CareFusion Alaris 8120, Alaris 8110 Service manual

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Technical Service Manual

Alaris®Syringe Module, 8110 Series

Alaris

Supports: Guardrails® (Suite v7 or Later)
November 2010

®

PCA Module, 8120 Series

General Contact Information

CareFusion
San Diego, California
http://www.carefusion.com/alaris

Customer Advocacy - North America

E-Mail: [e-mail]

Maintenance and service information support; troubleshooting.

Clinical and technical feedback.

Phone: [phone]

Technical Support - North America

United States:

Phone:

888.876.4287

Instrument return, service assistance, and order placement.

United States:

Phone: [phone]

Canada:

Phone:

800.387.8309

Customer Care - North America

Canada:

Phone: [phone]

TABLE OF CONTENTS

i

Chapter 1 - General Information

1.1 Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Precaution Definitions

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

1.3 Specifications

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

1.4 Operating Features, Controls and Indicators

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

1.5 Accessories

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

1.6 Alarms, Errors, Messages

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

1.6.1 Silencing Alarms

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

1.7 Trumpet and Start-Up Curves

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Chapter 2 - Checkout and Configuration

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

2.2 New Instrument Checkout

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

2.3 Configuration Options and Defaults - Syringe Module

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

2.3.1 Factory Default Setting

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

2.4 Configuration Setup - Syringe Module

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

2.4.1 All Mode

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

2.4.2 Auto Pressure

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

2.4.3 Back Off

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

2.4.4 Fast Start

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

2.4.5 KVO

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

2.4.6 Max Rate

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

2.4.7 Near End

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

2.4.8 Pressure Limit - Disc

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

2.4.9 Pressure Limit - No Disc

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

2.4.10 Priming

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

2.5 Configuration Setup - Shared Infusion Pump and Syringe

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

2.6 Configuration Options and Defaults - PCA Module

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

Chapter 3 - Preventive Maintenance

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

3.2 Regular and Preventive Maintenance Inspections, Calibration

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

3.3 Cleaning

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

Chapter 4 - Principles of Operation

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

4.2 General Information

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

4.3 Display Board Assembly

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

Alaris®Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

ii

TABLE OF CONTENTS

Alaris®Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

Chapter 4 - Principles of Operation (Continued)

4.3.1 Microcontroller

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

4.3.2 LED Display Driver

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

4.3.3 Comparator/Safety Monitor

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

4.3.4 Status and Backlight LEDs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

4.4 Logic Board Assembly

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

4.5 Drivetrain Assembly

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

4.6 Drive Head

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

4.7 Plunger Head Board Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

4.8 Force Sensor Subsystem

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

4.9 Pressure Sensor Subsystem (Syringe Module Only)

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

4.10 Patient Handset Circuit and Door Lock Sensor Circuit (PCA Module Only)

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

Chapter 5A

- Corrective Maintenance - Syringe Module

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

5.2 Disassembly/Reassembly

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

5.2.1 Removing Latch Assembly and Feet

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

5.2.2 Removing IUI Connector Assemblies

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

5.2.3 Separating Rear Case from Chassis Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5

5.2.4 Removing Handle

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

5.2.5 Removing Flex Cable Retainer

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

5.2.6 Removing IUI Board Assembly

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

5.2.7 Removing Logic Board Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-9

5.2.8 Removing Internal Frame Assembly

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

5.2.9 Removing Drivetrain Assembly

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

5.2.10 Removing Display Board Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12

5.2.11 Removing Pressure Sensor Board Assembly

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

5.2.12 Removing Top Disk Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-14

5.2.13 Removing Sensor Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-15

5.2.14 Removing Syringe Size Sensor Assembly

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

5.2.15 Removing Syringe Barrel Clamp Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-17

5.2.16 Removing Status Indicator Lens

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

5.2.17 Removing Housing Assembly and Guide Rod

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

5.2.18 Removing Motor/Pulley Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-21

5.2.19 Removing Leadscrew Assembly and Bottom Plate

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

5.2.20 Removing Linear Sensor Assembly

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

5.2.21 Removing Force Sensor and Actuator Knob Assemblies

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-24

5.2.22 Removing Actuator Knob Assembly Parts

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

TABLE OF CONTENTS

iiiAlaris

®

Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

Chapter 5B - Corrective Maintenance - PCA Module

5.1 Introduction

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

5.2 Disassembly/Reassembly

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

5.2.1 Removing Latch Assembly and Feet

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

5.2.2 Removing IUI Connector Assemblies

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B-4

5.2.3 Removing Handle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5

5.2.4 Removing Door Assembly

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

5.2.5 Removing Rear Case

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

5.2.6 Removing Flex Cable Retainer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B-9

5.2.7 Removing IUI Board Assembly

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

5.2.8 Removing Logic Board Assembly

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

5.2.9 Removing Internal Frame Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12

5.2.10 Removing Lock Assembly

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

5.2.11 Removing Latch Module and Drivetrain Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14

5.2.12 Removing Display Board Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-15

5.2.13 Removing Sensor Board Assembly

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

5.2.14 Removing Syringe Size Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17

5.2.15 Removing Syringe Barrel Clamp Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-18

5.2.16 Removing Status Indicator Lens

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

5.2.17 Removing Handset Harness

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-21

5.2.18 Removing Latch Lever Assembly

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

5.2.19 Removing Housing Assembly and Guide Rod

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

5.2.20 Removing Motor/Pulley Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24

5.2.21 Removing Leadscrew Assembly and Bottom Plate

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

5.2.22 Removing Linear Sensor Assembly

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

5.2.23 Removing Force Sensor and Actuator Knob Assemblies

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-27

5.2.24 Removing Actuator Knob Assembly Parts

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

Chapter 6 - Troubleshooting

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

Chapter 7A

- Illustrated Parts Breakdown - Syringe Module

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

7.2 Illustrations

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

7.3 Parts List

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

7.4 Ordering Parts

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

iv

TABLE OF CONTENTS

Alaris®Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

Chapter 7B - Illustrated Parts Breakdown - PCA Module

7.1 Introduction

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

7.2 Illustrations

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

7.3 Parts List

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

7.4 Ordering Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B-2

List of Figures

4-1 Block Diagram: Syringe and PCA Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

7A-1 Actuator Knob Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-7

7A-2 Housing Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-8

7A-3 Drivetrain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-9

7A-4 Front Case Assembly - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-11

7A-5 Front Case Assembly - Part 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-12

7A-6 Top Disk Holder - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-13

7A-7 Front Case, Syringe Barrel Clamp Assembly, Top Disk Holder -- Interchangeability . . . . . . . . . . 7A-14

7A-8 Front Case Assembly Kit

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

7A-9 Drivetrain Assembly - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-16

7A-10 Internal Frame Assembly - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-17

7A-11 Logic Board and IUI Board Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-18

7A-12 Flex Cable Retainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-19

7A-13 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-20

7A-14 Rear Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-22

7A-15 Display Board Assembly

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

7A-16 IUI Interface Board Assembly

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

7A-17 Logic Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-25

7B-1 Actuator Knob Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-7

7B-2 Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-8

7B-3 Drivetrain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-9

7B-4 Front Case Assembly - Part 1

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

7B-5 Front Case Assembly - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-12

7B-6 Latch Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-13

7B-7 Drivetrain Assembly - Front Case Assembly

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

7B-8 Internal Frame Assembly - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-15

7B-9 Logic Board and IUI Board Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-16

7B-10 Flex Cable Retainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-17

7B-11 Rear Case - Front Case Assembly

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

7B-12 Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-19

7B-13 Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-21

7B-14 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-22

TABLE OF CONTENTS

List of Figures (continued)

7B-15 Key Kit and Handset

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

7B-16 Display Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-24

7B-17 IUI Interface Board Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B-25

7B-18 Logic Board Assembly

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

List of Tables

1-1 Abbreviations, Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

5A-1 Required Materials, Supplies and Tools - Syringe Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2

5A-2 Torque Values - Syringe Module

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

5A-3 Level of Testing Guidelines- Syringe Module

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-27

5B-1 Required Materials, Supplies and Tools - PCA Module

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

5B-2 Torque Values - PCA Module

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

5B-3 Level of Testing Guidelines- PCA Module

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

6-1 Technical Troubleshooting Guide

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

6-2 Subsystem Codes

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

6-3 Error Code Matrix

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

6-4 Error Codes

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

7A-1 Parts List - Syringe Module

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

7B-1 Parts List - PCA Module

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

vAlaris

®

Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

vi

TABLE OF CONTENTS

Alaris®Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

THIS PAGE

INTENTIONALLY

LEFT BLANK

1 GENERAL INFORMATION

Chapter 1 — GENERAL INFORMATION

CAUTION

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

1.1 INTRODUCTION

This manual describes how to service the

®

Alaris

8110 Series) and Alaris

Module”,

Syringe Module (“Syringe Module”,

®

PCA Module (“PCA

8120

Series). Use this manual in
conjunction with the following Alaris
documents and software:

• Alaris

®

Point-of-Care unit (“PC Unit”,
Series) / Alaris®Pump Module (“Pump
Module”,

8100 Series) Technical Service

Manual

®

• Alaris

System Directions for Use (DFU)

• Maintenance Software and User Manual
(Software v7.x or later)

PRODUCT NAME NOTE: The “Alaris

System” was formerly known as the “Medley
System” and is described in the Alaris
System DFU.

This manual is intended for personnel
experienced in analysis, troubleshooting,
and repair of analog/digital microprocessor­based electronic equipment.

®

System

8000

®

®

™

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.

If either module requires service while under
warranty, it must be serviced only by
CareFusion authorized service
personnel. Refer to the “Warranty” and
“Service Information” sections of the Alaris

®

System DFU.

The Alaris®System is a modular infusion
and monitoring system intended for use in
adult, pediatric and neonatal healthcare.

The Syringe Module is intended for facilities
that use syringe pumps to deliver fluids,
medications, blood, and blood products
using continuous or intermittent delivery
through clinically acceptable routes of
administration, such as intravenous (
intra-arterial (

IA), subcutaneous, epidural,

IV),

enteral, or irrigation of fluid spaces.

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

1-1

The PCA Module is intended for facilities
that use syringe pumps to deliver fluids or
medications using continuous or intermittent
delivery through clinically acceptable routes
of administration, such as intravenous (

IV),

subcutaneous, or epidural.

Refer to the product-specific (Syringe
Module or PCA Module) section of the
Alaris

®

System DFU for a list of features and
detailed information regarding setup and
operation.

1.2 PRECAUTION DEFINITIONS

Refer to the Alaris

®

System DFU .

1.3 SPECIFICATIONS

Refer to the product-specific section of the
Alaris

®

System DFU.

1.4 OPERATING FEATURES, CONTROLS
AND INDICATORS

Refer to the product-specific section of the
Alaris

®

System DFU.

1.5 ACCESSORIES

The Syringe Module uses standard, single­use, disposable syringes (with luer-lock
connectors) and administration sets
designed for use on syringe pumps.

The PCA Module uses standard or pre-filled,
single-use disposable syringes (with luer­lock connectors) and non-dedicated
administration sets with integrated anti­siphon valves designed for use on syringe­type PCA devices. For specific
administration set instructions, reference the
directions for use provided with the set.

1.6 ALARMS, ERRORS, MESSAGES

Alarm messages are displayed on the
scrolling Message Display bar. Refer to the
product-specific section of the Alaris

®

System DFU for detailed information.

1.6.1 Silencing Alarms

All alarms can be temporarily silenced by
pressing the

SILENCE key on the PC Unit.

1.7 TRUMPET AND START-UP CURVES

Refer to the product-specific section of the
Alaris

®

System DFU.

Use only specified syringes and
administration sets with the Syringe and
PCA Modules. Using other syringes or
administration sets can cause improper
instrument operation, inaccurate fluid
delivery or pressure sensing, or other
potential hazards. For a list of compatible
syringes, refer to the product-specific
section of the Alaris

®

System DFU. For a list
of compatible administration sets, refer to
the module’s Administration Set
Compatibility Card/Insert (provided
separately).

WARNING

If an alarm condition on the module occurs
while the audio alarm is silenced, the only
alarm indications will be visual displays and
symbols related to the alarm condition.

WARNING

GENERAL INFORMATION

1-2 Alaris

®

Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

1.1 INTRODUCTION (Continued)

GENERAL INFORMATION

1-3Alaris

®

Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

CHSE HD cheese head (screw)

DB0 database zero
DFU Directions for Use

IA intra-arterial
IUI inter-unit interface

NEOI near end of infusion

TR HD truss head (screw)

VDAC voltage DAC

Table 1-1. Abbreviations, Acronyms

Various abbreviations and acronyms are used throughout this manual. The following are those that are
not commonly known or easily recognized.

GENERAL INFORMATION

1-4 Alaris

®

Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

THIS PAGE

INTENTIONALLY

LEFT BLANK

2 CHECKOUT & CONFIGURATION

Chapter 2 — CHECKOUT AND CONFIGURATION

CAUTION

Should an instrument be jarred severely or
dropped, remove it from use immediately. It
should be thoroughly tested and inspected by
qualified service personnel to ensure proper
function prior to reuse.

2.1 INTRODUCTION

This chapter describes initial setup and
configuration for the Syringe and PCA
Modules.

NOTE: Due to product changes over time,

configurations described in this chapter may
differ from the instrument under service. If
there are any questions, contact CareFusion
Technical Support.

2.2 NEW INSTRUMENT CHECKOUT

Prior to placing a new instrument in use,
perform a check-in procedure using the
Maintenance Software.

When powering up the instrument, verify the
instrument beeps and all display

LED

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 will alarm and display 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.

®

Syringe Module (8110 Series)

®

PCA Module (8120 Series)

Alaris

Technical Service Manual

2-1Alaris

2.3 CONFIGURATION OPTIONS AND
DEFAULTS - SYRINGE MODULE

NOTES:

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

• If Factory Default is Yes, then all the

configuration settings are set to their
factory default.

• If Factory Default is No, then one or

more of the configuration settings has

been changed. Setting Factory Default
to Yes sets all configuration settings to

their factory default.

• With the Profiles feature enabled, the
settings are configured independently for
each profile. A hospital-defined, best­practice data set must be uploaded to
enable the Profiles feature. Date and
Time is a system setting and is the same
in all profiles.

Refer to the Alaris®System DFU for the
following:

• System Settings

• Shared Infusion Settings (Pump Module
and Syringe Module)

• Syringe Module Settings

2.3.1 Factory Default Setting

To allow changes to System Configuration
parameters:

1. Hold

OPTIONS key at power up.

2. Press Factory default soft key.

3. Press No soft key.

4. To accept change, press

EXIT soft key.

• Option setting changes and main

System Config - Module

screen

displays.

2.4 CONFIGURATION SETUP - SYRINGE
MODULE

NOTES:

• Pressing the EXIT soft key while in a

System Config - Module screen

immediately powers the system down, with
no “Powering Down” display.

• Pressing the EXIT soft key while in a
System Config - Syringe screen returns
the display to the main System Config -

Module screen.

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>Select an Option

or EXIT

EXIT

Factory default:

Yes

System Config - Module 1 of 2

PC Unit

Shared Infusion Settings

Pump Module

SPO2 Module

PAGE

DOWN

EXIT

System Configuration

Factory Default
Settings?

Yes

No

Selection of Yes sets all
System Configuration
parameters to the factory
default setting.

NOTES: (Continued)

• Pressing the

CONFIRM soft key while in a

System Configuration option screen:

♦ accepts existing setting or setting

change

♦ displays next option setting screen (if

applicable) or returns display to System
Config - Syringe screen

• Pressing the PC Unit

CANCEL key while in

a System Configuration option screen:

♦ leaves setting unchanged
♦ returns display to System Config -

Syringe screen

To access System Configuration options:

1. Hold

OPTIONS key at power up.

2. Press

PAGE DOWN soft key.

3. Press Syringe Module soft key.

4. To view additional options, press

PAGE

DOWN

soft key.

2.4.1 All Mode
Enabling All mode allows

ALL to be

selected as the volume to be infused (VTBI),
to deliver the entire contents of the syringe.

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2.4 CONFIGURATION SETUP - SYRINGE
MODULE (Continued)

If KVO and ALL modes are both enabled,
the

ALL mode will not deliver the entire

syringe contents. A small percentage of the
syringe contents will be left available for

KVO operation.

CAUTION

System Config - Module 1 of 2

Factory default:

Shared Infusion Settings

PC Unit

Pump Module

SPO2 Module

>Select an Option

or EXIT

EXIT

No

PAGE

DOWN

System Config - Syringe 1 of 2

All Mode:

Auto Pressure:

Back Off:

Fast Start:

KVO:

>Select an Option

or EXIT

EXIT

Disabled

Disabled

Disabled

Disabled

Disabled

PAGE

DOWN

System Config - Syringe 2 of 2

Max rate:

Near End:

Pressure limit-Disc:1000

Pressure limit-NoDisc: Med

Priming: Disabled

>Select an Option

or EXIT

PAGE

EXIT

UP

999 mL/h

Disabled

mmHg

System Config - Module 2 of 2

Syringe Module

EtCO2 Module

>Select an Option

or EXIT

PAGE

EXIT

UP

1. After accessing System Config ­Syringe options display, press All Mode

soft key.

2. To change option setting, press soft key

next to applicable option (Enable or
Disable).

• Option setting changes and System

Config - Syringe page

1 displays.

2.4.2 Auto Pressure

Enabling Auto Pressure allows the Auto

Pressure option to be displayed in the
Pressure Limit screen when a pressure
sensing disc is in use. Auto Pressure
automatically sets the alarm limit for a
shorter time to alarm, as follows:

• If current pressure is

100 mmHg or less,

system adds

30 mmHg to current

pressure, to create a new alarm limit.

• If current pressure is greater than

100 mmHg, system adds 30% to current

pressure, to create a new alarm limit.

1. After accessing System Config -

Syringe options display, press Auto
Pressure soft key.

2. To change option setting, press soft key

next to applicable option (Enable or
Disable).

• Option setting changes and System

Config - Syringe page 1 displays.

2.4.3 Back Off

When Back Off mode is enabled and a

pressure sensing disc is in use, the motor
reverses plunger movement during an
occlusion until the pressure returns to
preocclusion levels, automatically reducing
bolus flow.

1. After accessing System Config -
Syringe options display, press Back Off

soft key.

2. To change option setting, press soft key

next to applicable option (Enable or
Disable).

• Option setting changes and System

Config - Syringe page

1 displays.

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2.4 CONFIGURATION SETUP - SYRINGE
MODULE (Continued)

2.4.1 All Mode (Continued)

System Configuration - Syringe

Back Off mode

Enable

Disable

Allows use of the
back off feature.

System Configuration - Syringe

Auto Pressure

Enable

Disable

Allows use of the
auto pressure feature.

System Config - Pump 2 of 3

System Configuration - Syringe

All mode

Allows use of the
All mode feature.

Enable

Disable

2.4.4 Fast Start

When Fast Start mode is enabled and a

pressure sensing disc is in use, the
instrument runs at an increased rate when
an infusion starts, taking up any slack in the
drive mechanism.

1. After accessing System Config -

Syringe options display, press Fast
Start soft key.

2. To change option setting, press soft key

next to applicable option (Enable or
Disable).

• Option setting changes and System
Config - Syringe page

1 displays.

2.4.5 KVO

Enabling

KVO allows some infusions to

automatically switch into

KVO (keep vein

open) mode upon completion. The

KVO

option setting cannot be changed after the
instrument is powered on and a profile
selected.

NOTE: In the following procedure, the KVO
option is changed to Enable. Changing the
option setting to Disable, disables the
Change Rate and Change Volume soft

keys, as displayed in step 1.

1. After accessing System Config -
Syringe options display, press KVO soft

key.

2. To change option setting, press soft key

next to applicable option (Enable or

Disable).

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System Configuration - Syringe

Fast Start mode

Enable

Disable

Allows use of the
fast start feature.

System Configuration - Syringe

KVO

Enable

Disable

Change

Rate

Change
Volume

Rate:

1 mL/h

Volume:

2%

Allows use of the KVO feature.

CONFIRM

System Configuration - Syringe

KVO

Enable

Disable

Change

Rate

Change
Volume

Rate:

1 mL/h

Volume:

2%

Allows use of the KVO feature.

CONFIRM

2.4 CONFIGURATION SETUP - SYRINGE
MODULE (Continued)

If

KVO and ALL modes are both enabled,

the

ALL mode does not deliver the entire

syringe contents, leaving a small
percentage of the syringe contents
available for

KVO

operation.

CAUTION

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3. To change

KVO rate, press Change

Rate soft key and enter new rate (

0.01 to

2.5 mL/h in 0.01 mL/h increments).

NOTE: Flow rates less than 0.01

mL/h
are available only with a 1cc syringe.
For larger syringes, the lower limit
adjusts to

0.1 mL/h.

4. To change

KVO

volume, press Change

Volume soft key and enter new volume

level (

0.5 to 5%).

5. To accept changes(s), press

CONFIRM

soft key.

• Settings change and System Config

- Syringe page

1 displays.

2.4.6 Max rate

The Maximum rate value identifies the

maximum rate at which a bolus dose can be

delivered. When the Max Rate option is

selected during bolus dose programming,
the bolus is delivered at the maximum rate
for an automatically calculated duration.

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

2, press

Max rate soft key.

2. To change maximum rate, press

Change Value soft key and enter new

rate (

0.1 to 99.9 mL/h in 0.1 mL/h

increments;

100 to 999 mL/h in 1 mL/h

increments).

2.4 CONFIGURATION SETUP - SYRINGE
MODULE (Continued)

2.4.5 KVO (Continued)

System Configuration - Syringe

Change

Value

Maximum rate
adjustment

Maximum
rate:

mL/h

___

System Configuration - Syringe

Change

Value

Confirm

Maximum rate
adjustment

Maximum
rate:

mL/h

999

System Configuration - Syringe

KVO

Enable

Disable

Change

Rate

Change
Volume

Rate:

2 mL/h

Volume:

_5%

Allows use of the KVO feature.

CONFIRM

-- Continued Next Page --

System Configuration - Syringe

CONFIRM

Enable

Disable

Change

Rate

Change
Volume

KVO

Rate:

_2mL/h

Volume:

2%

Allows use of the KVO feature.

3. To accept change, press Confirm soft

key.

• Setting changes and System Config

- Syringe page

2 displays.

2.4.7 Near End

Enabling Near-End-of-Infusion (

NEOI)

allows an alert to be set from

1 to

60

minutes before the infusion is complete.
The alert occurs at the configured time or
when

25% of the VTBI remains, whichever

occurs later.

NOTE: In the following procedure, the Near

End option is changed to Enable. Changing

the option setting to Disable disables the

Change Time soft key, as displayed in

step

1.

1. After accessing System Config -

Syringe options display, page

2, press

Near End soft key.

2. To change option setting, press soft key

next to applicable option (Enable or
Disable).

3. To change Alert Time, press Change
Time soft key and enter new time

(

1 to 60 minutes).

4. To accept changes(s), press

CONFIRM

soft key.

• Settings change and System Config

- Syringe page

2 displays.

2.4 CONFIGURATION SETUP - SYRINGE
MODULE (Continued)

2.4.6 Max rate (Continued)

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®

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System Configuration - Syringe

Maximum rate
adjustment

Maximum
rate:

99.9

mL/h

Change

Value

Confirm

System Configuration - Syringe

CONFIRM

Enable

Disable

Change

Time

DisableDisable

Near-End-of
Infusion

Alert Time:

2 min

Allows use of the Near-End-of
Infusion feature.

System Configuration - Syringe

CONFIRM

Enable

Disable

Change

Time

DisableDisable

Near-End-of
Infusion

Alert Time:

2 min

Allows use of the Near-End-of
Infusion feature.

System Configuration - Syringe

CONFIRM

Enable

Disable

Change

Time

DisableDisable

Near-End-of
Infusion

Alert Time:

10 min

Allows use of the Near-End-of
Infusion feature.

2.4.8 Pressure Limit - Disc

This option allows setting an occlusion
pressure point when a pressure sensing
disc is in use.

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

2, press

Pressure limit-Disc soft key.

2. To change pressure limit, press Change
Value soft key and enter new limit (

25 to

1000 mmHg in 1 mmHg increments).

3. To accept change, press

CONFIRM soft

key.

• Setting changes and System Config

- Syringe page

2 displays.

2.4.9 Pressure limit - No Disc

This option allows setting an occlusion
pressure point when no

pressure sensing

disc is in use.

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

2, press

Pressure limit-NoDisc soft key.

2. To change pressure limit (occlusion
pressure set point), press applicable soft

key (Low, Med, High).

3. To accept change, press

CONFIRM soft

key.

• Setting changes and System Config

- Syringe page

2 displays.

2.4 CONFIGURATION SETUP - SYRINGE
MODULE (Continued)

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System Configuration - Syringe

Pressure Limit Selection
(no disc)

CONFIRM

High

Med

Low

System Configuration - Syringe

Pressure Limit Selection
(no disc)

CONFIRM

Low

High

Med

System Configuration - Syringe

Pressure Limit Selection
(disc present)

Change

Value

Current limit

_ 600

mmHg

CONFIRM

System Configuration - Syringe

Pressure Limit Selection
(disc present)

Change

Value

Current limit

1000

mmHg

CONFIRM

2.4.10 Priming

Enabling Priming mode allows a limited

volume of fluid to be delivered to prime the
administration set before connecting to a
patient or following a syringe change. When
priming, a single continuous press of the

PRIME soft key delivers up to

2 mL of

priming fluid.

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

2, press

Priming soft key.

2. To change option setting, press soft key

next to applicable option (Enable or
Disable).

• Option setting changes and System

Config - Syringe page

2 displays.

2.5 CONFIGURATION SETUP - SHARED
INFUSION - PUMP AND SYRINGE
MODULES

Refer to the

8000/8100 Series Technical

Service Manual.

2.6 CONFIGURATION OPTIONS AND
DEFAULTS - PCA MODULE

NOTE: With the Profiles feature enabled, the

settings are configured independently for
each profile. A hospital-defined, best­practice data set must be uploaded to enable
the Profiles feature. Date and Time is a
system setting and is the same in all profiles.

System Settings: Refer to the PC Unit

section of the Alaris®System

DFU.

PCA Module Settings: Refer to the PCA

Module section of the Alaris

®

System DFU.

PCA Module Configuration Parameters:

Select system configuration settings for the
PCA Module during data set development,
then upload them as part of the data.

CHECKOUT AND CONFIGURATION

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2.4 CONFIGURATION SETUP - SYRINGE
MODULE (Continued)

System Config - Pump 2 of 3

System Configuration - Syringe

Priming mode

Allows use of the
priming feature.

Enable

Disable

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3 PREVENTIVE MAINTENANCE

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
Syringe and PCA Modules remain in good
operating condition:

• Perform regular inspections before each
use.

• Perform preventive maintenance
inspections annually.

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

JCAHO) requirements.

3.2 REGULAR AND PREVENTIVE
MAINTENANCE INSPECTIONS,
CALIBRA TION

Use the Maintenance Software to perform
calibration and preventive maintenance.

Contact CareFusion Technical Support
for help obtaining or using Maintenance
Software.

3.3 CLEANING

Refer to the Alaris

®

System DFU.

®

Syringe Module (8110 Series)

®

PCA Module (8120 Series)

Alaris

Technical Service Manual

3-1Alaris

PREVENTIVE MAINTENANCE

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4 PRINCIPLES OF OPERATION

Chapter 4 — PRINCIPLES OF OPERATION

4-1Alaris

®

Syringe Module (8110 Series)

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PCA Module (8120 Series)

Technical Service Manual

4.1 INTRODUCTION

This chapter describes the principles of
operation for the Syringe and PCA Modules.

Refer to the PC Unit/Pump Module
(

8000

/8100 Series) Technical Service Manual

for PC Unit information.

4.2 GENERAL INFORMATION

The Syringe and PCA Modules function as
part of the Alaris

®

System, and function only

when attached to a PC Unit.

• PCA Module: the PCA Module includes

a locking security door and patient
handset. Only one PCA Module can be
attached to the PC Unit, and the PCA
Module must be attached directly to the
right of the PC Unit.

• Syringe Module: the Syringe Module

includes a pressure sensing subsystem
for use with administration sets that
include pressure discs. Up to four
Syringe Modules can be attached to the
PC unit.

• Both modules can be used in conjunction
with any combination of other Alaris

®

Modules.

Both modules are appropriate for
intermittent or continuous delivery of

IV

fluids. Both modules can provide smooth
delivery of small quantities of

IV fluid within a

very low contained volume. Both modules
include these advanced features: bolus
delivery, drug library, drug dose calculator,
loading dose, titrate without stopping,
syringe size detector, one-handed syringe
loading, several modes of delivery, multi­channel coordinated infusion, and dose
limits.

PRINCIPLES OF OPERATION

4.2 GENERAL INFORMATION (Continued)

Both the Syringe and PCA Modules include
display, logic, drivetrain, drive head, plunger,
and force sensor subsystems.

NOTE: All circuit boards in the Syringe and

PCA Modules are not field repairable and
must be returned to a CareFusion
Service Center for repair.

4.3 DISPLAY BOARD ASSEMBL Y

The keypad sends signals to the
microcontroller on the Display Board, whose
function is to manage displayed information.
The Logic Board provides

5V power to the

Display Board through a 10-pin connector.

4.3.1 Microcontroller

The Display Board's microcontroller
provides four keypad functions: Channel
Select, Pause, Channel Off, and Restart.
The microcontroller controls the keypad
backlight and the Alarm, Infusing, and
Standby

The microcontroller controls the

LEDs.

LED display

driver for the Channel Identification
(Channel ID) and 7–segment rate displays.

The microcontroller also drives the scrolling
alphanumeric display that shows module
status (such as "

CHANNEL MALFUNCTION").

"

INFUSION COMPLETE" or

The microcontroller performs safety
monitoring and generates alerts (including
the Alarm LED and applicable error
messages) if critical circuitry does not
function properly.

The display driver uses a discrete resistor
for brightness control. Module software
provides three brightness levels: low (
full brightness), used when the PC Unit is
operating on battery power; medium (
full brightness), used when the PC Unit is
operating on AC power; and high (100%
brightness) is the maximum level possible.

Rate:

The display driver controls the five

7

–segment displays used for the Rate

display: three

7–segment displays and two

small 7–segment displays (the smaller
displays show fractional digits). The five
displays show infusion rates from
to 999 mL/h. The Rate display is readable in
normal hospital lighting conditions from a
distance of

15 feet and provides a 45°

viewing angle.

Channel Identification:

The display driver controls the
Channel

A

through H. The Channel

ID display, which can display letters

14–segment

ID display is

readable in normal hospital lighting
conditions from a distance of
provides a

viewing angle.

45°

15 feet and

4.3.3 Comparator/Safety Monitor

The comparator/safety monitor circuit
detects short or open failures of the Alarm

LED or rate display and sends that

information to the microcontroller. This
ensures correct alarm notification and
prevents the module from displaying an
invalid infusion rate.

4.3.4 Status and Backlight LEDs

27% of

47% of

0.01 mL/h

4.3.2 LED Display Driver

The microcontroller communicates serially
with the LED driver for the

7-segment LED display.

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8-digit,

A constant current drives and ensures
consistent brightness levels for the three
status

LEDs (Alarm, Infusing, Standby) and

the keypad backlight LED.

4.4 LOGIC BOARD ASSEMBLY

The Logic Board receives its power from the

8V supply on the PC Unit via the IUI

connector. The Logic Board contains

DC-to-
DC converters to convert the +8V supply to
+3.3V, +5V, and

+15V supplies,

and a
variable voltage supply to the motor. The
Logic Board also contains an inverting
circuit to produce a -

5V supply. The field-

programmable gate array (

FPGA) on the

Logic Board controls the supply voltages
(

5V, 3.3V) to the digital and analog sensors.

The Logic Board monitors the supply
voltages and analog sensor signals, and
sets up the nominal power level for any
particular pumping rate. Incoming analog
sensor signals (from the pressure sensor,
force sensor, syringe sizer, and plunger
position sensor) are filtered and buffered,
and then fed to the

ADC as inputs.

The Logic Board includes a processor, a

1M x 8 flash ROM, 512K x 8 static RAM, and

a watchdog timer circuit. The watchdog
timer circuit has a 1.6–second timeout that
can put the Syringe or PCA Module into a
safe state if the Logic Board main processor
fails.

The Logic Board reads and writes to the

FPGA via I/O address space. The FPGA

contains the digital logic for generating
control signals for ADC, DAC, sensors, motor
feedback circuitry, module detection and
identification circuit interface, and 10-phase
step signals for the motor drive circuitry.
The

FPGA also generates a master RESET

signal for the module.

The Logic Board’s main processor
communicates with the Display Board’s
microcontroller via a serial channel. The
Logic Board provides the Power-On Reset
signal to the Display Board. Upon keypad
input to the Display Board, the Logic Board

receives a Channel Off signal to stop the
motor.

The Logic Board contains

IUI interface

circuitry that allows it to communicate with
the PC Unit.

The digital sensor interface on the Logic
Board contains current sense circuitry,
which reads output signals from the
photointerrupters on the lever detect sensor,
nut engaged sensor, and flange sensor. On
the Syringe Module only, the Logic Board
also reads signals from the

SET IN sensor

(pressure sensor).

The motor drive circuitry on the Logic Board
uses a variable voltage supply to drive a
5

-phase stepper motor and save power,

depending on the torque loading. A
combination of software settings and motor
feedback loop circuitry adjusts the motor
supply voltage in response to detected
motor loading. The motor feedback loop
starts with a nominal voltage based on
pumping rate, and adjusts motor voltage as
needed to maintain constant peak motor
current levels, independent of torque load.
The motor feedback loop keeps the voltage
range constant for any given pumping rate.

4.5 DRIVETRAIN ASSEMBLY

The drivetrain is a linear positioning device.
The geared stepper motor powers the
drivetrain, and the linear motion of the
drivetrain controls the drive head to push
the syringe plunger accurately and with
enough force to deliver medication from
many different syringes. Because system
positioning is open loop, the mechanical
parts and assembly must maintain a high
degree of accuracy.

PRINCIPLES OF OPERATION

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4.6 DRIVE HEAD

The drive head captures the syringe by the
syringe plunger and uses the drivetrain to
drive the plunger in a controlled fashion.
The drive head has claw-like arms (plunger
grippers) that capture the syringe plunger.
The plunger grippers allow the drive head to
capture a wide variety of syringes (see the
Syringe or PCA Module section of the
Alaris

®

System DFU and Set Compatibility
Card for more information on suitable
syringes).

To load a syringe into the drive head, the
gripper control/drive head release lever
rotates

90° clockwise. This rotates an inner

shaft, which is connected to a slide plate.
Two holes in the slide plate interface with
two pinion gears that make direct contact
with the plunger grippers. Once the slide
plate moves back, the gears rotate and the
plunger grippers open to accept the syringe
plunger flange.

Once the syringe is loaded, a plunger detect
flag interfaces with an optical switch to
indicate that a syringe is properly loaded
into the plunger grippers. The drive head
also includes a flag that indicates the drive
head position, preventing an infusion from
beginning prematurely.

Several other components of the drive head
control the opening and closing of the split
nuts on the leadscrew. A pull rod cam
attached to the end of the rotating shaft in
the drive head interfaces with a rod and
head piece that can rotate to lift the rod
attached to the drivetrain carriage and cam
lock at the other end, allowing the split nuts
to open. Once the rotating shaft rotates
clockwise to load a syringe and then
released, a torsion spring returns the gripper
control to its original position. This torsion
spring ensures that the gripper control

returns to its vertical (closed) position and
confirms that the split nuts are closed.

The drivetrain is contained in the lower and
upper housings. The lower housing is also
attached to the drive tube that connects to
the drivetrain carriage at the opposite end.
A plastic sleeve over the drive tube provides
environmental and

ESD protection to the flex

circuit routed up to the drive head.

4.7 PLUNGER HEAD BOARD ASSEMBLY

A strain gauge on the Plunger Head Board
senses the force applied to the syringe
plunger: the greater the force, the more
negative the amplifier output . The resulting
signal is inverted and offset on the Logic
Board.

The optical switches on the Plunger Head
Board detect whether a syringe is properly
loaded and whether the plunger grippers are
position to capture a syringe plunger. When
either optical switch is unblocked, current­sensing circuitry on the Logic Board detects
a current from the switch.

4.8 FORCE SENSOR SUBSYSTEM

The force sensor subsystem includes a
force sensor mounted in the drive head,
rather than at the drivetrain as in other
designs.

The cantilevered force sensor contact plate
pivots on a lock plate mounted to the
underside of the lower housing. The force
sensor is positioned so that the cantilevered
contact plate acts as a moment arm from
the pivot point, providing mechanical
advantage from the syringe force to the
force sensor.

PRINCIPLES OF OPERATION

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This mechanical advantage amplifies the
input for a given force from a syringe, which
improves system resolution. Improved
resolution is particularly beneficial for
smaller syringes with lower syringe forces.

A protrusion on the contact plate
concentrates force from all syringe sizes to
a specific location on the contact plate,
which minimizes the effect of variations in
syringe loading and in the syringe push
button geometry inherent in plastic syringes.
The protrusion also creates a longer
moment arm for smaller size syringes,
because they contact the protrusion further
from the contact plate pivot. This increases
the sensor force of small size syringes,
allowing better system resolution. A silicone
seal is also trapped between the force
sensor and the lower housing.

4.9 PRESSURE SENSOR SUBSYSTEM
(SYRINGE MODULE ONLY)

The pressure sensor subsystem includes
the Pressure Sensor Board Assembly, disc
detect system, and related hardware. The
pressure sensor subsystem is only activated
when an administration set with a pressure
disc is used and the pressure disc is
installed, and enhances overall pressure
detection in the patient line.

The Pressure Sensor Board includes: a
pressure sensing transducer that makes
intimate contact with a flexible membrane
(pressure disc) on the administration set.
The pressure of the fluid in the
administration set is transmitted through the
membrane and into the gel of the sensor,
where it is measured by a piezoresistive
pressure transducer.

Circuitry on the Pressure Sensor Board
amplifies pressure transducer output. The
board also includes an optical switch that
detects the presence of an administration
set pressure disc.

4.10 PATIENT HANDSET CIRCUIT AND
DOOR LOCK SENSOR CIRCUIT (PCA
MODULE ONLY)

The PCA Module Logic Board includes a
patient handset circuit, which senses
whether a dose request cord is attached. A
button on the dose request cord allows a
patient to request a dose of analgesia
according to clinician-programmed
parameters.

The PCA Module Logic Board also includes
a door lock sensor circuit that detects the
position of the door lock (

UNLOCK,

PROGRAM, or LOCK):

•

UNLOCK allows syringe loading or

unloading, or access to the latch that
allows the PCA Module to be detached.

•

PROGRAM allows changes to

programmed parameters without
interrupting an infusion.

•

LOCK is the only position that allows an

infusion to start.

PRINCIPLES OF OPERATION

4-5

Alaris®Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

4.8 FORCE SENSOR SUBSYSTEM

(Continued)

PRINCIPLES OF OPERATION

4-6

Alaris®Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

THIS PAGE

INTENTIONALLY

LEFT BLANK

PRINCIPLES OF OPERATION

Figure 4-1. Block Diagram: Syringe and PCA Modules

4-7

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

ALARM

LED (red)

INFUSE

LED (green)

STANDBY

LED (yellow)

7-segment

driver/check

circuit

LED

driver/check

circuit

Display board

microcontroller

7-Segment

Displays

Scrolling
Displays

Channel

ID Display

Keypad

backlight

Keypad

Select

Pause

Channel Off

Restart

Handset

LED

Patient

Handset

Circuit

Door Lock

Sensor Circuit

Door Lock Sensor

Patient Switch

Model 8120 PCA Module Only

Channel Off

Power On Reset

FPGA

Logic board

microcontroller

Address

Latch

Watchdog/

System Reset

Address/

Data/Control Bus

Flash
ROM

Static RAM DUART

Transceiver

Left IUI Connector

Right IUI Connector

12-Bit ADC

8 Channel

8-Bit DAC

(parallel) &

Amp

Variable

Motor

Voltage Drive

5-Phase

Stepper

Motor Driver

Unit Detect

& ID Circuit

Sensors Signal

Conditioning &

Drive Circuit

Force Sensor Out
Plunger Sensor Position
Motor Drive Voltage
Pressure Disc Sensor (8110 only)
Syringe Size Sensor
Pressure Sensor Current Sense
+3.3V
+5V

Plunger Detect Sensor
Lever Detect Sensor
Flange Sensor
Split Nut Engaged Sensor
Set In Sensor (8110 only)
Door Lock Sensor (8120 only)

DC/DC

Converter &

Regulators

2.5V

Reference

Circuit

+3.3 V
+5V

-5 V
+15 V

From IUI Connectors

5V +2.5V Ref

Model 8110 Syringe Module Only

Amp, Current
Sense & Test

Circuit

Pressure

Disc

Set In

Sensor

Motor

Connection

Flex Cable

Connection

Plunger
Position

Sensor

5-Phase

Stepper Motor

Syringe Barrel

Gripper

Split Nut Engaged

Sensor

Carriage Flex

Circuit

Drivetrain
Assembly

Flange Sensor

Flex Cable

Syringe Size

Sensor

Flex

Cable

Drive Head

Amp

Plunger

Force

Sensor

Plunger Detect

Sensor

Lever Detect

Sensor

PRINCIPLES OF OPERATION

4-8 Alaris

®

Syringe Module (8110 Series)

Alaris

®

PCA Module (8120 Series)

Technical Service Manual

THIS PAGE

INTENTIONALLY

LEFT BLANK

5A CORRECTIVE MAINTENANCE

SYRINGE MODULE

Chapter 5A — CORRECTIVE MAINTENANCE

Syringe Module

5A-1

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

WARNING

Disconnect the instrument from the Alaris

®

System before performing maintenance. Only
qualified personnel using proper grounding
techniques should open the instrument case.

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.

NOTES:

• Replacing the Complete Housing Assembly,
Force Sensor Assembly or Logic Board
Assembly in a Syringe Module with version
earlier software requires special calibration
equipment. Until version
the Syringe Module, these assemblies must be
replaced at the depot. Call CareFusion
Technical Support (
assistance and information.

7.1 or later is installed in

800.854.7128 ext. 6003) for

7.0 or

5.1 INTRODUCTION

This chapter describes how to disassemble
and reassemble the Syringe Module.

For more efficient repair, read the “Principles
of Operation” chapter for information on the
mechanical and electrical functions of the
Syringe Module.

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

Whenever the Syringe Module is repaired,
perform the minimum tests required for new
instrument checkout using Maintenance
Software.

For information on replacement parts, see
the “Illustrated Parts Breakdown” chapter.

Following any level of maintenance, perform
the applicable tests (refer to “Level of
Testing Guidelines” table).

• Due to product changes over time, components/
assemblies illustrated in this chapter may differ
from the disassembled instrument. If there are
any questions, contact CareFusion Technical
Support.

Follow these procedures in order for the
most efficient disassembly of Syringe
Module subassemblies. To reassemble the
Syringe Module, reverse the disassembly
steps.

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

70%

Isopropyl Alcohol.

CORRECTIVE MAINTENANCE

Syringe Module

5A-2

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY

To avoid the risk of electrical hazard or
damage to the instrument circuitry, do not
spray fluids directly onto the instrument or
allow fluids to enter the instrument.

CAUTION

Table 5A-1. Required Materials, Supplies and Tools - Syringe Module

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

• Small Diagonal Cutters

• Lint-free cloth (such as, Kimwipes or lint-free tissue)

The following items may be purchased from

TECHNI-TOOL (800.832.4866; http://www.techni–tool.com).

• Hex Head Bit,

1

/

16 HX, 1

15

/

16” Length, TT #758SC0172 (used for 0.062” Park Position Collar Setscrew)

• Power Bit, Ball Hex

5

/64, ¼ HX, 3½” Length, TT #758SC0172

• Power Bit, Ball Hex 3/32, ¼ HX, 3½” Length, TT #758SC0173

• Torque Screwdriver with a minimum range of 3-15 in-lbs. Recommend torque screwdriver, Micro­Adjustable, TT #844SC5002 or TT #304TO034.

• Torx Bit, Size

T6, 1

15

/16” Length, TT #758SC0301

The following items may be purchased from McMaster-Carr (562.692.5911; http://www.mcmaster.com).

• Insert-Bit Holder,

¼” Hex Drive, 6” Length, #7225A42

• Insert-Bit, 0.05” Hex Size, ¼” Hex Shank, 1” Length, #8526A46 (used for 0.05” Park Position Collar
Setscrew)

• Slotted Screwdriver,

1

/8” Tip Width, 3” Long Blade, #5682A37

5.2.1 Removing Latch Assembly and Feet

1. Remove two (

2) screws attaching Latch

Assembly to bottom of Rear Case and
remove Latch Assembly Components.

2. Pull two (2) Feet from underside of
module.

NOTE: When reinstalling the Compression

Spring, be sure to orient as shown during
reassembly.

During Reassembly:

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

NOTE: The Feet press-fit into the module.

5A-3

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

Rear Case

Latch Screws

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Compression Spring

Feet

CORRECTIVE MAINTENANCE

Syringe Module

5A-4

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5.2.2 Removing IUI Connector Assemblies

Remove two (

2) screws attaching each IUI

(left and right) to module.

During Reassembly:

• Do not mix gray (old) and black (new) IUI

Connectors.

• 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 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 Connector, Left

IUI Connector, Right

IUI Connector Seal, Left

IUI Connector Gasket, Right

Ground clip at each mounting
hole on both IUI Connectors.

5A-5

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.3 Separating Rear Case from Chassis
Assembly

1. Remove four (

4) screws (and associated

washers) attaching Rear Case to
chassis assembly.

2. Separate Rear Case from Front Case by
pulling Rear Case away from chassis
assembly.

During Reassembly:

• Ensure Silicone Tubing gasket in Rear
Case is in place and undamaged. (See
Figure

7A-12

)

• Raise Drive Head to highest position
before sliding Chassis Assembly into
Rear Case.

• Ensure wiper assembly seals between
cutout in rear case.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Rear Case Assembly

Chassis Assembly

CORRECTIVE MAINTENANCE

Syringe Module

5A-6

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5.2.4 Removing Handle

Remove six (

6) screws attaching left and

right handles to each other and to module.

Right Handle

Left Handle

Rear Case

5A-7

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5.2.5 Removing Flex Cable Retainer

1. Peel Flex Cable Retainer from Internal
Frame.

2. Use a cotton swab or soft cloth lightly
dampened with

70% Isopropyl Alcohol to

remove adhesive debris from Internal
Frame.

During Reassembly: (see Figure

7A-11)

1. Ensure Internal Frame surface (where
retainer is adhered) is clean and free of
adhesive debris.

2. Remove protective backing from
replacement retainer and adhere
retainer to Internal Frame.

3. If necessary, bend retainer on each fold
line at a

90° angle, toward front of

instrument.

4. Lay retainer over Flex Cable and tuck
inside Front Case.

Flex Cable Retainer

Retainer tucks into

Front Case here.

Retainer adheres to

Internal Frame here.

5.2.6 Removing IUI Board Assembly

1. If present, remove Retainer Clip from
Dual Connector Cable-IUI Board
connection.

2. Disconnect Dual Connector Cable from

IUI Board

J2.

3. Disconnect Syringe Size Sensor
harness from

IUI Board J4.

4. Disconnect Flex Cable from

IUI Board

J3.

5. Use small diagonal cutters to lift and
remove snap rivet from

IUI Board.

6. Remove

IUI Board Assembly.

During Reassembly:

Route Dual Connector Cable and Syringe
Size Sensor harness under

IUI Support

Bracket.

CORRECTIVE MAINTENANCE

Syringe Module

5A-8

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Dual Connector Cable

IUI Board Assembly

Snap Rivet

Flex Cable

Syringe Size

Sensor

Harness

IUI Support Bracket

Do not cut rivet.

CAUTION

Retainer Clip

5A-9

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.7 Removing Logic Board Assembly

NOTE: If the Logic Board must be replaced

on a Syringe Module with version 7 or earlier
software, the Logic Board must be replaced
at the depot. See the note at the beginning
of this chapter for more information.

1. If present, remove Retainer Clip from
Dual Connector Cable-Logic Board
connection.

2. Disconnect Dual Connector Cable from
Logic Board

J8.

3. Disconnect Linear Sensor harness from
Logic Board

J12.

4. Remove one (

1) screw attaching Keypad

ground wire and Logic Board to

IUI

Support Bracket.

5. Remove one (

1) screw attaching Logic

Board to Internal Frame Assembly.

6. Disconnect harnesses from following
locations on Logic Board:

J4 (display)
J7 (motor)
J11 (flange detect)
J14 (pressure sensor)

7. Remove Logic Board.

During Reassembly:

Route Dual Connector Cable and Linear
Sensor Harness under

IUI Support Bracket.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Dual Connector Cable

Logic Board Assembly

Internal Frame Assembly

Keypad Ground Wire

Retainer Clip

Linear Sensor Harness

CORRECTIVE MAINTENANCE

Syringe Module

5A-10

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.8 Removing Internal Frame Assembly

1. Remove three (

3) screws attaching

Internal Frame to Front Case Assembly.

2. Remove

IUI Bracket Strap.

3. Remove one (

1) screw attaching IUI

Support Bracket to IUI Bracket.

4. Remove

IUI Support Bracket and

IUI

Bracket.

5. Remove two (

2) screws attaching

Internal Frame to Drivetrain Assembly.

6. Remove Internal Frame.

During Reassembly:

Route Linear Sensor Harness between IUI
Bracket and Internal Frame.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Drivetrain Assembly

IUI Bracket

Internal Frame

IUI Bracket

Strap

IUI Support Bracket

Front Case Assembly

Linear Sensor Harness

To replace an Internal Frame whose Barrel
Clamp Assembly has a park position “pin”
(rather than a “collar”), replace with Front
Case Assembly Kit (Table 7A-1, item 9).

CAUTION

-- Barrel Clamp Assembly (Partial View) --

Park Position “Collar” Park Position “Pin”

5A-11

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.9 Removing Drivetrain Assembly

1. Remove five (

5) screws attaching

Drivetrain Assembly to Front Case.

2. Remove Drivetrain Assembly.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Drivetrain Assembly

Front Case

CORRECTIVE MAINTENANCE

Syringe Module

5A-12

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.10 Removing Display Board Assembly

1. Disconnect harness/flex cable from
following locations on Display Board:

J1 (keypad)
J4 (backlight)

2. Remove Display Board.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Display Board Assembly

LED Backlight Harness

Keypad Flex Cable

5A-13

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.11 Removing Pressure Sensor Board
Assembly

1. Disconnect Pressure Sensor Harness
from Pressure Sensor Board.

2. Remove four (

4) screws attaching Base

Disk Holder to Top Disk Holder and
Front Case.

3. Remove Base Disk Holder and Pressure
Sensor Board Assembly.

During Reassembly:

When installing an old version of Base Disk
Holder, use 4-40 x

5

/

16 screws (item 486) in

upper mountings, and

4-40 x

3

/16

screws

(item

484

) in lower mountings. When
installing a newer version of Base Disk
Holder, use

4-40 x

5

/16

(item 486) for all

mountings. (Reference Figure

7A-4.)

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Pressure Sensor Board AssemblyPressure Sensor

Harness

Base Disk Holder (old)

(See CAUTION statement)

To avoid damage to the Front Case when
reinstalling the Base Disk Holder, use
correct size screws (reference Figure

7A-4).

CAUTION

Base Disk Holder (new)

(See CAUTION statement)

No boss

Boss

4-40 x

5

/16 (4 PL)

4-40 x

5

/16

(upper mountings)

4-40 x

3

/

16

(lower mountings)

CORRECTIVE MAINTENANCE

Syringe Module

5A-14

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.12 Removing Top Disk Holder

1. Remove two (

2) screws attaching Top

Disk Holder to Front Case.

2. Remove Top Disk Holder.

NOTE: When replacing the Top Disk Holder,

remove the Flag Disk Holder and Spring from
the old part and reuse.

During Reassembly:

• Set spring torque by inserting end of

Spring in hole of Flag Disk Holder and
winding holder counterclockwise.

• Ensure Silicone Tubing and Gasket in

Top Disk Holder mounting area on Front
Case are in place and undamaged. (See
Figure

7A-5)

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Flag Disk Holder

Spring

Top Disk Holder

To replace “Older Version” Top Disk Holder
(see below), replace with Front Case
Assembly Kit (Table

7A-1, item

9).

CAUTION

“Older Version”

Top Disk Holder

See CAUTION

statement above.

5A-15

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.13 Removing Sensor Board Assembly

1. Remove Flag Leaf Spring and Barrel
Position Flag as required.

2. Remove one (

1) screw attaching Sensor

Board to Front Case.

3. Remove Sensor Board.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Sensor Board

Barrel

Position Flag

Flag Leaf

Spring

CORRECTIVE MAINTENANCE

Syringe Module

5A-16

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.14 Removing Syringe Size Sensor
Assembly

1. Remove one (

1) screw attaching Syringe

Size Sensor Assembly and Shaft
Support to Front Case.

2. Remove Syringe Size Sensor Assembly.

During Reassembly:

1. Insert tab on Syringe Size Sensor
Assembly into Potentiometer Extension
Guide.

2. Secure Syringe Size Sensor Assembly
to Front Case.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Syringe Size Sensor Assembly

Potentiometer Extension Guide

5A-17

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.15 Removing Syringe Barrel Clamp
Assembly

1. Loosen set screw securing park position
collar to Barrel Clamp and remove collar.

2. Remove Potentiometer Extension
Guide.

3. Remove one (

1) screw attaching Shaft

Support to Front Case.

4. Remove Retaining Rings, Compression
Spring, Bushing and Barrel Clamp.

During Reassembly:

1. If Shaft Seal has been removed:

a. Reinstall with wide lip facing Front

Case.

b. Use a #2 flat-bladed screwdriver to

carefully push around edges of seal
until it is fully seated into Front Case
recess.

c. Verify seal is completely seated by

slowly pulling Barrel Clamp out ½ to

1 inch and then slowly pushing it

back in, ensuring seal does not
move out of recess.

2. Potentiometer Extension Guide:

a. Fully retract Barrel Clamp (seat

against Front Case).

b. Insert Potentiometer Extension

Guide through Shaft Support and
“snap” into place on shaft.

3. Tighten park position collar setscrew
against flat on end of shaft.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

To replace a Syringe Barrel Clamp
Assembly with a park position “pin” (rather
than a “collar”), replace with Front Case
Assembly Kit (Table 7A-1, item 9).

CAUTION

-- Barrel Clamp Assembly (Partial View) --

Park Position “Collar” Park Position “Pin”

-- Continued on Next Page --

CORRECTIVE MAINTENANCE

Syringe Module

5A-18

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.15 Removing Syringe Barrel Clamp
Assembly (Continued)

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Syringe Barrel

Clamp Assembly

Shaft Seal

(see installation illustration)

Compression Spring

Shaft Support

Bushing

Potentiometer

Extension Guide

Park Position Collar

and Setscrew

Retaining Rings

Shaft Seal Installation

Front Case

Recess

Bushing

Shaft Seal

Front Case

Shaft Seal

(fully seated)

Press around edges

until seated in recess.

Step 1 Step 2

5A-19

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.16 Removing Status Indicator Lens

1. Remove two (2) screws attaching Status
Indicator Lens to Front Case.

2. Remove Status Indicator Lens.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Status Indicator Lens

Front Case

CORRECTIVE MAINTENANCE

Syringe Module

5A-20

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.17 Removing Housing Assembly and
Guide Rod

NOTE: If the Housing Assembly must be

replaced on a Syringe Module with version

7

or earlier software, the Housing Assembly
must be replaced at the depot. See the note
at the beginning of this chapter for more
information.

1. Pull Linear Sensor Harness loose from
clamps on Top Plate.

2. Remove two (

2) screws attaching Top

Plate to Extrusion Frame.

3. Gently place assembly in a standing
position and orient it with motor facing
inward.

4. Rotate knob (gripper control) to
disengage plunger grippers and slowly
raise Housing Assembly until Carriage
Assembly nears top of Extrusion Frame.

5. Angle Housing Assembly away from
Linear Sensor Assembly so that
Conductive Wiper does not contact
Linear Sensor.

6. Gently remove Housing Assembly.

7. Lift Guide Rod from Bottom Plate and
remove.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Linear Sensor Harness

Housing Assembly

Guide Rod

Extrusion Frame

Leadscrew

Assembly

Wiper Assembly

Top Plate

Carriage Assembly

Harness Clamp (2 PL)

Conductive

Wiper

(Reference)

Use EXTREME CAUTION

when removing
Housing Assembly. If the Conductive Wiper
is damaged, replace the entire

Lower

Housing/Carriage Assembly.

CAUTION

Knob (gripper control)

When performing the next step, use care to
avoid damaging the leadscrew pulley.

CAUTION

5A-21

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.18 Removing Motor/Pulley Assembly

1. Remove four (

4) screws attaching

Motor/Pulley Assembly to Bottom Plate.

2. Remove Motor Belt.

3. Remove Motor/Pulley Assembly.

During Reassembly:

1. To prevent pinion damage, install
Motor/Pulley Assembly through Bottom
Plate at a slight angle.

2. Install Motor Belt:

a. Install wide end of belt onto

leadscrew pulley.

b. Tilt Motor/Pulley Assembly and

install other end of belt onto motor
pulley. Do not stretch belt to fit over
pulley.

3. Screw Motor/Pulley Assembly in place.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Motor Belt

Motor/Pulley Assembly

Bottom Plate

CORRECTIVE MAINTENANCE

Syringe Module

5A-22

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.19 Removing Leadscrew Assembly and
Bottom Plate

1. Remove two (

2) screws attaching

Leadscrew Assembly to Bottom Plate.

2. Remove Leadscrew Assembly.

3. Remove remaining screw attaching
Bottom Plate to Extrusion Frame.

4. Remove Bottom Plate.

During Reassembly:

If replacing Bottom Plate, remove bushings
and grommets from old plate and install into
new plate.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Leadscrew Assembly

Bushing (8 PL)

Bottom Plate

Extrusion Frame

Grommet (4 PL)

5A-23

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.20 Removing Linear Sensor Assembly

1. Peel Linear Sensor Assembly off
Extrusion Frame.

2. Use alcohol to clean adhesive debris
from Extrusion Frame.

During Reassembly:

1. Ensure Extrusion Frame surface is
clean.

2. Before adhering Linear Sensor
Assembly to Extrusion Frame:

a. Remove protective backing from

Linear Sensor.

b. Align hole in Linear Sensor

Assembly with hole in Extrusion
Frame.

3. Use a burnishing tool to ensure that
Linear Sensor Assembly is securely
adhered to Extrusion Frame.

4. Clean Linear Sensor Assembly surface
using alcohol and lint-free cloth (such as
Kimwipes or lint-free tissue).

5.2 DISASSEMBLY/REASSEMBLY (Continued)

To avoid damaging the Linear Sensor
Assembly, do not touch with bare hands.

CAUTION

Alignment Hole

Extrusion Frame

Linear Sensor Assembly

CORRECTIVE MAINTENANCE

Syringe Module

5A-24

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.21 Removing Force Sensor and Actuator
Knob Assemblies

NOTE: If the Force Sensor Assembly must

be replaced on a Syringe Module with version

7 or earlier software, the Force Sensor

Assembly must be replaced at the depot.
See the note at the beginning of this chapter
for more information.

1. Loosen four (

4) screws attaching Upper

Housing to Lower Housing just far
enough to remove Upper Housing,
leaving O-Rings attached to screws.

NOTE: To avoid losing O-Rings, push

each screw upward to grab and hold its
O-Ring before removing screws from
Upper Housing.

2. Disconnect flex cable from Force Sensor
Board

J1.

3. Lift Force Sensor Board off mounting
posts.

4. Remove Actuator Knob Assembly.

5. Remove four (

4) screws attaching Force

Sensor Assembly to Lower Housing.

6. Remove Force Sensor Assembly.

7. Remove Force Sensor Lock Plate, Force
Sensor Plate, Force Sensor Seal and
Upper Housing.

During Reassembly: (see Figure 7A-1)

• Ensure Silicone Tubing gasket in Upper

Housing is undamaged and is in place.

• Ensure Plunger Flag (part of Lower

Housing Assembly) and Force Sensor
Assembly plunger are seated in Force
Sensor Seal.

• Ensure Force Sensor Assembly flex

cable is tucked inside upper and lower
housings.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Upper Housing

(Silicone Tubing

gasket not shown

)

Force Sensor

Board Assembly

(P/O Force Sensor

Assembly Kit)

Actuator Knob

Assembly

Force Sensor

Assembly Kit

Lower

Housing/Carriage

Assembly Kit

Force Sensor Seal

Force Sensor

Lock Plate

Force Sensor Plate

Wiper Assembly, Top Plate, and

Carriage Assembly are not shown.

O-Rings (4 PL)

Plunger

To avoid damaging Lower Housing, use
Nylok screws to install Force Sensor
Assembly.

CAUTION

Nylok Screws

(4 PL, P/O Force

Sensor Assembly

Kit and Lower

Housing Carriage

Assembly Kit)

5A-25

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Actuator Knob

Compression

Spring

Interrupter Flag

Screw

Pullrod Cam

Slide Plate

5.2.22 Removing Actuator Knob Assembly
Parts

1. Use a small pair of needle-nose pliers to
gently pull Interrupter Flag from Actuator
Knob Assembly.

2. Remove screw to remove Slide Plate,
Compression Spring, and Pullrod Cam.

During Reassembly:

• Install Slide Plate and Compression
Spring onto Actuator Knob, compress
Spring with Pullrod Cam, then install
screw.

CORRECTIVE MAINTENANCE

Syringe Module

5A-26

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

Table 5A-2. Torque Values - Syringe Module

Functional Application Item Description Torque Value

DRIVETRAIN ASSEMBLY

Bottom Plate 6-32 x

7

/16 12 in-lb

Leadscrew Assembly 6-32 x

7

/16 12 in-lb

Motor/Pulley Assembly M2.5 x 12 4 in-lb
Top Plate 6-32 x

7

/

16 6 in-lb

FINAL ASSEMBLY

Handle Assembly 4-40 x

3

/4 6 in-lb

IUI Connectors 6-32 x

7

/16 12 in-lb

Latch Assembly 4-40 x

5

/16 6 in-lb

Rear Case - Front Case 4-40 x

5

/16 6 in-lb

Rear Case - Internal Frame 6-32 x

7

/

16 12 in-lb

FRONT CASE ASSEMBLY

Disk Holder, Base - Disk Holder 4-40 x

5

/16 6 in-lb

Disk Holder, Base - Front Case 4-40 x

1

/4 6 in-lb

Disk Holder, Top 4-40 x

3

/16 6 in-lb

Drivetrain Assembly - Front Case 4-40 x

5

/

16 6 in-lb

Internal Frame - Drivetrain Assembly 6-32 x

5

/16 12 in-lb

Internal Frame - Front Case 4-40 x

5

/16 6 in-lb

IUI Support Bracket 6-32 x

5

/

16 12 in-lb

Logic Board Assembly 4-40 x

5

/16 6 in-lb

Park Position Collar setscrew - no

nylon patch 6 in-lb

setscrew - with nylon patch 10 in-lb

Sensor Board Assembly 4-20 x

5

/16 6 in-lb

Status Indicator Lens 4-20 x

5

/

16 6 in-lb

Syringe Barrel Clamp Assembly 4-40 x

5

/16 6 in-lb

Syringe Size Sensor Assembly 4-40 x

5

/16 6 in-lb

HOUSING / CARRIAGE ASSEMBLY

Actuator Knob Assembly 4-40 x

1

/4 6 in-lb

Force Sensor Assembly 2-56 x

3

/16 6 in-lb

Upper - Lower Housing 4-20 x 1 8 in-lb

5A-27

CORRECTIVE MAINTENANCE

Syringe Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

Table 5A-3. Level of Testing Guidelines - Syringe Module

Actuator Knob Assy. NNX N X N

Disc Holder, Top / Base NN

Display Board Assy. NNN NN

Drivetrain Assy. NN N X NN N
Force Sensor Assy. NNNNX N
Front Case N X NN N X NN

Handle Assy. N

Housing/Carriage Assy., Lower NN N X NN N
Housing Assy., Complete NN N X N X N

Internal Frame Assy. NN

IUI Board Assy. N X NNX N X N

IUI Connector Assy. NN

Latch Assy. N

Leadscrew Assy. NNX N X N

Logic Board Assy. NN N N N N N N N N

Pressure Sensor Board Assy. NN N N N

Rear Case NN

Sensor Board Assy. NN N X N X N

Status Indicator Lens NN NN

Syringe Barrel Clamp assy. NNN N

Syringe Size Sensor Assy. NNN N N

Channel ID/IUI Connector Test

Barrel Size Calibration

Plunger Position Calibration

Plunger Force Sensor

Calibration

Binary Switches Test

Pressure Disc Accuracy

Verification

Keypad Test

Plunger Force Accuracy

Verification

Alarm Test

Plunger Position Accuracy

Verification

Barrel Size Accuracy Verification

Pressure Disc/Sensor

Calibration

Tests to Perform

N

= Required

X = If verification fails.

Blank = Not Applicable

Repair/Replacement of: Ð

Simultaneous Display Test

Visual/Instrument Inspection

-- Continued Next Page --

CORRECTIVE MAINTENANCE

Syringe Module

5A-28

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

NOTES:

• Use the Maintenance Software to perform testing and calibration.

• After performing any calibration procedure, always perform the
associated verification test.

Table 5A-3. Level of Testing Guidelines - Syringe Module (Continued)

Miscellaneous: Ð

Instrument Dropped NN NNN N N N NN

Instrument Software Flashed N

New Instrument Checkout NN NNN N N N NN

No Fault Found

N NNN NN

(instrument not opened)

No Fault Found

NN NNN N N N NN

(instrument opened)

Channel ID/IUI Connector Test

Barrel Size Calibration

Plunger Position Calibration

Plunger Force Sensor

Calibration

Binary Switches Test

Pressure Disc Accuracy

Verification

Keypad Test

Plunger Force Accuracy

Verification

Alarm Test

Plunger Position Accuracy

Verification

Barrel Size Accuracy Verification

Pressure Disc/Sensor

Calibration

Tests to Perform

N

= Required

X = If verification fails.

Blank = Not Applicable

Repair/Replacement of: Ð

Simultaneous Display Test

Visual/Instrument Inspection

5B CORRECTIVE MAINTENANCE

PCA MODULE

Chapter 5B — CORRECTIVE MAINTENANCE

PCA Module

5B-1

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

WARNING

Disconnect the instrument from the Alaris

®

System before performing maintenance. Only
qualified personnel using proper grounding
techniques should open the instrument case.

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 (

ESD) protected environment using

approved ESD protective procedures, including
personnel grounding.

NOTE: Due to product changes over time,

components/assemblies illustrated in this chapter
may differ from the disassembled instrument. If
there are any questions, contact CareFusion
Technical Support.

5.1 INTRODUCTION

This chapter describes how to disassemble
and reassemble the PCA Module.

For more efficient repair, read the “Principles
of Operation” chapter for information on the
mechanical and electrical functions of the
PCA Module.

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

Whenever the PCA Module is repaired,
perform the minimum tests required for new
instrument checkout using Maintenance
Software.

For information on replacement parts, see
the “Illustrated Parts Breakdown” chapter.

Following any level of maintenance, perform
the applicable tests (refer to “Level of
Testing Guidelines” table).

Follow these procedures in order for the
most efficient disassembly of PCA Module
subassemblies. To reassemble the PCA
Module, reverse the disassembly steps.

NOTE: Perform all maintenance on an

antistatic surface, preferably a grounded
antistatic mat.

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

70% Isopropyl Alcohol.

5B-2

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY

Disconnect the PCA Module from the Alaris

®

System before attempting disassembly.

CAUTION

To avoid the risk of electrical hazard or
damage to the instrument circuitry, do not
spray fluids directly onto the instrument or
allow fluids to enter the instrument.

CAUTION

Table 5B-1. Required Materials, Supplies and Tools - PCA Module

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

• Small diagonal cutters

• Lint-free cloth (such as, Kimwipes or lint-free tissue)

The following items are available from

TECHNI-TOOL (800.832.4866

; http://www.techni–tool.com).

• Hex Head Bit,

1

/16 HX, 115/16” Length, TT #758SC0172 (used for 0.062” Park Position Collar Setscrew)

• Power bit, ball hex

5

/64, ¼ HX, 3½” length, TT #758SC0172

• Power bit, ball hex 3/32, ¼ HX, 3½” length, TT #758SC0173

• Tamper-resistant Torx bit, size T8, 115/16“ length, TT #758SC0321

• Torque screwdriver with a minimum range of

3-15 in-lbs. Recommend torque screwdriver,

Micro-Adjustable,

TT #844SC5002 or TT #304TO034.

• Torque wrench with a minimum range of

40 in-lbs. Recommend ¼ torque wrench #155IE150.

• Torx Bit, Size

T6, 1

15

/16” Length, TT #758SC0301

The following items may be purchased from McMaster-Carr (562.692.5911; http://www.mcmaster.com).

• Insert-bit holder,

¼” hex drive, 6” length, #7225A42

• ¼” drive 9/16” deep-well socket (available at any hardware or tool store)

• Slotted screwdriver,

1

/

8” tip width, 3” length blade, #5682A37

• Insert-Bit, 0.05” Hex Size, ¼” Hex Shank, 1” Length, #8526A46 (used for 0.05” Park Position Collar
Setscrew)

5.2.1 Removing Latch Assembly and Feet

1. Remove two (

2) screws attaching Latch

Assembly to bottom of Rear Case and
remove Latch Assembly components.

2. Pull two (

2) Feet from underside of

module.

NOTE: When reinstalling the Compression

Spring, be sure to orient as shown during
reassembly.

During Reassembly:

• When reinstalling Latch Assembly, press
toward outer edge of module and screw
into position.

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

NOTE: The Feet press-fit into the module.

5B-3

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

Feet

Rear Case

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Compression Spring

Latch Screws

5B-4

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5.2.2 Removing IUI Connector Assemblies

Remove two (

2) screws attaching each IUI

(left and right) to module.

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 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 Connector, Left

IUI Connector, Right

IUI Connector Seal, Left

IUI Connector Gasket, Right

Ground clip at each mounting
hole on both IUI Connectors.

5.2.3 Removing Handle

1. Remove six (

6

) screws attaching Left

and Right Handles.

2. Remove two (

2) screws attaching Left

Handle to Lock Housing.

3. Detach Left and Right Handles from

each other and module.

During Reassembly:

• Assemble Left Handle over Lock Housing
and ensure that Lock Harness is routed
under Lock Housing boss.

• Use two (

2) screws to attach Left Handle

to Lock Housing.

• Install Right Handle over Left Handle and
secure with six (

6) screws.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5B-5

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

Right Handle

Left Handle

Rear Case

Screws attach Left Handle
to Lock Housing

Lock Harness

Lock Housing

5B-6

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5.2.4 Removing Door Assembly

1. Remove four (

4) T8 Torx Security screws

and four (4) Hinge Bushings attaching
Door Assembly to right side of Front
Case.

2. Unlock Door, and lift Lock Assembly
away from Door. Take care not to pull
on Lock Assembly harness.

3. Remove Door Assembly.

Disassembling Door Assembly:

4. Remove four (

4) screws attaching Front

Door, Rear Door Lockplate, and Rear
Door.

5. Remove seven (

7) screws attaching

Hinge to Front Door and Lockplate.

6. Remove two (

2) screws attaching

Lockplate and Strikeplate Lockplate to
Front Door.

During Reassembly:

Reassembling Door Assembly:

1. Use two (

2) screws to assemble Door

Strikeplate to Front Door.

2. From inside of Door, align Front Door
Lockplate holes with through-holes on
Door. From outside of Door, align holes
on hinge with those on Door and Front
Door Lockplate. Install but only loosely
tighten seven (

7) screws to attach hinge.

Front Case

Door

Assembly

Lock

Assembly

Harness

T8 Torx Security

Screws and Hinge

Bushings (x4)

5.2.4 Removing Door Assembly (Continued)

3. Align Rear Door Lockplate to inside of
Rear Door. Install but only loosely
tighten four (4) screws on upper section
of hinge.

Reinstalling Door Assembly:

4 Install four (

4) Hinge Bushings into four

(4) slots on lower section of hinge.

5. Install but only loosely tighten four (

4)

T8 Torx Security screws.

6. Close Door in Lock position and align
Door edges (front and back doors flush),
then tighten all screws.

5B-7

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

CORRECTIVE MAINTENANCE

PCA Module

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Hinge

Front

Door

Front
Door

Lockplate

Front

Door

Rear Door

Lockplate

Rear Door

Front

Door

Lockplate

Strikeplate

5B-8

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.5 Removing Rear Case

1. Remove four (

4) screws (and associated

washers) attaching Rear Case to
chassis assembly.

2. Pull Rear Case away from chassis
assembly.

During Reassembly:

• Ensure that Silicone Tubing gasket in

Rear Case is in place and undamaged
(see Figure

7B-10).

• Raise Drive Head to highest position
before sliding Chassis Assembly into
Rear Case.

• Slide edges of Rear Case into Wiper
Assembly flange.

• Route Lock Assembly harness along
flange on Rear Case.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Rear Case Assembly

Chassis Assembly

Slide edge of Rear Case

into Wiper Assembly

flange at reassembly

Drive Head

Lock Assembly Harness

5B-9

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5.2.6 Removing Flex Cable Retainer

1. Peel Flex Cable Retainer from Internal
Frame.

2. Use a cotton swab or soft cloth lightly
dampened with

70% Isopropyl Alcohol to

remove adhesive debris from Internal
Frame.

During Reassembly: (see Figure

7B-9)

1. Ensure Internal Frame surface (where
retainer is adhered) is clean and free of
adhesive debris.

2. Remove protective backing from
replacement retainer and adhere to
Internal Frame.

3. If necessary, bend retainer on each fold
line at a

90° angle, toward front of

instrument.

4. Lay retainer over Flex Cable and tuck
inside Front Case.

Flex Cable Retainer

Retainer tucks into

Front Case here.

Retainer adheres to

Internal Frame here.

5B-10

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Dual Connector Cable

IUI Board

Snap Rivet

(do not cut)

Flex

Cable

Syringe Size Sensor

IUI Support Bracket

Retainer Clip

5.2.7 Removing IUI Board Assembly

1. If present, remove Retainer Clip from
Dual Connector Cable-IUI Board
connection.

2. Disconnect Dual Connector Cable from

IUI Board J2.

3. Disconnect Syringe Size Sensor
harness from

IUI Board J4.

4. Disconnect Flex Cable from

IUI Board

J3

.

5. Use small diagonal cutters to lift and
remove snap rivet from

IUI Board.

6. Remove

IUI Board.

During Reassembly:

Route Dual Connector Cable and Syringe
Size Sensor harness under IUI Support
Bracket.

Do not cut rivet.

CAUTION

5B-11

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

Internal Frame Assembly

5.2.8 Removing Logic Board Assembly

1. If present, remove Retainer Clip from
Dual Connector Cable-Logic Board
connection.

2. Disconnect Dual Connector Cable from
Logic Board

J8.

3. Disconnect Linear Sensor Harness from
Logic Board

J12.

4. Remove one (

1) screw attaching Logic

Board to

IUI Support Bracket.

5. Remove one (

1) screw attaching Logic

Board to Internal Frame Assembly.

6. Disconnect harnesses from following
locations on Logic Board:

J4 (display)
J7 (motor)
J11 (flange detect)
J13 (lock harness)

7. Remove Logic Board.

During Reassembly:

Route Dual Connector Cable and Linear
Sensor Harness under

IUI Support Bracket.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Dual Connector Cable

Logic Board

J12

Linear Sensor Harness

IUI Support Bracket

J8

J11

J4

J7

J13

Retainer Clip

5B-12

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.9 Removing Internal Frame Assembly

1. Remove one (

1) screw attaching three

(3) ground wires to IUI

Support Bracket.

2. Remove three (

3) screws attaching

Internal Frame to Front Case Assembly.

3. Remove

IUI Bracket Strap.

4. Remove one (

1) screw attaching

IUI

Support Bracket to IUI Bracket.

5. Remove

IUI Support Bracket and IUI

Bracket.

6. Remove two (

2) screws attaching

Internal Frame to Drivetrain Assembly.

7. Remove Internal Frame.

During Reassembly:

• Route Linear Sensor Harness between

IUI Bracket and Internal Frame.

• Route Lock Assembly harness through

top of and under Internal Frame so that
Frame does not pinch harness when
attached to Front Case, and harness can
reach Logic Board

J13.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Drivetrain
Assembly

IUI Bracket

Ground wires

IUI Bracket Strap

IUI Support Bracket

Front Case

Assembly

Linear Sensor Harness

Internal Frame

Lock Assembly

5B-13

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5.2.10 Removing Lock Assembly

1. Already disassembled: Handle, Rear
Case,

IUI

and Logic Boards, and Internal

Frame.

2. Remove Lock Assembly.

NOTE: Remove or install the Lock Assembly

harness carefully to avoid damage to the
harness.

During Reassembly:

Route Lock Assembly harness through top
of and under Internal Frame so that Frame
does not pinch harness when attached to
Front Case, and harness can reach Logic
Board

J13.

Rear Case

Lock Assembly

Lock Assembly harness

5B-14

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.11 Removing Latch Module and
Drivetrain Assembly

1. Remove two (

2) screws on Latch

Bushings and remove Latch Module
from underside of Drivetrain.

2. Disassemble Latch Module parts (Latch
Bushing Supports, Latch Bushings,
Latch Rod).

3. Remove five (

5) screws attaching

Drivetrain Assembly to Front Case, and
remove Drivetrain Assembly.

During Reassembly:

• Ensure both legs of Latch Bushings seat
in the square cutouts on Drivetrain
bottom plate.

• Thread Latch Rod through Latch Lever.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Drivetrain

Assembly

Front Case

Latch Module (Underside of

Drivetrain Assembly)

Latch Lever

Latch Bushing

Support

Latch Bushing

Screw

Latch Rod

5B-15

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.12 Removing Display Board Assembly

1. Disconnect cables from these Display
Board connectors:

J1 (keypad)
J3 (Handset Harness)
J4 (backlight)

2. Remove Display Board.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Display Board

LED Backlight

Harness

Keypad Flex Cable

Handset Harness

5B-16

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.13 Removing Sensor Board Assembly

1. Remove Flag Leaf Spring and Barrel
Position Flag as required.

2. Remove one (

1) screw attaching Sensor

Board to Front Case.

3. Remove Sensor Board.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Sensor Board

Barrel

Position Flag

Flag Leaf

Spring

5B-17

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.14 Removing Syringe Size Sensor
Assembly

1. Remove one (

1) screw attaching Syringe

Size Sensor Assembly and Shaft
Support to Front Case.

2. Remove Syringe Size Sensor Assembly.

During Reassembly:

1. Insert tab on Syringe Size Sensor
Assembly into Potentiometer Extension
Guide.

2. Secure Syringe Size Sensor Assembly
to Front Case.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Syringe Size

Sensor Assembly

Potentiometer

Extension Guide

Front Case

5B-18

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.15 Removing Syringe Barrel Clamp
Assembly

1. Loosen set screw securing park position
collar to Barrel Clamp and remove collar.

2. Remove Potentiometer Extension
Guide.

3. Remove one (

1) screw attaching Shaft

Support to Front Case.

4. Remove Retaining Rings, Compression
Spring, Bushing and Barrel Clamp.

During Reassembly:

1. If Shaft Seal has been removed:

a. Reinstall with wide lip facing Front

Case.

b. Use a #2 flat-bladed screwdriver to

carefully push around edges of seal
until it is fully seated into Front Case
recess.

c. Verify seal is completely seated by

slowly pulling Barrel Clamp out ½ to

1 inch and then slowly pushing it

back in, ensuring seal does not
move out of recess.

2. Potentiometer Extension Guide:

a. Fully retract Barrel Clamp (seat

against Front Case).

b. Insert Potentiometer Extension

Guide through Shaft Support and
“snap” into place on shaft.

3. Tighten park position collar setscrew
against flat on end of shaft.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5B-19

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.15 Removing Syringe Barrel Clamp
Assembly (Continued)

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Syringe Barrel

Clamp Assembly

Shaft Seal

(see installation illustration)

Compression

Spring

Shaft

Support

Bushing

Potentiometer

Extension Guide

Park Position Collar

and Setscrew

Retaining

Rings

Shaft Seal Installation

Front Case

Recess

Bushing

Shaft Seal

Front Case

Shaft Seal

(fully seated)

Press around edges

until seated in recess.

Step 1 Step 2

5B-20

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.16 Removing Status Indicator Lens

1. Remove two (

2) screws attaching Status

Indicator Lens to Front Case.

2. Remove Status Indicator Lens.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Status Indicator Lens

Front Case

5B-21

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5.2.17 Removing Handset Harness

NOTE: Use a

9

/16-in. deep-well socket at
least 4 in. deep to remove and install the
Handset Harness.

1. Ensure that 9/

16-in. socket is on top nut,

then remove top nut (first of 2nuts) that
secures Handset Harness to Front
Case.

2. Use socket to remove second nut.

3. Remove Ground Harness.

4. Remove Handset Harness (already
disconnected from Display Board

J3).

During Reassembly:

1. Install Handset Harness with red dot
pointing to top of Front Case.

2. Install Ground Harness, then install first
nut and tighten.

3. Install second nut and tighten, ensuring
that socket is on top nut (second of

2

nuts) only.

4. Connect Handset Harness to Display
Board

J3.

Handset Harness

Front Case

Ground Harness

Nut

Nut

5B-22

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Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

5.2.18 Removing Latch Lever Assembly

1. Remove two (

2) screws attaching Latch

Cover to inside of Front Case.

2. Remove Ground Harness.

3. Remove Latch Lever and Latch Seal.

During Reassembly:

1. Install Latch Seal onto shaft of Latch
Lever.

2. Install Latch Lever into Front Case,
using a blunt instrument to seat seal into
oval recess.

3. Attach Latch Cover to Front Case.

Latch

Cover

Latch
Lever

Latch

Seal

Latch Seal
installs into
oval recess

5B-23

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.19 Removing Housing Assembly and
Guide Rod

1. Pull Linear Sensor Harness loose from
clamps on Top Plate.

2. Remove two (

2) screws attaching Top

Plate to Extrusion Frame.

3. Gently place assembly in a standing
position and orient it with motor facing
inward.

4. Rotate knob (gripper control) to
disengage plunger grippers and slowly
raise Housing Assembly until Carriage
Assembly nears top of Extrusion Frame.

5. Angle Housing Assembly away from
Linear Sensor Assembly so that
Conductive Wiper does not contact
Linear Sensor.

6. Gently remove Housing Assembly.

7. Lift Guide Rod from Bottom Plate and
remove.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Linear Sensor Harness

Housing Assembly

Guide Rod

Extrusion Frame

Leadscrew Assembly

Wiper Assembly

Top Plate

Carriage Assembly

Harness Clamp (2 PL)

Conductive

Wiper

(Reference)

Use EXTREME CAUTION

when removing
Housing Assembly. If the Conductive Wiper
is damaged, replace the entire

Lower

Housing/Carriage Assembly.

CAUTION

Knob (gripper control)

When performing the next step, use care to
avoid damaging the leadscrew pulley.

CAUTION

5B-24

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.20 Removing Motor/Pulley Assembly

1. Remove four (

4) screws attaching

Motor/Pulley Assembly to Bottom Plate.

2. Remove Motor Belt.

3. Remove Motor/Pulley Assembly.

During Reassembly:

1. To prevent pinion damage, install
Motor/Pulley Assembly through Bottom
Plate at a slight angle.

2. Install Motor Belt:

a. Install wide end of belt onto

leadscrew pulley.

b. Tilt Motor/Pulley Assembly and

install other end of belt onto motor
pulley. Do not stretch belt to fit over
pulley.

3. Screw Motor/Pulley Assembly into place.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Motor Belt

Motor/Pulley Assembly

Bottom Plate

5B-25

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PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.21 Removing Leadscrew Assembly and
Bottom Plate

1. Remove two (

2) screws attaching

Leadscrew Assembly to Bottom Plate.

2. Remove Leadscrew Assembly.

3. Remove remaining screw attaching
Bottom Plate to Extrusion Frame.

4. Remove Bottom Plate.

During Reassembly:

If replacing Bottom Plate, remove bushings
and grommets from old plate and install into
new plate.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Leadscrew Assembly

Bushing (8 PL)

Bottom Plate

Extrusion Frame

Grommet (4 PL)

5B-26

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.22 Removing Linear Sensor Assembly

1. Peel Linear Sensor Assembly off
Extrusion Frame.

2. Use alcohol to clean adhesive debris
from Extrusion Frame.

During Reassembly:

1. Ensure Extrusion Frame surface is
clean.

2. Before adhering Linear Sensor
Assembly to Extrusion Frame:

a. Remove protective backing from

Linear Sensor.

b. Align hole in Linear Sensor

Assembly with hole in Extrusion
Frame.

3. Use a burnishing tool to ensure that
Linear Sensor Assembly is securely
adhered to Extrusion Frame.

4. Clean Linear Sensor Assembly surface
using alcohol and lint-free cloth (such as
Kimwipes or lint-free tissue).

5.2 DISASSEMBLY/REASSEMBLY (Continued)

To avoid damaging the Linear Sensor
Assembly, do not touch with bare hands.

CAUTION

Alignment Hole

Extrusion Frame

Linear Sensor Assembly

5B-27

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2.23 Removing Force Sensor and Actuator
Knob Assemblies

1. Loosen four (

4) screws attaching Upper

Housing to Lower Housing just far
enough to remove Upper Housing,
leaving O-Rings attached to screws.

NOTE: To avoid losing O-Rings, push

each screw upward to grab and hold its
O-Ring before removing screws from
Upper Housing.

2. Disconnect flex cable from Force Sensor
Board

J1.

3. Lift Force Sensor Board off mounting
posts.

4. Remove Actuator Knob Assembly.

5. Remove four (

4) screws attaching Force

Sensor Assembly to Lower Housing.

6. Remove Force Sensor Assembly.

7. Remove Force Sensor Lock Plate, Force
Sensor Plate, Force Sensor Seal and
Upper Housing.

During Reassembly: (see Figure 7B-1)

• Ensure Silicone Tubing gasket in Upper

Housing is undamaged and in place.

• Ensure Plunger Flag (part of Lower

Housing Assembly) and Force Sensor
Assembly plunger are seated in Force
Sensor Seal.

• Ensure Force Sensor Assembly flex

cable is tucked inside upper and lower
housings.

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Upper Housing

(Silicone Tubing gasket not shown)

Force Sensor Board

(P/O Force Sensor

Assembly Kit)

Actuator Knob

Assembly

Force

Sensor

Assembly

Kit

Lower

Housing/Carriage

Assembly Kit

Force Sensor

Seal

Force Sensor

Lock Plate

Force Sensor Plate

Wiper Assembly, Top Plate, and

Carriage Assembly not shown.

O-Rings (4 PL)

Plunger

To avoid damaging Lower Housing, use
Nylok screws to install Force Sensor
Assembly.

CAUTION

Nylok Screws

(4 PL, P/O Force

Sensor Assembly

Kit and Lower

Housing Carriage

Assembly Kit)

5B-28

CORRECTIVE MAINTENANCE

PCA Module

Alaris®Syringe Module (8110 Series)

Alaris®PCA Module (8120 Series)

Technical Service Manual

5.2 DISASSEMBLY/REASSEMBLY (Continued)

Actuator Knob

Compression

Spring

Interrupter Flag

Screw

Pullrod Cam

Slide Plate

5.2.24 Removing Actuator Knob Assembly
Parts

1. Use a small pair of needle-nose pliers to
gently pull Interrupter Flag from Actuator
Knob Assembly.

2. Remove screw to remove Slide Plate,
Compression Spring, and Pullrod Cam.

During Reassembly:

• Install Slide Plate and Compression
Spring onto Actuator Knob, compress
Spring with Pullrod Cam, then install
screw.