

System Configuration - Pump

Pressure mode selection

Pressure mode:

Selectable

mmHg

350

Lock status:

Unlocked

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Selectable

Lock Status

CONFIRM

Pump

Change

System Configuration - Pump

Secondary to primary transition alert

Causes six audio tones to sound when the infusion transitions from secondary to primary.

Enable

Disable

2. To change setting, press soft key next to applicable option (Enable or Disable).

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CHECKOUT AND CONFIGURATION

2.5 CONFIGURATION SETUP - PUMP

MODULE (Continued)

2.5.10 Secondary

The Secondary mode is used to deliver

2 different fluids sequentially through the

same line.

1. After accessing System Config - Pump options display, page

2, press

Secondary soft key.

System Configuration - Pump

Secondary mode

Allows use of the secondary feature.

Enable

Disable

2. To change setting, press soft key next to applicable option (Enable or Disable).

2.6 CONFIGURATION SETUP - SHARED INFUSION

2.6.1 Access System Configuration Options

1. Hold

OPTIONS key at power up.

System Configuration - Module

Factory default:

Shared Infusion Settings

PC Unit

Pump Module

SPO2 Module

>Select an Option

or EXIT

EXIT

PAGE

DOWN

2. Press Shared Infusion Settings soft key.

System Config - Shared

Delay Options:

Drug Calculation:

Multidose:

Pressure dynamic:Disabled

Volume/Duration:

>Select an Option

or EXIT

EXIT

Disabled

2.6.2 Delay Options

Enabling Delay Options allows the system to be programmed to delay the start of an infusion a) for up to a specific time up to

120 minutes or b) for

23 hours 59 minutes.

A callback for a programmed delay can be scheduled to give an alert Before an infusion is to be initiated, After an infusion is completed, Before and After an infusion, or to give no alert (None).

In the following procedure, Delay Options is changed to Enable. Changing the option setting to Disable disables the Callback soft key, as displayed in step

1. After accessing System Config -

Shared options display, press Delay Options soft key.

System Configuration - Shared

Delay Options

Callback:

None

Allows use of the Delay Options and Callback features.

Enable

Disable

Callback

CONFIRM

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Pump Module

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CHECKOUT AND CONFIGURATION

2.6 CONFIGURATION SETUP - SHARED

MODULE (Continued)

2.6.2 Delay Options (Continued)

2. To change setting, press soft key next to applicable option (Enable or Disable).

System Configuration - Shared

Delay Options

Callback:

None

Allows use of the Delay Options and Callback features.

Enable

Disable

Callback

CONFIRM

3. To change callback setting: a. Press Callback soft key.

System Configuration - Shared

Callback Options

Before

None

& After

After

None

System Configuration - Shared

Callback Options

Before

4. To accept setting, press

& After

After

None

CONFIRM

CONFIRM soft

key.

2.6.3 Drug Calculation

Enabling Drug Calculation allows:

• entry of drug dose (correct flow rate to achieve desired dose is automatically calculated),

• entry of flow rate (corresponding drug dose is automatically calculated).

In the following procedure, the Drug Calculation option is changed to Enable. Changing the option setting to Disable disables the Bolus Dose soft keys, as displayed in step

2-1 4

CONFIRM

b. Press soft key next to applicable

setting (following example illustrates Before as having been selected).

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

1. After accessing System Config -

Shared options display, press Drug Calculation soft key.

System Configuration - Shared

Drug Calculation

Allows use of the Drug Calculation feature.

Bolus Dose

Allows use of the Bolus Dose feature.

CONFIRM

Enable

Disable

Enable

Disable

DisableDisable

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CHECKOUT AND CONFIGURATION

2.6 CONFIGURATION SETUP - SHARED

MODULE (Continued)

2.6.3 Drug Calculation (Continued)

2. To change Drug Calculation setting, press soft key next to applicable option (Enable or Disable).

System Configuration - Shared

Drug Calculation

Allows use of the Drug Calculation feature.

Bolus Dose

Allows use of the Bolus Dose feature.

CONFIRM

Enable

Disable

Enable

Disable

DisableDisable

3. To change Bolus Dose setting, press soft key next to applicable option (Enable or Disable).

System Configuration - Shared

Drug Calculation

Allows use of the Drug Calculation feature.

Bolus Dose

Allows use of the Bolus Dose feature.

Enable

Disable

Enable

Disable

DisableDisable

the same administration set at regularly scheduled intervals.

In the following procedure, the Multidose option is changed to Enable. Changing the option setting to Disable disables the Callback soft key, as displayed in step

1. After accessing System Config -

Shared options display, press Multidose soft key.

System Configuration - Shared

Multidose

Callback:

None

Allows use of the Multidose and Callback features.

Enable

Disable

Callback

DisableDisable

CONFIRM

2. To change setting, press soft key next to applicable option (Enable or Disable).

System Configuration - Shared

Multidose

Allows use of the Multidose and Callback features.

Enable

Disable

Callback

DisableDisable

CONFIRM

4. To accept setting, press

CONFIRM soft

key.

2.6.4 Multidose

Enabling Multidose allows

2 to 24 doses

to be programmed at equally spaced intervals on the same Pump Module over a

24-hour period. This mode is designed to

allow delivery of multiple, equal doses from

CONFIRM

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CHECKOUT AND CONFIGURATION

2.6 CONFIGURATION SETUP - SHARED

INFUSION (Continued)

2.6.4 Multidose (Continued)

3. To change callback setting: a. Press Callback soft key.

System Configuration - Shared

Callback Options

Before

CONFIRM

Before & After

After

None

Callback:

None

b. Press soft key next to applicable

setting (following example illustrates Before as having been selected).

System Configuration - Shared

Callback Options

Before

CONFIRM

Before & After

After

None

Callback:

Before

1. After accessing System Config Shared options display, press Pressure dynamic soft key.

System Config - Pump 2 of 3

System Configuration - Shared

Dynamic Pressure Display

Allows use of the dynamic pressure display feature.

Enable

Disable

2. To change setting, press soft key next to applicable option (Enable or Disable).

2.6.6 Volume/Duration

Enabling Volume/Duration infusion mode allows a volume-to-be-infused (

VTBI) and

duration (infusion time) to be programmed, automatically calculating the flow rate.

1. After accessing System Config -

Shared options display, press Volume/ Duration soft key.

System Config - Pump 2 of 3

System Configuration - Shared

Volume/Duration infusion mode

Allows the use of the Volume over Duration infusion feature.

Enable

Disable

4. To accept setting, press

CONFIRM soft

key.

2.6.5 Pressure dynamic

Enabling Dynamic Pressure Display graphically displays the current patient-side occlusion pressure set point and patient-side operating pressure for that module.

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2. To change setting, press soft key next to applicable option (Enable or Disable).

Page 33

Chapter 3 – PREVENTIVE MAINTENANCE

WARNING

Failure to perform regular and preventive

maintenance inspections may result in improper instrument operation.

3.1 INTRODUCTION

Perform regular and preventive maintenance inspections to ensure that the Alaris remains in good operating condition.

• Perform regular inspections before each

use.

• Perform preventive maintenance

inspections once a year.

Use the applicable maintenance software to check-in, upgrade/repair, diagnose, calibrate and perform preventive maintenance.

CareFusion does not recommend the use of automatic testers to check rate accuracy. Generally, these devices collect small samples and the test results may incorrectly indicate a rate accuracy failure. Use of the following Alaris

•

8100-RCS (Rate Cal Set), to perform rate

products is recommended:

verification and/or calibration.

System

•

8100-PCS (Pressure Cal Set), to perform

pressure calibration.

These requirements and guidelines are intended to complement the intent of the Joint Commission on Accreditation of Healthcare Organizations ( requirements.

3.2 CLEANING

Reference the Alaris

System DFU.

JCAHO)

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Chapter 4 – PRINCIPLES OF OPERATION

4.1 INTRODUCTION

This chapter describes the principles of operation for the PC Unit and Pump Module.

4.2 PC UNIT

All circuit boards are not field repairable and must be returned to a CareFusion Service Center for repair.

4.2.1 Logic Board Assembly - Model 8000

The Logic Board has:

• Field-Programmable Gate Array (

containing following circuits:

DRAM interface and refresh logic

- protected

ISA bus conversion interface

- audio amplitude

I/O ports (1 input, 2 output)

- main

SRAM interface

PWM and control logic

LCD backlight PWM control

source

- wait-state generation logic

1 Hz display SYNC signal from 32 MHz

time base

- keypad processor clock generation from

14.318 MHz

- address decoder for

RTC

ISA bus, display,

- bus-width control logic

• Flash

ROM: Contains main program.

FPGA),

• Keypad control processor: Interfaces keypad to microprocessor.

• Intel microprocessor (

25 MHz): Controls

all user interface, power distribution, communications, and

•

PWM: Drives audio speaker.

Technical Service Manual

IUI interfacing.

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PRINCIPLES OF OPERATION

4.2 PC UNIT (Continued)

4.2.1 Logic Board Assembly - Model 8000

(Continued)

• Real-Time Clock (RTC ): Manages timed functions.

•

RS-232 communications IC: Allows

communications to/from a computer, through

•

RS-485 transceivers: Bidirectional

RS-232 port on rear of PC Unit.

communications with attached module, through an

•

SRAM (battery-backed): Stores critical

IUI interface.

real-time operational data.

• Watchdog circuit: Sounds an alarm if microprocessor stops running or runs at wrong speed.

• Tested main audio circuit.

• Interface bus buffers for

3 expansion

slots.

• Keypad backlight driver.

• Graphic board memory, voltage shifter ( to

• Software-controlled programming of flash

RS-232 interface.

LCD controller with 30K byte on

3.3V logic

5V logic) for display.

VPP supply for self-

ROMs through

• Supercap-powered backup audio circuit with self test.

• Digitally controlled contrast (

VEE)

generator.

I/O:

Latch provides the outputs to the module communications port.

UNIT_ID_ENBL_R is output to the right of

the PC Unit, to indicate that the attached modules should try to "

UNIT_ID_ENBL_L is input from the left for the

ID" themselves, and

same reason. Additional output port bits are used to control

A programmable power supply allows

LEDs on the front panel.

contrast voltage adjustment for proper viewing of the front panel

The

RTC IC has a battery-backed RAM and

includes an electronic serial number. crystal provides a time base for the

LCD display.

RTC. It

can maintain time and date information down

1/100th second. It also includes the chip-

to select gating for the log-static

RAM, which is

protected in the event of a power loss. The keypad processor interface block is

implemented using a serial interface.

Main Processor:

The main processor is an Intel microprocessor that provides a core with a

5-channel interrupt controller,

16-bit mP

chip-select serial input/output, timers and refresh timing functions, and

I/O ports. One

serial channel from the microprocessor is connected to the keypad processor. Clocking of the microprocessor is done by a

32 MHz oscillator. The programmable

power supply

microprocessor if the acceptable level for operation.

provides a reset pulse to the

Vcc level falls below an

The watchdog

timer provides a signal to the microprocessor if it fails to pulse the watchdog timer often enough. The signal is also monitored by the

PSP and the backup alarm circuit sets PSP

to power off the instrument with the

switch during watchdog events.

SYSTEM

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PRINCIPLES OF OPERATION

4.2 PC UNIT (Continued)

4.2.1 Logic Board Assembly - Model 8000

(Continued)

Memory:

The

4.5M byte Flash File type ROM is

intended to contain the files needed to operate the system. The address is software-selectable. Information from this memory is used to control or derive all functions. hold log information, stack, and other

512K x 16 static RAM is used to

RAM

needs of the system. They are supplied with a battery-backed supply voltage and the chip-select is protected by the

RTC chip,

so that data is not lost during power-down states. Its address is software-selectable using the microprocessor select ports.

1M x 16 DRAM or 4M x 16 is used for system RAM needs.

4.2.2 Logic Board Assembly - Model 8015

The Logic Board has:

• Main audio: Has an audio Coder.Decoder (

CODEC) device that converts audio files

into an audio signal.

• Auxiliary connector: Provides communication needed to debug PC Unit. Connection is used for Nurse Call Accessory and, if needed, can be used for future options.

• Dual Universal Asynchronous Receiver/ Transmitter (

DUART): Provides a serial

communication link to Auto-ID Module through

SPARE_A and SPARE_B ports.

Interfaces with main processor through Intel bus. These signals are needed on

IUI connector.

• Keypad processor: Uses high-end microcontroller. Senses keypad activity and handles

IUI communication, and

sends this information to main processor. Provides to adjust

PWM signals that are used

LCD display and keypad LED

backlights.

• Compact flash memory: Stores application software, audio wave files, Data Set, and hex files data for operating system software, all needed to operate

Alaris

System.

• On-board flash memory: Contains software needed to initially turn on

Alaris

System. Stores boot software application, and events, errors and battery logs.

• Intel microprocessor (

32-bit): Main

processor. Controls all user interface and communications, and provides digital control of

• Real-Time Clock (

LCD display.

RTC): Manages timed

functions. Lithium battery keeps clock running when there is no

AC or DC power.

• Complex Programmable Logic Device (

CPLD): Programmable logic that

provides glue logic for compact flash bus. Has miscellaneous logic that allows proper reset to on-board flash, and divides clock associated with

DUART.

•

SDRAM (128 MB): Has volatile memory

used primarily to execute application code stored in compact flash memory. Stores variables associated with software and

Alaris

System.

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PRINCIPLES OF OPERATION

4.2 PC UNIT (Continued)

4.2.2 Logic Board Assembly - Model 8015

(Continued)

• Watchdog and backup circuits: A watchdog device is used to ensure proper software operation. Backup circuits are logic that activates backup alarm if software problems occur. Output of backup circuit drives an panel and a backup speaker at a

LED with front

0.5 Hz

rate. A super cap provides power to this circuit if

AC and DC power fails.

• Compact flash bus for wireless connectivity: Interfaces between main processor and compact flash memory card.

4.2.3 Power Supply Board Assembly

The Power Supply Board charges the primary ( voltages to run the Alaris

NiMH) battery and supplies all

System. All voltages needed by an attached module are supplied by the PC Unit. An attached module does, however, regulate some voltages supplied by the PC Unit for its own use.

The output of the charger section of the Power Supply Board is used to charge the battery. The PC Unit power cord plugs into a hospital grade applied to the the PC Unit. The filter and

AC fuse holder built in. The fused

and filtered output of the

AC receptacle. AC power is

AC input module in the rear of

AC input module has a line

AC input module is

applied to the input of an off-line switching power supply having an output of

24 VDC.

This is connected to the input, Power Supply Board

J3. Certain circuits are powered

continually, either from the battery or line power, allowing the System On to be active

even with the power off. This is essential, considering the fact that the PC Unit uses a soft on circuit to power on. When the PC Unit is powered on, unregulated voltage

VRAW) is applied to the input of several

( regulators through

2 power FETs. The

outputs of these regulators supplies the

Alaris

VRAW is supplied directly to +5 nonswitched

( allows

System with required voltages.

NSW), even while the power is off. This

+5 NSW to be available for the System

On circuitry, even with the power off. Power is obtained from the AC Mains power

and self-contained battery. Backup power for alarms and the

RTC is located on the

PC Unit Logic Board. Further backup power for the

RTC is supported by a lithium battery,

which is switched-in if all other forms of power are removed or depleted.

Battery charging while on AC Mains is completely separate from power supply conversion and the battery is automatically switched-in when the AC Mains power is removed. The power sources used by the PC Unit are identified in Table

4-1 and

voltages supplied by the Power Supply Board are identified in Table

4-2. The

charger section of the Power Supply Board is used to charge the

The PC Unit uses a

NiMH battery.

12V 4 Ah NiMH battery.

The charger uses a constant current (limited to approximately

2.0A) until the battery

reaches the end of charge, allowing the charger to quick-charge the battery without undue stress. The from

VRAW through a current regulating

circuit, assuring that the

NiMH battery is charged

NiMH battery is

charged according to the manufacture's specifications. These voltages (except for battery charge voltage checked at

J3 or at

battery terminals) may be checked at Power Supply Board

J4 or Logic Board J8.

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PRINCIPLES OF OPERATION

4.2 PC UNIT (Continued)

4.2.4 Power Requirements

+5V This supply is generated on the

Power Supply Board and is used to power the watchdog circuits, and

LCD and keypad backlight,

RS-232

communication.

3.3V This supply is generated on the Power

Supply Board.

Model

8000: Main supply used to

power microprocessor, memory, interface,

RS-232 converter, RS-485

connectors, keypad controller, and

RTC.

Model

8015: Main supply used to

power microprocessor, memory, interface,

RS-485 connectors, keypad

controller, wireless card, and main audio.

NSW +5 This supply is generated on the

Power Supply Board. It is used to provide power at all times for powering instrument on and to supply voltage for battery-backed

RAM (Model 8000 only) and the RTC on the Logic Board. It is

regulated to provide not switched off until removed and the

3.3V and is AC power is

NiMH battery is

fully discharged. Battery-backed

RAM (Model 8000 only) and RTC

are further backed up by a lithium battery, which is switched-in by the

RTC when 3.3V is less than 3.0V.

Power supply communications are provided by the

TxD (transmit data) and RxD (receive

data) lines, which can be configured to send/ receive any information desired.

Table 4-1. Power Sources

Power Source How Used

+12V AMP @4 Ah NiMH

Battery Lithium Battery Backs up Super Capacitor Provides power to backup alarm.

Powers PC Unit when it is unplugged. Monitored by power supply processor

PSP) to ensure it discharges and charges correctly.

(

RTC.

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PRINCIPLES OF OPERATION

4.2 PC UNIT (Continued)

Table 4-2. Power Supply Board Voltages

Voltage Where Used

+3.3 Volts Supply to Logic Board for all circuits requiring +3.3 volts. +5 Volts Supply to Logic Board for all circuits requiring +5 volts, including LCD display. +5 Volts NSW Supply to Logic Board to maintain SRAMs and RTC, and to Power Supply Board for

System On circuits. Present even with system powered off. Must be there to enable System On circuits or system will not power on.

+8 Volts Supply to attached modules through IUI interconnects. Powers main audio circuit and

LCD backlight circuit. +12 Volts (nominal) Battery connection for battery charge and discharge. +24 Volts (VRAW) Supply to regulators to supply regulated voltages and to charge NIMH battery. Current-

limited for

NIMH charge.

4.2.5 Mechanical

The PC Unit is made up of the following subassemblies.

Battery pack and feet. Front Case Assembly - consists of:

• front case (high impact plastic)

• hardware

• keypad (data entry)

•

LCD (displays user information)

• Model

8015: backlight inverter board

Internal Frame Assembly - aluminum and consists of:

•

AC input module

• battery discharge resistor

• logic board

• off-line switching power supply

• power supply board

• Model

8015: compact flash memory card

IUI - consists of:

•

IUI circuit boards, right and left

•

IUI module connectors, right and left

• hardware See “

IUI", "Mechanical Interface” section for

a more detailed description. Pole Clamp Assembly - consists of:

• hardware

• knob

• lead screw

• pole clamp

• pole clamp mounting plate Power Cord Retainer - consists of:

• brass snap

• hardware

• retainer

• wrap

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PRINCIPLES OF OPERATION

4.2 PC UNIT (Continued)

4.2.5 Mechanical (Continued) Rear Case Assembly - consists of:

• backup speaker

• battery interface connector

• gasket

• latch block and hook

• latch spring and release lever

• rear case (high impact plastic) Serial I/O board - consists of:

• main speaker

•

RS-232 interface

• tamper switch

Model 8015: Wireless Network Card Assembly - consists of:

• card cover

• rear panel

• wireless network card

4.3 PUMP MODULE

All circuit boards are not field repairable and must be returned to a CareFusion Service Center for repair.

The Pump Module is used to pump fluid to the patient in a controlled manner. The PC Unit supplies the Pump Module with all power requirements and interface logic control. Even though the Pump Module has its own Logic Board, it must receive its commands from a PC Unit to function.

The Pump Module has an internal highstrength frame which supports all internal and external assemblies. When the door is opened, a spring loaded platen swings back with the door, allowing an administration set to be installed. The set interface is visible with the door open and interfaces with the Pump Module through the following devices.

• Air-in-Line Detector: The air-in-line detector uses

2 sensor assemblies.

When the administration set is installed, the lower portion of the set (just below pumping segment) is installed into the air-in-line detector. When the tubing is installed into this detector, the transmitting transducer sends an ultrasonic signal through the tubing. If there is fluid in the tubing, the receiver receives a strong signal and a low signal (through a logic circuit), which indicates to the Logic Board that there is fluid in the tubing and pumping can continue. If there is air in the tubing, the receiver receives a very weak signal and a high signal (through a logic circuit), which indicates to the Logic Board that there is air in the tubing. This prompts the Logic Board to stop pumping and sounds the air-in-line alarm.

• Door Open Sensor: This sensor is part of the sensor assembly and is comprised of an

LED/phototransistor pair, which are

biased by the end of the sear when the door is fully closed.

• Safety Clamp Detector: The safety clamp detector has an

LED/

phototransistor pair that are biased when the safety clamp detector is installed, allowing the Logic Board to determine if a set is installed. When the door is closed on the administration set, the safety clamp detector automatically opens, pump fingers are engaged to stop fluid flow, and the Pump Module is ready to pump fluid. When the door is opened, the safety clamp detector automatically closes and stops fluid flow.

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Pump Module

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PRINCIPLES OF OPERATION

4.3 PUMP MODULE (Continued)

• Pressure Sensors, Upper and Lower: The pressure sensors sense the pressure in the tubing by converting the pressure to a voltage. The Logic Board detects bottle-side as well as patient-side pressures by looking at these voltages. If the voltage (pressure) is high or low enough, the Pump Module signals an occlusion alarm.

• Pumping Fingers: There are fingers. Two of these are considered occluders (identified by their small profile), in that their primary function is to prevent fluid flow by the phasing of the fingers. The primary function of the

2 pumping fingers (identified by their

larger profile) is to pump fluid. The fingers cycle toward the tubing to

push fluid to the patient and then cycle back to fill the tubing. The occluders cycle toward the tubing to control flow throughout the delivery. The occluders and fingers work together to form 2 chambers. Both occluders and the upper (larger) finger form the upper chamber and the lower occluder, and lower (smaller) finger form the lower chamber, which is open-ended to the patient.

At the start of the pumping cycle:

- Upper occluder is pushed forward,

blocking flow.

- Lower occluder is pulled back, allowing

flow.

- Upper finger is cycling forward,

pushing fluid from upper chamber past lower occluder and lower finger (toward patient).

4 pumping

2 pumping

When the upper finger has cycled forward as far as it can:

- Lower occluder cycles forward to stop flow.

- Lower finger starts to cycle forward to keep fluid flowing from lower chamber toward patient.

- Upper occluder cycles back to allow fluid flow and upper finger cycles back to fill upper chamber.

When the lower finger gets to the point where it can no longer move forward to displace fluid:

- Upper occluder moves forward to stop flow (upper chamber should now be full).

- Lower occluder moves back to allow flow.

- Upper finger starts to move forward to push fluid to patient.

- Lower finger cycles back to fill lower chamber, getting ready for next cycle.

4.3.1 Display Board Assembly

The Display Board interface is a serial communications interface between the microprocessor on the Logic Board and the Display Board controller (through door harness assembly). The interface also provides the

SYNC signal to the Display

Board and a power-on reset signal for initialization of all Display Board logic. The channel-off signal from the keypad is provided as an input to the microprocessor on the Logic Board.

The Display Board processor is the interface from the keypad to the Logic Board. When a key is pressed on the keypad, it is read by the Display Board processor. The processor then relays this information

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4.3 PUMP MODULE (Continued)

4.3.1 Display Board Assembly (Continued)

(through door harness) to the Pump Module microprocessor, which in turn relays this information to the PC Unit main processor (through

The Display Board has four used to display rate information,

LEDs, and 1 alpha-numeric LED capable

IUI).

7-segment LEDs

4 discrete

of displaying a module identification letter (

A to H). One white LED is for keypad

backlight through fiber optic. The other

3 LEDs are: yellow for Standby, green for

Infusing, red for Alarm. The Display Board also has an

8-character 5 x 7 dot-matrix

display for displaying information pertaining to that particular Pump Module.

All communications between the Display Board processor and the Pump Module microprocessor is through the door harness assembly. This consists of a serial interface consisting of

RxD.

2 logic interface lines, TxD and

Interface:

The Display Board interface is a serialcommunications interface between the microprocessor on the Logic Board and the Display Board controller. The interface also provides the

SYNC signal to the Display

Board and a power-on reset signal for initialization of all Display Board logic. The channel-off signal from the Pump Module keypad is provided as input to the FieldProgrammable Gate Array (

FPGA) on the

Logic Board.

4.3.2 Logic Board Assembly

The Logic Board consists of a processor core using an Intel microprocessor running

PRINCIPLES OF OPERATION

16 MHz, a 1M x 8 Flash ROM and a

512K x 8 Static RAM. A watchdog timer

circuit is used to put the Pump Module into a safe state (puts microprocessor in

RESET

state) if the microprocessor has a hard failure.

The board also has a safety processor using an Intel controller running at an internal

256 byte static RAM. The safety processor

8K byte ROM and an internal

3.58 MHz,

is used to monitor Pump Module operations and is capable of putting the module into a safe state if a failure occurs independent of the microprocessor. The safety processor and microprocessor communicate with each other through a serial interface.

The

FPGA uses an Actel IC. This device

contains digital logic for controlling the parallel communications interface, analog-to-digital converter ( digital-to-analog converter (

ADC), DAC), pressure

transducers, and sensors circuit interface. It is also used to generate the master

RESET

signal and provide signals to the Motor Controller Board for driving the motor.

ADC:

12-bit ADC is used to monitor various

Pump Module analog signals, including pressure sensor and motor signals. It has an

8-bit parallel interface to the main

processes data bus and its control signals are generated by the external

2.5V reference, which is buffered by

FPGA. It uses an

an operational amplifier and is used to drive the

DAC reference.

Initially the by the conversions. The specific

1.333 MHz clock must be enabled

FPGA so that the ADC can perform

ADC input

channel is selected by writing the module number to the

ADC. To read the voltage of a

specific module, a low-going pulse must be

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Pump Module

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PRINCIPLES OF OPERATION

4.3 PUMP MODULE (Continued)

4.3.2 Logic Board Assembly (Continued) ADC: (Continued)

applied to the /START The microprocessor monitors the

CONVERSION signal.

ADC BUSY

signal and can read the voltage when the

ADC BUSY signal is asserted low.

The

ADC contains self calibration and system

calibration options to ensure accurate operation over time and temperature. The system calibration calibrates for system offset or system gain errors. To perform an

ADC calibration, a low-going pulse is applied

to the

/ADC

CAL signal.

DAC:

8-bit DAC is used to generate the VDAC

analog signal for driving the Motor Controller Board. The

DAC has an 8-bit parallel

interface to the microprocessor’s data bus and its control signals are generated by the

FPGA. The DAC produces a current output,

which is converted to a voltage output by an operational amplifier.

The

DAC has an 8-bit input latch that

contains data written to it from the

/DAC

microprocessor. The from the

FPGA is asserted low when this

data is written to it. The

WRITE signal

DAC converts the

digital value to a proportional current on its output. This current is then converted to a voltage signal

VDAC, which drives the Motor

Controller Board.

and provide signals to the Motor Controller Board for driving the motor.

The processor interface section of the produces the signals for controlling the chip-selects for controlling the digital ports in the

FPGA, signals for controlling the

FPGA

ADC,

I/O

parallel communications interface between the safety processor and microprocessor, logic for demultiplexing the address/data bus from the microprocessor, and circuitry to produce the

188_RESET

signal that resets the microprocessor. It also has an input port for reading the

SYNC, safety clamp

detector, pump encoder, air-in-line, and door sensor signals. The processor interface also uses the

1.33 MHz clock signal for driving the ADC.

76 MHz system clock to produce a

The I/O interface section of the FPGA produces signals for controlling the motor interface section, chip-selects for controlling the output ports in this section, and logic to shut down the motor if the Logic Board has a hardware failure. The chip-selects enable the output ports that produce signals to enable and test the air-in-line detection circuitry, enable the pump encoder, enable the safety clamp detector, and enable the pressure sensor. It also generates signals to control the motor interface to the Motor Controller Board.

The motor interface section of the

FPGA

produces the various phase signals to the Motor Controller Board in order to drive the motor.

FPGA:

The

FPGA uses an Actel IC. This device

contains digital logic for controlling the parallel communications interface,

DAC, and sensor circuit interface. It is also

used to generate the master

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RESET signal

ADC,

Main Processor:

The Logic Board consists of a processor core using an Intel microprocessor running at

16 MHz, a 1 MB x 8 flash ROM and a

512 Kb x 8 static RAM. A watchdog timer

circuit is used to put the Pump Module into a safe state (puts microprocessor in

RESET

Page 45

PRINCIPLES OF OPERATION

4.3 PUMP MODULE (Continued)

4.3.2 Logic Board Assembly (Continued) Main Processor: (Continued)

state) if the microprocessor has a hard failure.

The microprocessor generates the upper chip-select signal ( the flash

ROM IC when doing read or write

/UCS) in order to enable

operations, when programming new software into the device. The microprocessor generates the lower chip-select signal ( in order to enable the static

RAM when doing

read or write operations. The address bus is demultiplexed by

transparent latches in order to generate the address lines, through

A19.

On power up, the watchdog timer generates the by the

FPGA, and generates the /_188_RESET

A0 through A7 and A16

/RESET signal, which is taken

signal to reset the microprocessor. The microprocessor then generates the

RESET

signal that is used to reset the safety processor. The microprocessor must strobe the watchdog timer

IC every 1 second or

less by generating a low-going pulse on the

/WDI signal line, in order to prevent it from

timing out. If the watchdog

IC times out due

to a hardware failure on the Logic Board,

/WDO output of the microprocessor is

the asserted low. This is applied to the

FPGA,

which generates a nonmaskable interrupt

NMD) to the microprocessor and asserts the

(

/_188_RESET signal low a few seconds later,

in order to put the microprocessor into a safe

RESET) state.

(

RS-485 IUI Interface:

The Logic Board contains interface circuitry to the

IUI. Two RS-485 transceiver chips

are used to interface the serial port of the

/LCS)

microprocessor to the and receive enable signals to the transceiver chips are lines from the of the microprocessor or

The microprocessor port

TE2, are used to enable the transmitters.

The microprocessor signals,

RE2, are used to enable the receivers.

IUI. The transmit

RS-485

I/O port

DUART.

2 signals, TE1 and

RE1 and

Data is transmitted and received on the microprocessor serial port when communicating with the Pump Module or PC Unit.

Safety Processor:

The safety processor uses an Intel controller running at

ROM, and an internal 256 byte static RAM. The safety processor is used to

3.58 MHz, an internal 8K byte

monitor Pump Module operations and is capable of putting the module into a safe state if a failure occurs independent of the microprocessor. The safety processor and microprocessor communicate with each other through a serial interface. The safety processor monitors door sensor, safety clamp detector, pump encoder sensor, and air-in-line sensor. If a failure occurs, the safety processor shuts down the motor in order to put the Pump Module into a safe state.

Sensor Circuit Interface:

The sensor interface consists of signals generated and received by the

FPGA:

air-in-line, door sensor, safety clamp detector, pressure sensor, and pump encoder.

The air-in-line signal is read by the microprocessor and safety processor. The

AIL SUPPLY must be enabled and the /ALE TEST

signal must be asserted low in order to

read this signal.

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PRINCIPLES OF OPERATION

4.3 PUMP MODULE (Continued)

4.3.2 Logic Board Assembly (Continued) Sensor Circuit Interface: (Continued)

The door sensor signal is read by the microprocessor and safety processor. The

DOOR_SENSOR_ENABLE signal must be

asserted high in order to read this sensor. The safety clamp signal is read by the

microprocessor and safety processor. The

DOOR_SENSOR_ENABLE signal must be

asserted high in order to read these signals. The pressure sensor voltages from the

bottle-side and patient-side sensors are read by the microprocessor. The

PRESSURE_SENSOR_SUPPLY voltage must

be enabled in order to read these sensors. The pump encoder sensor signal is read by the microprocessor and safety processor. The

PUMP_ENCODER_LED voltage must be

enabled in order to read the encoder.

4.3.3 Motor Controller Board Assembly:

The motor drive logic signals are generated by the Logic Board and fed to the power drive circuits on the Motor Controller Board. These circuits drive the

5-phase stepper

motor, which is used to drive a cam shaft that biases the pumping fingers, to generate pressurized fluid flow to the patient (pressure depends on many variables but will not exceed maximum design pressure). The Motor Controller Board also monitors the motor's needs and supplies the correct amount of motor drive voltage, depending on a number of variables, not the least of which is load. This ensures an adequate amount of power is available to the motor at all times. The motor speed is based on the rate settings signal sent by the microprocessor.

4.3.4 Mechanical

The Pump Module consists of the following major assemblies.

Fluid Delivery Subassembly ( uses a very high strength plastic frame and mechanically supports following parts:

• air-in-line sensor

• bezel

• bezel seal

• cam shaft

• door hinges (break away)

• encoder sensor (detects motor movement)

• gear train

• hardware

• harnesses

• latch yoke (door catch)

• logic board

• motor

• motor controller board

• platen

• pressure sensors, upper and lower

• pumping and occluding fingers

• safety clamp detector

Door Assembly - attaches to

2 hinges and consists of following parts:

FDSA with

• covers, front and rear

• display board

• door lever (latch)

• hardware

• harness

• keypad

• protective lens

• seals

IUI - consists of:

• hardware

•

IUI circuit boards, right and left

•

IUI module connectors, right and left

See “

IUI", "Mechanical Interface” section for

a more detailed description.

FDSA) -

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PRINCIPLES OF OPERATION

4.4 POWER CONTROL CIRCUIT

The power control circuitry prevents power from being applied to module connections when a module is not attached to the Alaris System. The same circuitry connects power to the attached to the Alaris

4-3). Each interface and attached module

contains

IUI connections when a module is

2 separate power switching circuits

System (see Table

to control power to modules attached to the left or right.

Left power circuit: Power to modules on the left is controlled by the module detect left signal ( transistor (

MODDETL) to the gate of field effect

FET). When the MODDETL signal

is logically high, power is not applied to the

IUI. When a module is attached to the

left left, circuitry in the newly attached module pulls the power is connected to the left

MODDETL signal logically low, and

IUI to operate

the newly attached module. Right power circuit: Power to modules

on the right is controlled by the module detect right signal ( of the

FET. When the MODDETR signal is

MODDETR) to the gate

logically high, power is not applied to the right

IUI. When a module is attached to the

right, circuitry in the newly attached module pulls the power is connected to the right

MODDETR signal logically low, and

IUI to operate

the newly attached module. When a previously attached module

is detached from the right or left, the respective module detect signal ( or

MODDETR) changes from the low state

MODDETL

(module attached, power applied to the high state (no module attached, power not applied to

IUI). Software within the

PC Unit or remaining attached module detects the high state of the module detect signal and determines that

1 or more

IUI) to

previously attached module is no longer attached.

4.5 INTER-UNIT COMMUNICATIONS

CIRCUIT AND CONNECTIONS

Software within the PC Unit and all attached modules provides bidirectional communications between a PC Unit and more attached module. Two pairs of signal lines are provided in both the left and right

IUI connectors for this purpose:

Transmit + ( Transmit _ ( Receive + ( Receive _ (

TxD [+])

TxD [ RxD [+]) RxD [

])

Each pair of signals (transmit or receive) is a differential pair, which allows rejection of common mode noise appearing on the signal pairs. The transmit pair originates communications from the PC Unit to more attached module. The receive pair originates communications from more attached module to the PC Unit, in response to a communications request from the PC Unit. This allows the PC Unit to coordinate communications from multiple function modules on a common transmit/ receive bus.

Bidirectional communications between the PC Unit and each attached module can range from a simple "report status" interaction to an extensive dialogue, to change operational parameters or transfer operating event history. At the start of each attempted dialogue, the PC Unit software sets a timer at the maximum time allowed for the attached module to respond. If the attached module does not respond in the allotted time, the timer expires and the PC Unit software determines a communications failure.

1 or

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PRINCIPLES OF OPERATION

4.5 INTER-UNIT COMMUNICATIONS

CIRCUIT AND CONNECTIONS

(Continued)

Software within the PC Unit and attached modules provides for communications during the following times.

Prior to logical unit ID assignment: Communications consist only of that required to assign unit

IDs. The UNIT

_ID_

ENABLE

signals control access to the communication channels.

After logical unit ID assignment: Communications between the PC Unit and attached modules use the assigned unit to communicate to, and receive responses from,

1 attached module at a time.

4.5.1 Software

Software running within the interface and attached module performs the following key aspects of

IUI functionality:

• Controls state of unit detect line.

• Reads state of incoming

ID_ENABLE_IN

line.

• Controls state of outgoing

OUT

line.

ID_ENABLE

• Performs bidirectional communications between PC Unit and

1 or more attached

module.

4.5.2 Unit Detection and Identification Circuitry

Unit (module) detection is required to detect:

• presence of attached modules

• new module attachment

• module detachment

Unit (module) identification is used to:

• identify attached module type

• logically assign module designation based on physical location

• designate inter-unit communications to and from a specific module

A combination of

2 signal lines is used

to accomplish module detection and, in conjunction with inter-unit communications, accomplish module identification.

Unit Detect Line:

The unit detect line from the is read by PC Unit software as

DETECT

. This allows the PC Unit to

IUI connectors

UNIT

determine when modules are attached to the left or to the right.

The

UNIT_DETECT line originates from

the PC Unit and passes through each attached module. The

UNIT_DETECT signal

is normally logically high due to circuitry within the PC Unit. Circuitry connected to the

UNIT_DETECT line within each attached

module is able to pull the

UNIT_DETECT

line logically low under control of the microprocessor within the PC Unit. The logical state of the

UNIT_DETECT signal is

able to be read by the microprocessor to determine if any module attached to the left is pulling the signal low.

ID ENABLE IN Line:

Software within each attached module reads the state of the incoming

ID_ENABLE_IN

line. The state of this signal is used by the software to determine whether the module can respond to unit

ID assignment messages

from the PC Unit. If this signal is high, the attached module is able to respond to unit

assignment messages. If this signal is low, the module is not able to respond to unit

assignment messages.

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PRINCIPLES OF OPERATION

4.5 INTER-UNIT COMMUNICATIONS

CIRCUIT AND CONNECTIONS

(Continued)

4.5.2 Unit Detection and Identification

Circuitry (Continued)

ID ENABLE IN Line: (Continued)

The ID

ENABLE line originates from the

attached module and passes on to either an operating module or PC Unit attached to the right. Circuitry connected to the

ID_ENABLE

line within each attached module receives the incoming signal ( left

IUI connector and outputs an outgoing

signal (

ID_ENABLE_OUT) to the right IUI

ID_ENABLE_IN) from the

connector. The incoming signal (

connected to

1 input of an FPGA and then

read by the microprocessor. The

ENABLE_IN

is also pulled logically high when

ID_ENABLE_IN) is

no module is attached to the left. The

ID_ENABLE_OUT of an attached module

is directly connected to the

ID_ENABLE_IN of

the module on its right. Using this scheme, the microprocessor in the module attached on the left allows the

ID_ENABLE_OUT to be

high only after the left module has completed its identification with the PC Unit.

4.5.3 IUI

When a module is attached to the PC Unit, it is connected through the is

4 attached modules per PC Unit. The

IUI. The limit

exception is the Auto-ID Module which can be a fifth module.

The

IUI consists of a left connector and a

right connector, with spring contacts. These connectors are used to attach a module to a PC Unit or another module, and provide physical support and electrical connections.

Mechanical Interface:

The mechanical interface consists of mechanically supporting electrical connectors, male on

1 module and female on

the other. These connectors mechanically interface to attach a module to the PC Unit, or

1 module to another module (for example,

when

2 modules are attached to 1 side

of PC Unit). In conjunction with these connectors there is a latching mechanism on the bottom of each module that helps secure the

2 modules together. Pushing on the

latching mechanism disengages an attached

module. Reference the Alaris

System DFU for module attachment and detachment instructions.

Electrical Interface:

The electrical interface between an attached module and the PC Unit is an integral part of the mechanical connector, consisting of

15 gold-plated pins. The pins on the module

interface with the pins on the PC Unit, or another module if more than

1 module is

attached to the same side of the PC Unit. Table

4-3 is a snapshot of the IUI connector

pin-outs. The electrical portion of the

IUI

consists of the following elements:

• Power control circuitry and connections.

• Module detection, and identification

circuitry and connections.

• Logical module assignment circuitry and

connections.

• Inter-unit communications circuitry and

connections.

• Spare

I/O.

All inter-unit connections are accomplished through the

IUI connectors located on the left

and right side of each PC Unit and attached module.

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PRINCIPLES OF OPERATION

4.5 INTER-UNIT COMMUNICATIONS

CIRCUIT AND CONNECTIONS

(Continued)

4.5.4 Module Detection and Logical Designation

Three situations may occur within the

IUI

which require software functionality for the assignment of a logical designation to an attached module, based on its physical position within the Alaris

System:

• System On.

• Attachment of

1 or more module to left

after System On.

• Attachment of

1 or more module to right

after System On.

Two additional situations may require either reassignment of logical designations and/or enunciation of alarms (see “Module Detachment” section):

• Attachment of

1 or more module to left

after System On.

• Attachment of

1 or more module to right

after System On.

4. PC Unit sends a message to all modules to pull unit detect line low.

5. PC Unit sequentially assigns unit from left to right, starting with "

IDs

A" and

ending when PC Unit senses unit detect line in high state.

When modules are attached on both sides of the PC Unit, the PC Unit controls the

D_ENABLE_R

line to modules on the right

UNIT

until all modules attached to the left have been identified ( high). The PC Unit then allows the

ENABLE_R

sets unit

IDs for modules to the right, still

UNIT_ID_DETECT_L line goes

UNIT_ID

line to go high and sequentially

going left to right. The sequential assignment of the unit

from left to right makes use of the fact that an attached module only senses a high state on the

CONNECT_SENSE) when:

ID_ENABLE_IN signal (also called

• Attached module is farthest to left.

• Module to left has completed its unit ID

and sets

ID_ENABLE_OUT signal.

4.5.5 Unit ID Assignment at System On

The basic scheme for assigning unit (module) position identification at System On involves the following sequence of events:

1. PC Unit and each attached module execute a Power On Self Test (

POST),

during which each attached module clears its unit

ID and, when POST is

complete, pulls unit detect line low.

2. As each module completes its

POST, it

releases unit detect line.

3. When all attached modules have released unit detect line, PC Unit senses unit detect line in high state.

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Tables

4-3 and 4-4 show the IUI signals for

logical module assignment in a system with

2 modules attached to the left and 2 modules

attached to the right of the PC Unit. All modules have been identified and the

sequence completes when the PC Unit receives the

ID complete message from the

last module and the unit detect line goes high. This same scheme is used for any configuration of up to

4 modules (exception,

Auto-ID Module can be recognized as a fifth module), ranging from all on the left, all on the right, or a mix of left and right modules.

Page 51

PRINCIPLES OF OPERATION

4.5 INTER-UNIT COMMUNICATIONS

CIRCUIT AND CONNECTIONS

(Continued)

Table 4-3. IUI Logic

Pin # Left IUI Right IUI

1 Common

SYS_GND Common SYS_GND

2 +V8 Pwr in/out +V8 Pwr in/out

/MODDETL

3 4

Spare A

Ground

Spare A 5 Unit ID Enable input Unit ID Enable output 6 Common Bus ( 7 Common Bus ( 8 Display

SYNC LEDs for module input Display SYNC input

9 Common Bus (

10 Common Bus (

485) transmit+ Common Bus (485) Receive+

485) transmit

485) Receive+ Common Bus (485) transmit+

485) Receive

Common Bus (485) Receive

Common Bus (485) transmit

11 Unit ID Detect output Unit ID Detect output 12 Spare B Spare B 13 Ground

/MODDETR

14 +V8 out +V8 Pwr in/out 15 Common

SYS_GND Common SYS_GND

Table 4-4. IUI Signals

The PC Unit only recognizes

4 modules at any 1 time, even though more than 4 modules may be

attached. The exception is the Auto-ID Module which can be recognized as a fifth module. The following diagram illustrates the system communications described in detail in the "Inter-Unit Communication Circuit and Connections" section.

Attached Module Attached Module Attached Module Attached ModulePC Unit

MODDET

TxD

RxD

Unit ID Detect

In OutIn Out

Unit ID Enable

In Out

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Technical Service Manual

In Out

Pump Module

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PRINCIPLES OF OPERATION

4.5 INTER-UNIT COMMUNICATIONS

CIRCUIT AND CONNECTIONS

(Continued)

4.5.6 Module Attachment After System On

When

1 or more module is attached to the

PC Unit after System On, the following events must occur:

• Assignment of logical unit

IDs to all newly

attached modules.

• Reassignment of all other modules within the system to next logical letter; " becomes "

B", "B" becomes "C", and so

on.

The assignment of logical unit

IDs to a

module newly attached to the left follows a scheme similar to the power up scheme:

1. Newly attached module pulls

DETECT

line low.

UNIT

2. Newly attached module executes its

POST, during which its unit ID is cleared.

3. When each module completes its

it releases

UNIT_DETECT line.

POST,

4. When all newly attached modules

release senses

UNIT_DETECT line, PC Unit UNIT_DETECT in high state.

5. PC Unit sends a message to all

modules to pull

6. PC Unit assigns a unit

UNIT_DETECT line low.

ID of "A" to left-

most newly attached module.

9. When next module completes setting its

ID, it sets UNIT_ID_ENABLE line high,

unit which sets sends an

ID_ENABLE_OUT high and

ID_COMPLETE message to

PC Unit.

When all newly attached modules have completed the unit

ID, the PC Unit

sequentially assigns a logical unit remaining modules. However, during the

ID assignment communications dialogue

between the PC Unit and the other attached modules, each attached module notifies the PC Unit that it already had a valid unit and that the new unit

ID is merely a position

reassignment. The PC Unit is therefore able to reassign all historical and operational data from the previous unit

ID to the new unit ID,

to maintain data continuity.

4.5.7 Module Detachment

If modules are detached while operating, the PC Unit, upon detecting the detachment, gives visual and audible indications requesting verification. If verification is received, the PC Unit reassigns logical unit

IDs similar to attaching a new module.

If verification is not received within a prescribed time period, the PC Unit places the system into an alarm state with audible and visual alarms. This alarm is detected by the communications time-out between the PC Unit and the detached modules.

4.5.8 Communications Time-Out

ID to the

7. When left-most newly attached module

completes setting its unit

UNIT_ID_ENABLE line high, which sets ID_ENABLE_OUT high and sends an ID_COMPLETE message to PC Unit.

ID, it sets

8. Attached module assigns a unit

to next left-most newly attached module.

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ID of "B"

After all modules in the system have been identified, the PC Unit begins systematic bidirectional communication with each attached module. These communications can range from a simple "report state” interaction to an extensive dialogue, to change operational parameters or transfer operating event history. In either case, the

Page 53

4.5 INTER-UNIT COMMUNICATIONS

CIRCUIT AND CONNECTIONS

(Continued)

4.5.8 Communications Time-Out (Continued)

PC Unit software initiates communications with each attached module on a periodic basis, to ensure system integrity.

At the start of each attempted dialogue, the PC Unit software sets a timer at the maximum time allowed for the attached module to respond. If the attached module does not respond in the allotted time, the timer expires and the PC Unit software determines a communications failure.

PRINCIPLES OF OPERATION

When

1 or more module is detached,

the PC Unit detects the detachment as a communications time-out with the detached modules.

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PRINCIPLES OF OPERATION

Figure 4-1. Block Diagram - Models 8000 and 8015

Module(s)

8V Switch

Data In

Data Out

Optical Bundle

VAC

Left IUI

Board

Keypad

Backlight

DRV In

Backup

Speaker

Power Entry, Fuse and Filter

Data

Dimmer

Control

Return

3.3V

8V Switch

Data In

Data Out

Backup

Alarm

(On Logic

Board)

Data

GND

CF Memory

(8015 only)

VAC

V-Backup

24V, 50W

Power Supply

24V OUT

GND 24V

Power Supply Board

Logic Board

GND

3.3V

Nurse Call

Station

3.3V 5V 8V

Data

12V Battery

BATT (-) BATT (+)

GND

3.3V

CF Radio

802.11 (8015)

CI Board (8000)

Data In

Wireless to

Data

Server

Data (Thermistor)

8V Switch

Data In

Data Out

Data

GND

SIO Bd

(

Main speaker,

RS-232, Tamper SW

Right IUI

Data

3.3V

GND

Dimmer Control

GND

)

Board

Color

Display

350VAC

Inverter

(8015 only)

Data In

8V Switch

Data In

Data Out

Module(s)

PC Unit

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Figure 4-2. Block Diagram - Model 8100

Keypad

Data In

Data Out

PRINCIPLES OF OPERATION

Display Board

Data GND

+5V

+8V Switch

PC Unit Pump Module(s)

GND GND GND

IUI Data IUI Data IUI Data

Motor Controller

+8V +8V Switch

+5V

Board

Phase Drive

Motor

Encoder Data

Out

Encoder Data

+3.3V

Data

Phase Data

AIL Sensor Board

Data InData Out Data InData Out

Door/

Flowstop

GND

+5V

Data

IV Set

Logic Board

GND Data

+5V

Pressure Sensors

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PRINCIPLES OF OPERATION

THIS PAGE

INTENTIONALLY

LEFT BLANK

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Chapter 5 – CORRECTIVE MAINTENANCE

WARNING

Disconnect from AC power prior to performing maintenance. The instrument case should only

be opened by qualified personnel using proper grounding techniques.

CAUTION

CMOS devices are sensitive to static electrical

charges and may be damaged during repair if the repair activity is not performed in an electrostatic discharge ( approved

ESD) protected environment using

ESD protective procedures, including

personnel grounding.

5.1 INTRODUCTION

This chapter describes how to disassemble and reassemble the PC Unit and Pump Module.

The circuit boards are fitted with surface mount devices and are not field repairable. Return circuit boards to an authorized CareFusion Service Center for repair. Attempting circuit board repairs voids all warranties.

For replacement part information, see the "Illustrated Parts Breakdown" chapter. Following any level of maintenance, perform the applicable tests, as identified in the "Level of Testing Guidelines" table.

Due to product changes over time, components/assemblies illustrated in this chapter may differ from the instrument being serviced.

CAUTION

To avoid the risk of an electrical hazard or damage to the instrument circuitry, do not

spray fluids directly onto the instrument or allow fluids to enter the instrument.

5.2 DISASSEMBLY / REASSEMBLY

The disassembly procedures in this chapter are presented in a sequence that provides the most efficient means of disassembling an instrument. To disassemble, perform the steps in order from the first step. To reassemble, perform the steps in their reverse order.

Before adhering gaskets and labels to the instrument, clean the surface with a cotton swab or soft cloth lightly dampened with Isopropyl Alcohol.

70%

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CORRECTIVE MAINTENANCE

Table 5-1. Required Materials, Supplies and Tools

NOTE: Contact/source information is subject to change.

• Silicone Grease, Dow Corning Molykote 33, or equivalent (http://www.dowcorning.com)

•

#1 Phillips Screwdriver

•

#2 Phillips Screwdriver

• Needle-Nose Pliers

• Small Diagonal Cutters

• Lint-free cloth (such as, Kimwipes or lint-free tissue) The following items may be purchased from Techni-Tool (

•

/16 Nut Driver, TT #272SC036

800.832.4866; http://www.techni–tool.com).

• 3/16 Nut Driver, TT #272SC116

• ¼ Nut Driver, TT #272SC144

• Torque Screwdriver with a minimum range of 3-15 in/lbs. Recommend torque screwdriver, MicroAdjustable,

TT #844SC5002 or TT #304TO034.

5-2

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5.3 PC UNIT

5.3.1 Battery Pack Assembly

CORRECTIVE MAINTENANCE

1. Remove screws (

4) from bottom of

PC Unit.

2. Remove Battery Pack Assembly.

Battery Pack Assembly

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CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.2 Latch Assembly

1. Remove screws (

2) attaching Latch

Assembly to bottom of Rear Case.

2. Remove Latch Assembly components from bottom of Rear Case. Pay close attention to Compression Spring location, to ensure proper installation during reassembly.

Compression Spring

Latch Support

Leaf Spring

Latch

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5.3 PC UNIT (Continued)

CORRECTIVE MAINTENANCE

5.3.3 Power Cord

1. Remove screw attaching Power Cord Wrap to PC Unit and remove Power Cord Wrap.

2. Remove screw attaching Power Cord Retainer to PC Unit and remove Power Cord Retainer.

NOTE: Pole Clamp Assembly may need to be loosened to remove retainer (see "Pole Clamp Assembly").

A Model 8000 (without CI Board or Nurse Call Accessory) is illustrated. The Model 8015 is the same except that a wireless network card would be visible.

3. Unplug Power Cord from PC Unit and remove.

During Reassembly:

If not present, install AC Filter Gasket.

External AC Filter Gasket

(see enlarged illustration)

Power Cord Retainer

Power Cord Wrap

Power Cord

Ensure this edge completely covers gap between AC Filter and Rear Case.

Align this edge with edge of AC Filter housing, as shown.

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CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.4 Pole Clamp Assembly

1. Remove screw attaching Pole Clamp to Pole Clamp Plate.

2. Remove screws (

4) attaching Pole

Clamp Plate to PC Unit.

3. Use a small punch and hammer to drive Pin out of tip of Lead Screw.

4. Remove knob from Pole Clamp.

A Model 8000 (without CI Board or Nurse Call Accessory) is illustrated. The Model except that a wireless network card would be visible.

8015 is the same

During Reassembly:

1. Use a small punch and hammer to reinstall Pin in Tip on Knob/Lead Screw.

2. When installing Pole Clamp Plate: a. Use new screws (see Figure

7-15 for

ordering options).

b. Hand tighten screws in sequence

indicated in illustration.

c. Torque screws in sequence indicated

in illustration.

d. Torque screws a second time in

sequence indicated in illustration.

Knob/Lead Screw

5-6

Technical Service Manual

Alaris® PC Unit

Pump Module

Alaris

Lead Screw Tip

Pole Clamp Plate

Gasket

Pole Clamp

Page 63

5.3 PC UNIT (Continued)

CORRECTIVE MAINTENANCE

5.3.5 Rear Panel (Model 8000) and Rear Panel Assembly

1. Remove and discard Gasket Strip.

2. Model

8000: Remove screws (4)

securing Rear Panel to Rear Case Frame.

NOTE: To remove CI Board Accessory, Wireless Network Card or Nurse Call Accessory, see applicable disassembly procedure.

3. Remove screws (4) securing Rear Panel Assembly to Rear Case Frame.

4. Gently slide Rear Panel Assembly out of instrument.

During Reassembly:

1. If a gasket is not visible along upper mounting on frame, install an Upper Rear Case Gasket.

2. If a Lower Rear Case Gasket is not present [see "Model Accessory (Model

8000: Nurse Call

8010)" for gasket

location]:

• Ensure a Rear Panel Gasket is

installed (see "Rear Panel Assembly Parts" for gasket location).

• Model

8000: Ensure Rear Panel

Gasket is installed.

3. Slide Rear Panel Assembly along left guide, raising it slightly as necessary to align board connection and pushing it into Logic Board connector. Connector is fully seated when panel is flush with mounting frame.

4. Ensure panels are flush to Rear Case and tighten mounting screws.

5. Install a new Gasket Strip.

Rear Panel Assembly

Shoulder Washer

RJ45 Connector Plug

Gasket Strip

Fold this flap out and adhere to Rear Case

Gasket on back of Rear Panel

(used only when a Lower Rear

Case Gasket is not present)

Rear Panel (Model 8000)

Upper Rear Case Gasket

(used only when a gasket is

not present between frame

and Rear Panel)

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CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.6 Rear Panel Assembly Parts

1. Cut cable tie holding Speaker and Tamper Resist Switch wiring together.

2. Unscrew Boot Seal from Tamper Resist Switch.

3. Remove Tamper Switch Shroud.

4. Disconnect Tamper Resist Switch from

RS-232 Board (J4).

5. Remove Tamper Resist Switch.

6. Disconnect Speaker from Isolated

RS-232 Board (J2).

7. Remove screws (

8. Remove

RS-232 Board, Speaker Bracket

2) from RS-232 Board.

and Speaker.

10. Remove and discard Speaker Gasket.

NOTE: The Speaker Gasket is adhered to both the Speaker and Rear Panel.

During Reassembly:

1. Install Speaker Gasket: a. Remove protective backing from side

facing Rear Panel.

b. Orient notches to line up with

standoffs on Rear Panel.

c. Adhere to Rear Panel.

2. Remove remaining protective backing from Speaker Gasket and adhere Speaker to gasket.

3. Tie Speaker and Tamper Resist Switch wiring together with a cable tie.

5-8

Tamper Switch Shroud

Boot Seal

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Technical Service Manual

Tamper Resist Switch

Page 65

5.3 PC UNIT (Continued)

5.3.6 Rear Panel Assembly Parts (Continued)

Rear Panel

CORRECTIVE MAINTENANCE

RS-232 Board Assembly

Speaker Bracket

(runs along 2 edges; not used if Lower

Rear Case Gasket is present)

Rear Panel Gasket

Tamper Resist Switch

Gasket

Speaker

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Technical Service Manual

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CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.7 Model 8000: CI Board Accessory (Model 8012)

1. Remove and discard Gasket Strip.

2. Remove screws (

6) securing Model 8012

to Rear Case Frame.

3. Gently slide Model

8012 out of

instrument.

During Reassembly or Installation:

1. If a gasket is not visible along upper mounting on frame, remove Rear Panel Assembly and install an Upper Rear Case Gasket [see "Rear Panel (Model

8000) and Rear Panel Assembly" for

gasket location].

2. If Model

8012 is being installed for first

time and a Lower Rear Case Gasket is present [see "Model Call Accessory (Model gasket from Model

3. Slide Model

8012 along right guide,

8000: Nurse

8010)"], remove

8012.

raising it slightly as necessary to align board connection and pushing it into Logic Board connector. Connector is fully seated when panel is flush with mounting frame.

4. Prior to tightening mounting screws, ensure Model

8012 Plate is flush to Rear

Case.

5. Install a new Gasket Strip.

5-10

Model 8012

Gasket Strip

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Technical Service Manual

Gasket - on back of

Model 8012 Panel

Page 67

5.3 PC UNIT (Continued)

CORRECTIVE MAINTENANCE

5.3.8 Model 8015: Wireless Network Card Assembly

1. Remove and discard Gasket Strip.

2. Remove screws (

4) securing Wireless

Network Card Cover to accessory Rear Panel and Rear Case Frame.

3. Remove Wireless Network Card Cover.

4. Remove Wireless Network Card.

5. Remove screws (

2) securing accessory

Rear Panel to Rear Case Frame.

Gasket Strip

Wireless Network Card

Cover / Foam Insert

Rear Panel /

Communications Board /

Gaskets

Wireless Network Card

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CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.8 Model 8015: Wireless Network Card Assembly (Continued)

6. Remove Foam Insert (if present) from Wireless Network Card Cover.

7. Remove accessory Rear Panel / Communications Board Assembly.

8. Remove screws (

2) securing

Communications Board to accessory Rear Panel.

Foam Insert

(0.35 x 1.75")

During Reassembly:

1. If a noticeable gap is visible between Network Card and Cover, ensure Foam Insert is installed. For example, Symbol Network Card requires use of Foam Insert but AmbiCom Network Card does not.

2. Prior to tightening mounting screws, ensure assembly is flush to Rear Case.

3. Install a new Gasket Strip.

5-12

Network Card Cover

Communications Board

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Gasket

Rear Panel

Gasket

Page 69

5.3 PC UNIT (Continued)

CORRECTIVE MAINTENANCE

5.3.9 Model 8000: Nurse Call Accessory (Model 8010)

1. Remove and discard Gasket Strips (

2. Remove screws ( Plates (

Block-Off Plate, #0

Gasket Strips

2) to Rear Case Frame.

4) securing Block-Off

3).

Model 8010

3. Remove screws (

2) securing Model 8010

to Rear Case Frame.

4. Gently slide Model instrument.

8010 out of

Block-Off Plate, #2

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Technical Service Manual

5-13

Page 70

CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.9 Model 8000: Nurse Call Accessory

(Model 8010) (Continued)

During Reassembly:

1. If a gasket is not visible along upper mounting on frame, remove Rear Panel Assembly and install an Upper Rear Case Gasket [see "Rear Panel (Model

8000) and Rear Panel Assembly" for

gasket location].

2. If Model

8010 is being installed for first

time: a. Remove Rear Panel Assembly. b. If present, remove and discard Rear

Panel Gasket (see "Rear Panel Assembly Parts" for gasket location).

c. Install a Lower Rear Case Gasket.

d. Reinstall Rear Panel Assembly. Do

not tighten screws.

e. Attach

#0 Block-Off Plate next to

Rear Panel Assembly and Off Plate to far right. Do not tighten screws.

3. Slide Model

8010 along guide rail,

raising it slightly as necessary to align board connection and pushing it into Logic Board connector. Connector is fully seated when panel is flush with mounting frame.

4. Ensure Model

8010 Plate, both Block-

Off Plates, and Rear Panel Assembly are flush to Rear Case. Tighten all mounting screws.

5. Install new Gasket Strips.

#2 Block-

Lower Rear Case Gasket

5-14

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Technical Service Manual

Page 71

5.3 PC UNIT (Continued)

CORRECTIVE MAINTENANCE

5.3.9 Model 8000: Nurse Call Accessory

(Model 8010) (Continued)

6. If Fair-Rite Suppressor Core is being installed for first time:

a. Open Fair-Rite Suppressor Core.

MaxLoad

NURSECALL

b. Route Model

8010 cable (plug end)

down along recessed area on right half of suppressor core, and then loop cable around and down through suppressor core.

c. Close and securely latch suppressor

core.

30V/1A

Gasket Strips

This end plugs into Nurse Call

Accessory.

Suppressor

Core

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Pump Module

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Technical Service Manual

5-15

Page 72

CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.10 Model 8000: Nurse Call / CI Board Accessory

1. Remove and discard Gasket Strip.

2. Remove screws (

6) securing Accessory

to Rear Case Frame.

3. Gently slide Accessory out of instrument.

During Reassembly or Installation:

1. If a gasket is not visible along upper mounting on frame, remove Rear Panel Assembly and install an Upper Rear Case Gasket [see "Rear Panel (Model

8000) and Rear Panel Assembly" for

gasket location].

2. If Accessory is being installed for first time and a Lower Rear Case Gasket is present [see "Model Call Accessory (Model

8000: Nurse

8010)"], remove

gasket from back of Accessory panel.

3. Slide Accessory along left guide, raising it slightly as necessary to align board connections and pushing it into Logic Board connector. Connector is fully seated when panel is flush with mounting frame.

4. Prior to tightening mounting screws, ensure Accessory panel is flush to Rear Case.

5. Install a new Gasket Strip.

Nurse Call / CI Board Accessory

Gasket Strip

5-16

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Gasket - on back of

Model 8012 Panel

Page 73

5.3 PC UNIT (Continued)

5.3.11 Handle

CORRECTIVE MAINTENANCE

1. Remove screws (

4) attaching handle

halves to each other.

2. Remove Handle Top and Bottom.

3. Remove Handle Shaft and O-Rings by sliding shaft to one side.

O-Ring (2 PL)

Handle Shaft

Handle Bottom

Handle Top

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Pump Module

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Technical Service Manual

5-17

Page 74

CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.12 Front and Rear Case Separation

1. Remove screws (

4) attaching F ron t Case

to Rear Case.

2. Carefully disconnect Keypad Backlight

LED connector from Logic Board (J9)

3. Disconnect harnesses/cables.

•

LCD/Display - Logic Board J3 (8000) / J7 (8015)

• Keypad - Logic Board

(

8015)

J2 (8000) / J4

• Ground - Ground Plate

• Inverter Display (

8015) - Logic Board

During Reassembly:

Ensure Silicone Tubing is in place and not damaged. (See Figure

7-3)

5-18

LCD/Display Harness

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Inverter Display Harness

(Model 8015)

Keypad Flex Cable

Ground Cable

Keypad Backlight LED

Page 75

5.3 PC UNIT (Continued)

5.3.13 Model 8000: Display and Retainer

CORRECTIVE MAINTENANCE

1. Remove screws (

2) from Retainer.

2. Remove Retainer and Front Case.

LCD Display Assembly

Retainer

LCD Display from

Front Case/Keypad Assembly

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Technical Service Manual

5-19

Page 76

CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.14 Model 8015: Display, Retainers, and Inverter Board

1. Remove screws (

2) from Upper Re tainer.

2. Remove Display/Retainer/Inverter Board Assembly from Front Case.

Front Case/Keypad Assembly

Display/Retainer/Inverter

Board Assembly

5-20

Upper Retainer

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Pump Module

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Technical Service Manual

Page 77

5.3 PC UNIT (Continued)

CORRECTIVE MAINTENANCE

5.3.14 Model 8015: Display, Retainers, and

Inverter Board (Continued)

3. Disconnect Display Harness and Inverter Display Harness from Inverter Board.

4. Separate Display from Retainer/Inverter Board Assembly.

5. Remove screws (

2) securing Inverter

Board to Retainer and separate board from Retainer.

Inverter Display Harness

During Reassembly:

1. When placing Display in Retainer route Display cable and harness through Retainer opening.

CAUTIONS

• Do not touch LCD screen with

fingers.

• Use care to not pinch or crease flex

cables.

2. After connecting Inverter Display Harness to Inverter Board, route Harness around retainer edge.

LCD Display Assembly

Display Harness

Inverter Board Assembly

Color Display Retainer

Technical Service Manual

Alaris® PC Unit

Pump Module

Alaris

5-21

Page 78

CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.15 IUI Connectors

1. Remove screws (

2) attaching each IUI

(left and right) to PC Unit.

2. Remove

During Reassembly:

IUI Connectors and Gaskets.

• Ensure ground clips are still installed on both

IUI connectors.

Right IUI Connector

• To install Right

IUI Connector Gasket,

remove protective backing and adhere to

IUI Connector.

• To install Left

IUI Connector Seal, position

seal on one end of connector and stretch to other end to conform to connector body. Gently press on seal to seat completely. Use lint-free swab to apply alcohol to top, sides, and bottom of seal for lubrication while installing to Rear Case. Do not apply alcohol to contacts or connector.

IUI Seal

IUI Gasket

Left IUI Connector

5-22

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Alaris

Technical Service Manual

Page 79

5.3 PC UNIT (Continued)

CORRECTIVE MAINTENANCE

5.3.16 Rear Case Assembly Parts

1. Remove screw from Ground Plate.

2. Gently slide assembly partially out of

rear case.

3. Disconnect harnesses.

• Battery Connector Assembly - Logic Board

• Backup Speaker - Logic Board J701

• Battery Discharge - Power Supply Board

• DC Output - Power Supply Board J3

4. Remove screw attaching Ground Strap to Ground Plate.

5. Remove screws (

2) from Power Supply

Board.

6. Separate board/ground plate assembly from Chassis Assembly.

7. Remove remaining screws ( Ground Plate.

8. Separate and remove Ground Plate, Logic Board and Power Supply Board.

9. If Rear Case is being replaced: a. Remove Backup speaker (adhered to

inside of Rear Case).

b. Remove screw attaching Battery

Connector Assembly to bottom of Rear Case and remove connector assembly.

c. Retain Backup speaker and Battery

Connector Assembly for use with new Rear Case.

4) from

During Reassembly:

WARNING

To maintain EMC compatibility:

• When installing a Rear Case on a Model

8000, ensure the case is shielded

(metallized).

• When installing a Power Supply Board in a Model shielded in

8015, ensure the board is

2 places (see Figure 7-25).

To ensure EMC compatibility:

• Replacement Rear Case Kits have a metallized Rear Case.

• Replacement Power Supply Board is shielded.

• Non-metallized Rear Cases and an unshielded Power Supply Board are not available as field replacement parts.

If Rear Case has been replaced:

1. Adhere Backup Speaker to gasket on

inside of Rear Case.

2. Using permanent black ink, print

instrument's model/reference number and serial number on Serial Number Replacement Label.

3. Apply Serial Number Replacement

Label to instrument.

4. Adhere transparent label over Serial

Number Replacement Label.

d. Make note of model/reference

number and serial number found on serial number label.

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Pump Module

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Technical Service Manual

5-23

Page 80

CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.16 Rear Case Assembly Parts (Continued)

Battery Connector Assembly

Battery Discharge Harness

DC Output Harness

Power Supply Board

Removed when separating cases.

Step 1

Step 4

Chassis Assembly

Step 5 (2 screws)

Logic Board

Model 8000: Insulator Panel

(on back of Ground Plate)

Ground Plate

Step 7 (4 screws)

5-24

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Technical Service Manual

Page 81

5.3 PC UNIT (Continued)

5.3.17 Model 8015: Memory Card

1. Remove screw from Retainer and remove Retainer from Logic Board.

2. Remove Memory Card.

CORRECTIVE MAINTENANCE

Logic Board

Retainer

Memory Card

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Pump Module

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Technical Service Manual

5-25

Page 82

CORRECTIVE MAINTENANCE

5.3 PC UNIT (Continued)

5.3.18 Chassis Assembly Parts

1. Use small diagonal cutters to lift and remove Snap Rivets from Left and Right IUI Board Assemblies, and remove board assemblies.

CAUTION

Do not cut rivet.

2. Cut cable tie securing Ferrite Bead to Power Supply.

3. Disconnect AC Filter from Power Supply

J1.

4. Remove lock washers (

2) and screw

securing AC Filter ground wire to Frame Assembly.

5. Remove screws (

2) attaching AC Filter

to Frame Assembly and remove AC Filter.

6. To access fuses, remove Fuse Holder from AC Filter. If fuses need replacing, Power Supply must also be replaced.

7. Cut cable tie securing Battery Discharge Harness Assembly to Frame Assembly.

8. Remove screw attaching Battery Discharge Harness Assembly to Frame Assembly and remove harness.

9. Remove screws (

4) attaching Power

Supply to Frame Assembly and remove Power Supply.

During Reassembly:

1. Install AC Filter with 2 AC wire connectors oriented toward Power Supply.

2. Angle Ground Wire toward AC Filter prior to applying torque.

3. Cable tie Ferrite bead over Cable Tie Mount or cooling fins, depending on type of Power Supply installed.

4. Tuck Dielectric Insulator between Ferrite Bead and Power Supply.

5. Cable tie Battery Discharge Harness over Cable Tie Mount.

5-26

Alaris® PC Unit

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Technical Service Manual

Page 83

5.3 PC UNIT (Continued)

5.3.18 Chassis Assembly Parts (Continued)

Power Supply

CORRECTIVE MAINTENANCE

DC Output Harness

IUI Board, Right

Ground Strap

Battery Discharge

Harness

Cable Tie Mount

Split Lock Washer

Internal Lock Washer

Dielectric Insulator

AC Filter

Ferrite Bead

Ground Wire

Frame Assembly

IUI Board, Left

AC Filter

Fuse Holder

Alaris® PC Unit

Pump Module

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Technical Service Manual

5-27

Page 84

CORRECTIVE MAINTENANCE

5.4 PUMP MODULE

5.4.1 Latch Assembly and Feet

1. Remove screws (

2) attaching Latch

Assembly to bottom of Rear Case.

2. Remove Latch Assembly components. Pay close attention to Compression Spring location, to ensure proper installation during reassembly.

3. Pull Feet (

2) from underside of module.

Latch Screws

Compression Spring

During Reassembly:

Apply thin layer of Dow Corning Molykote 33 (or equivalent) silicone grease to Feet.

NOTE: The feet press-ﬁ t into the module.

This screw is for locking Pump Module to PC Unit, for fixed configurations.

5-28

Foot (2 PL)

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Rear Case

Page 85

5.4 PUMP MODULE (Continued)

CORRECTIVE MAINTENANCE

5.4.2 IUI Connectors and Rear Case

1. Remove screws (

2) attaching each IUI

(left and right) to module.

2. Remove

3. Remove screws (

IUI Connectors and Gaskets.

2) and associated

washers attaching Rear Case to Chassis Assembly.

4. Remove Rear Case by pulling it away from Chassis Assembly.

5. If Rear Case is being replaced, make note of model/reference number and serial number found on serial number label.

During Reassembly:

• Ensure ground clips are still installed on

both

IUI connectors.

• To install Right

IUI Connector Gasket,

remove protective backing and adhere to

IUI Connector.

• To install Left

IUI Connector Seal, position

• Ensure Silicone Tubing in Rear Case is in place and not damaged.

• If Rear Case has been replaced:

a. Using permanent black ink, print

instrument's model/reference number and serial number on Serial Number Replacement Label.

b. Apply Serial Number Replacement

Label to instrument.

c. Adhere transparent label over Serial

Number Replacement Label.

IUI Connector, Right

IUI Connector, Left

Silicone Tubing

Chassis Assembly

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

5-29

Page 86

CORRECTIVE MAINTENANCE

5.4 PUMP MODULE (Continued)

5.4.3 Door/Display Board Assembly

1. Remove screws (

4) from Inner Door and

remove Inner Door from Door/Display Board Assembly.

2. Disconnect Door Harness (not illustrated) from Display Board

J4.

3. Remove Door/Display Board Assembly.

NOTE: The Platen Assembly is not illustrated.

During Reassembly:

Ensure Silicone Tubing is in place and not damaged.

J2 and

Silicone Tubing

5-30

Door/Display

Board Assembly

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Inner Door

Page 87

5.4 PUMP MODULE (Continued)

5.4.4 Display Board Assembly

1. Disconnect harnesses from Display Board:

CORRECTIVE MAINTENANCE

• Keypad

LED Backlight - D8

• Keypad Connector - J1

• Keypad Ground - J3

2. Remove Display Board.

Keypad Harness

Door Assembly

Keypad LED Backlight Harness

Display Board

Keypad Ground Wire

Alaris® PC Unit

Pump Module

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Technical Service Manual

5-31

Page 88

CORRECTIVE MAINTENANCE

5.4 PUMP MODULE (Continued)

5.4.5 Door Latch Assembly

1. Slowly (Torsion Spring is loaded) remove Latch Pivot from Door Assembly and discard.

2. Remove Door Latch Assembly

3. Retain Torsion Spring, if not being replaced.

During Reassembly:

• If Torsion Spring has been replaced, use

• Tighten Latch Pivot to torque value

Latch Pivot

wire cutters to cut off excess length after installation.

specified in Table

5-3 (important to

ensure Door Latch Assembly is securely installed).

5-32

Torsion Spring

Door Latch Assembly

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Door Latch Assembly Installed

Old Door New Door

(Groove for Spring)

Page 89

5.4 PUMP MODULE (Continued)

5.4.6 Platen Assembly

1. Use small diagonal cutters to lift and remove Snap Rivet from hinge block.

CAUTION

Do not cut rivet.

2. Remove Platen Assembly.

Platen Assembly

Snap Rivet

CORRECTIVE MAINTENANCE

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

5-33

Page 90

CORRECTIVE MAINTENANCE

5.4 PUMP MODULE (Continued)

5.4.7 Logic and Motor Controller Board Assemblies

If the Motor Controller Board is being replaced, identify the connector type (see illustration) before ordering the replacement (see "Illustrated Parts Breakdown", "Table

7-2").

Style Replacement old Motor Controller Board / Motor Kit

new Motor Controller Board with new

style connector

Motor Controller Board J3

1. Remove Retainer Clips from Dual Cable Assembly.

2. Disconnect Dual Cable Assembly from Logic Board Board

J3 and Motor Controller

J4.

3. Remove Retainer Cap from Logic Board

J8 connection.

4. Remove screw securing Door Ground to Logic Board (near

New Style Connector Old Style Connector

J4).

Dual Cable Assembly

Logic Board J3

Retainer Clip (2 PL)

Motor Controller Board J4

Retainer Cap

Logic Board J8

5-34

Alaris® PC Unit

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Technical Service Manual

Page 91

5.4 PUMP MODULE (Continued)

CORRECTIVE MAINTENANCE

5.4.7 Logic and Motor Controller Board

Assemblies (Continued)

5. Disconnect harnesses:

•

AIL Sensor Assembly - Logic Board

• Door - Logic Board J2

• Pressure Transducer - Logic Board

• Motor - Motor Controller Board J3

Door Harness Ground

Snap Rivet

6. Use small diagonal cutters to lift and remove Snap Rivets (

2) from Logic and

Motor Controller Boards.

CAUTION

Do not cut rivet.

7. Remove screws (

3) from Logic and

Motor Controller Boards.

8. Remove Logic and Motor Controller Boards.

Logic Board

IUI Bracket

Motor Controller Board

Snap Rivet

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Pump Module

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Technical Service Manual

5-35

Page 92

CORRECTIVE MAINTENANCE

5.4 PUMP MODULE (Continued)

5.4.8 Motor, Air-in-Line (AIL) Sensor Assembly, and Bezel Assembly

If the Motor is being replaced, identify the connector type (see illustration) before ordering the replacement (see "Illustrated Parts Breakdown", "Table

7-2"). The

replacement must have the same style connector as the existing Motor.

1. Remove Hex Standoff from AIL Sensor Assembly.

2. Remove screws (

4) from AIL Sensor

Assembly.

3. Remove Motor Mount from Gear Box and Motor.

4. Remove Motor from Bezel Assembly.

New Style Connector Old Style Connector

During Reassembly:

1. Secure Motor Mount to 4 mounting pins on Gear Box.

2. Prior to installing AIL Sensor Assembly: a. Ensure Pinion Gear is properly

installed by rotating Cluster Gear by hand and feeling for a vibration as Motor steps through its rotation.

b. To prevent

LED damage, rotate

Cluster Gear until Motor Encoder is in illustrated position.

5-36

Motor Harness

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Page 93

5.4 PUMP MODULE (Continued)

CORRECTIVE MAINTENANCE

5.4.8 Motor, Air-in-Line (AIL) Sensor

Assembly, and Bezel Assembly

(Continued)

AIL Assembly

Gasket

(adhered to AIL

Sensor Assembly)

Bezel Assembly

Motor Mount

Motor

Hex Standoff

Pinion Gear/Coupling Assembly

Torsion Bearing

O-Ring

Gear Box

(part of Bezel Assembly)

Motor Encoder

Cluster Gear

Pressure Transducer

Harness Assembly

Alaris® PC Unit

Alaris

Technical Service Manual

Pump Module

5-37

Page 94

CORRECTIVE MAINTENANCE

5.4 PUMP MODULE (Continued)

5.4.9 Membrane Frame Assembly and Pressure Sensors

1. Disconnect Pressure Transducer Harness Assembly from Pressure Sensors.

2. Remove screw from Membrane Frame Assembly.

3. Use small diagonal cutters to lift and remove Snap Rivet from Membrane Frame Assembly.

CAUTION

Do not cut rivet.

4. Remove Membrane Frame Assembly from Bezel by releasing snaps and hooks.

5. Push on Pressure Sensor release tabs and remove Pressure Sensors from Bezel.

CAUTION

To avoid Pressure Sensor damage, do not apply pressure to the center of the Pressure Sensors.

Snap Rivet

Membrane Frame Assembly

5-38

Snaps and Hooks

Pressure Sensor, Lower

Door Harness

Bezel Assembly

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

Pressure Sensor, Upper

Release tab for Upper

Pressure Sensor

Release tab for Lower

Pressure Sensor

Page 95

CORRECTIVE MAINTENANCE

Table 5-2. Torque Values - Models 8000 and 8015

Functional Application Item Description Torque Value

FINAL ASSEMBLY

Battery Pack Block-Off Plate (Model 8010) Carry Board (Model 8015) Communications Board Assembly (Model 8012) Ground Cable (Front Case - Ground Plate) Handle I/O Rear Panel Assembly Network Card Cover (Model 8012) Network Card Cover (Model 8015) Nurse Call Accessory (Model 8010) Pole Clamp (to plate) Pole Clamp Plate Power Cord Retainer Power Cord Wrap Rear Panel (Model 8000) RJ45 Connector Plug

FRONT CASE

Inverter Board Assembly (Model 8015) Retainer, LCD Upper Display

1/4-20 x 1/2

6-32 x

4-40 x 1/4 4-40 x 5/16 4-40 x 5/16 4-40 x 5/16

4-40 x 1/4

4-40 x 1/4 4-40 x 5/16

4-40 x 1/2

4-40 x 1/4

8-32 x 5/8

4-40 x 1/2

4-40 x 1/4

4-40 x 1/2

2 x

/16

6-32 x 7/16

/16

6 in-lb 6 in-lb 6 in-lb 6 in-lb 6 in-lb 6 in-lb 6 in-lb 6 in-lb 6 in-lb 6 in-lb

150 in-lb

16 in-lb

6 in-lb 8 in-lb 6 in-lb 6 in-lb

3 in-lb 6 in-lb

INTERNAL SUPPORT FRAME

AC Filter Assembly AC Filter Ground Wire Battery Discharge Harness Assembly Ground Strap Logic Board Assembly - Ground Plate Power Supply Power Supply Board Assembly Retainer, Memory Card (Model 8015) Standoffs to Power Supply Board Assembly

REAR CASE

Battery Connector Assembly Internal Support Frame Assembly IUI Connectors Latch Mechanism Rear Case (lower mountings) Rear Case (upper mountings)

REAR PANEL

I/O Rear Panel RS-232 Board Assembly Speaker Bracket Tamper Switch

4-40 x 4-40 x

10-32

/16 4-40 x 9/16 4-40 x 9/16

4-40 x 1/2 4-40 x 1/2 4-40 x 1/4 4-40 x 1/4

4-40 x

/4 4-40 x 9/16 6-32 x 7/16 4-40 x 5/16

6-32 x 1/4

6-32 x 23/8

4-40 x

/4 4-40 x 5/16

kep nuts

Boot Seal

6 in-lb

12 in-lb

6 in-lb 6 in-lb 6 in-lb 6 in-lb 6 in-lb 6 in-lb 6 in-lb

6 in-lb 6 in-lb

12 in-lb

6 in-lb 12 in-lb 12 in-lb

6 in-lb

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Pump Module

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Technical Service Manual

5-39

Page 96

CORRECTIVE MAINTENANCE

Table 5-3. Torque Values - Model 8100

Functional Application Item Description Torque Value

CHASSIS ASSEMBLY

AIL Sensor Assembly Logic Board Assembly Membrane Frame Assembly Motor Controller Board Assembly

FINAL ASSEMBLY

Chassis to Rear Case Assembly Door Cover Door Harness Ground to IUI Bracket Door Latch Pivot IUI Connector Latch Mechanism

4-40 x

4-40 x 1/4

4-40 x 3/16

4-40 x 1/4

6-32 x

4-40 x 3/8 4-40 x 1/4

6-32 x 4-40 x 5/16

----

/16

6 in-lb 6 in-lb 3 in-lb 6 in-lb

/16

12 in-lb

6 in-lb 6 in-lb

/16

10 in-lb 12 in-lb

6 in-lb

5-40

Alaris® PC Unit

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Technical Service Manual

Page 97

Table 5-4. Level of Testing Guidelines - Models 8000 and 8015

Use the applicable maintenance software to perform testing.

Perform

l = Required

8 = Optional

Blank = Not Applicable

CORRECTIVE MAINTENANCE

Repair/Replacement of: 

Battery Battery Connector Front Case/Keypad Assembly IUI Boards Logic Board Main LCD Module Pole Clamp Power Supply Power Supply Board Rear Case Speaker Tamper Resist Switch Miscellaneous:  Instrument Dropped New Instrument Check-in No Fault Found Software Flashed

Alarm Test

Battery Runtime

Channel ID/IUI Connectors Test

Charge Battery

Conﬁ guration Setup

Display Test

Ground Leakage Test

Keypad Test

Network Connectivity (if installed)

Nurse Call Option Test

Upload Data Set

Instrument Inspection

ll l

lllll ll

llllll ll

ll l

llll ll

ll l

lll ll

lll l

llll ll

NOTE: If the Battery is removed, recharge it ½ to 1 hour to reset the charge timer.

Alaris® PC Unit

Pump Module

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Technical Service Manual

5-41

Page 98

CORRECTIVE MAINTENANCE

Table 5-5. Level of Testing Guidelines - Model 8100

Use the applicable maintenance software to perform testing and calibration.

Perform

l = Required

Blank = Not Applicable

Repair/Replacement of: 

Air-in-Line Assembly Bezel Assembly Display Board Door/Keypad Assembly IUI Connectors Logic Board Membrane Frame Assembly Motor Motor Controller Board Platen Assembly Pressure Sensors Rear Case Miscellaneous:  Instrument Dropped New Instrument Check-in No Fault Found

Air-in-Line Sensor Test

Alarm Test

Channel ID/IUI Connectors Test

Conﬁ guration Setup

Display Test

Door Ajar/Safety Clamp Sensors Test

Fluid Side Occlusion Test

Keypad Test

Patient Side Occlusion/Pressure Veriﬁ cation

Pressure Calibration

Rate Accuracy Veriﬁ cation

Rate Calibration

Instrument Inspection

ll l l

llllllll

l llll

ll ll l l

ll lll

lll

ll lll

lll

llllllll

l llll ll l l

lllll ll

Software Flashed

5-42

Alaris® PC Unit

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Technical Service Manual

Pump Module

Page 99

Chapter 6 – TROUBLESHOOTING

6.1 INTRODUCTION

This chapter contains possible technical problems that can occur while using the

Alaris attempting to service the PC Unit or Pump Module. Reference the applicable module's service manual before attempting to service another module attached to the Alaris System.

To facilitate troubleshooting when an operating malfunction occurs, the instrument alarms and displays an error message and/or error code. Use the information in this chapter to help diagnose and correct technical problems. Use the applicable maintenance software to perform preventive maintenance, calibration, and verification procedures.

System. Refer to this chapter before

6.2 ERRORS

Through the use of diagnostic hardware testing and software error trapping, the

Alaris

System ensures that all hardware and software errors are logged and the appropriate action is taken. The Error Log, in contrast to all other logs, is required to take steps that ensure logging still proceeds correctly in the face of a compromised software system. There is provision made in the Error Log for the storage of a small amount of error-specific data. All errors are recorded in this log; specifically, soft faults, system and channel errors, audio failure, and rate display failure.

Errors fall into two broad categories, software and hardware. All software errors (soft faults) are considered very serious because they indicate that the system has become unstable and cannot be relied on to execute the software correctly, or the

Alaris® PC Unit

Pump Module

Alaris

Technical Service Manual

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TROUBLESHOOTING

6.2 ERRORS (Continued)

software has detected an illegal software condition and the software system has been compromised. A hardware error is external to the

CPU or memory, and does not indicate

an unstable computing environment. The integrity of the software is still sound and it can be relied on to handle or report the error condition.

6.2.1 Error Numbering Scheme

All errors share a common numbering system:

Subsystem Code Failure Code

XXX .XXXN

XXX

represents the three-digit code that identifies the hardware subsystem to which the error appears most closely related, such as, logic board or pressure sensor.

XXXN represents the subcode that describes

the subsystem failure.

N represents the

numeral that indicates whether the error was detected at the Power On Self Test ( (

1) or at run time (0 - zero), or if it is a log only

event (

5). The system monitors and logs “log

only” events, which do not affect the overall

operation of the Alaris

System. These non-malfunction events are logged to enable the PC Unit characteristic in instrument populations to be tracked. All error events which end with a value of

5 or 5.5 fall into

the log only category (for example, or

100.6075.5). A soft fault error code

cannot happen in

POST and in this case

the subcode is defined as the domain that logged the fault.

POST)

100.6075

There are two additional

32-bit data items

associated with errors. This data is displayed only in debug builds but is always logged.

6.3 MAINTENANCE MODE

When in the Maintenance Mode:

• To exit, power system off.

• To return to a previous screen, press soft key.

• Pressing

EXIT soft key in Maintenance

Mode option screen powers system off

immediately, with no "Powering Down" display .

To access Maintenance Mode options:

1. Hold down Tamper Resist switch on rear

of PC Unit during power-up. (Reference

Alaris

System DFU for an illustration

showing Tamper Resist switch location.)

Maintenance Mode

** Not For Human Use **

WARNING

Maintenance Mode is only

to be used for

troubleshooting and

servicing by qualified

personnel.

DISPLAY

CONTRAST

PROCEED

SYSTEM

OFF

EXIT

6-2

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Pump Module

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Technical Service Manual

Alaris PC Unit 8000, PC Unit 8015, Pump Module 8100 User manual

Specifications and Main Features

Frequently Asked Questions

User Manual