Hospira Plum A+ Service Manual Plum A+ Service Manual

INFUSION SYSTEM

For use with list numbers 12348-04 and 12618-04

RR

3

Technical Service Manual

430-95424-002 (Rev. 01/06)

©

Hospira, Inc.

This document and the subject matter disclosed herein are proprietary information.
Hospira retains all the exclusive rights of dissemination, reproduction, manufacture, and sale.
Any party using this document accepts it in confidence, and agrees not to duplicate it in whole
or in part nor disclose it to others without the written consent of Hospira.

430-95424-002 (Rev. 01/06) Plum A+®3 Infusion System

Change History

Part Number Description of Change

430-95424-001
(Rev. 09/03)

430-95424-002
(Rev. 01/06)

Original Issue

Second Issue

Updated Section 1, Section 5,
Section 6, and Section 8

Updated battery information

Incorporated Hospira name change
and updated to current style

Updated graphics throughout

Updated back page

Technical Service Manual 430-95424-002 (Rev. 01/06)

CHANGE HISTORY

This page intentionally left blank.

430-95424-002 (Rev. 01/06) Plum A+®3 Infusion System

Contents

Section 1

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

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

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

1.3 COMPONENT DESIGNATORS . . . . . . . . . . . . . . . . . . 1-2

1.4 ACRONYMS AND ABBREVIATIONS . . . . . . . . . . . . . . . . 1-3

1.5 USER QUALIFICATION . . . . . . . . . . . . . . . . . . . . . 1-5

1.6 ARTIFACTS . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.7 INSTRUMENT INSTALLATION PROCEDURE . . . . . . . . . . . . 1-5

1.7.1 UNPACKING . . . . . . . . . . . . . . . . . . . . . . 1-6

1.7.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 1-6

1.7.3 SELF TEST. . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.8 BIOMED SETTINGS . . . . . . . . . . . . . . . . . . . . . . 1-8

1.8.1 IV PARAMETERS . . . . . . . . . . . . . . . . . . . . . 1-10

1.8.2 ALARMS LOG . . . . . . . . . . . . . . . . . . . . . . 1-11

1.8.3 SETTING THE TIME AND DATE . . . . . . . . . . . . . . . 1-12

Section 2

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

Section 3

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

Section 4

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . 4-1

4.2 ELECTRONIC SUBSYSTEM OVERVIEW . . . . . . . . . . . . . . . 4-2

4.2.1 CPU SUBSYSTEM . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.1.1 CPU . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.1.2 SYSTEM MEMORY ADDRESS MAP . . . . . . . . . . . 4-3

4.2.1.3 PROGRAMMABLE READ-ONLY MEMORY . . . . . . . . 4-4

4.2.1.4 STATIC RANDOM ACCESS MEMORY . . . . . . . . . . 4-4

4.2.1.5 CONTROL LOGIC . . . . . . . . . . . . . . . . . 4-4

4.2.1.6 LCD CONTROLLER . . . . . . . . . . . . . . . . . 4-4

4.2.1.7 LCD BACKLIGHT CONTROL . . . . . . . . . . . . . 4-5

4.2.1.8 LCD CONTRAST CONTROL. . . . . . . . . . . . . . 4-5

4.2.1.9 REAL-TIME CLOCK . . . . . . . . . . . . . . . . . 4-5

4.2.1.10 VOLTAGE MONITOR WATCHDOG TIMER . . . . . . . . 4-6

4.2.1.11 ANALOG-TO-DIGITAL CONVERTER . . . . . . . . . . 4-6

4.2.1.12 DIGITAL-TO-ANALOG CONVERTER . . . . . . . . . . 4-8

4.2.1.13 FRONT PANEL KEYPAD MATRIX . . . . . . . . . . . 4-8

4.2.1.14 FRONT PANEL [ON/OFF] KEY . . . . . . . . . . . . . 4-8

4.2.1.15 FRONT PANEL LED INDICATORS . . . . . . . . . . . 4-8

4.2.1.16 KEYPAD LOCKOUT INTERFACE . . . . . . . . . . . . 4-9

4.2.1.17 NURSE CALL INTERFACE . . . . . . . . . . . . . . 4-9

4.2.1.18 AUDIBLE INDICATORS . . . . . . . . . . . . . . . 4-9

4.2.1.19 BARCODE READER INTERFACE . . . . . . . . . . . . 4-9

4.2.1.20 DATAPORT INTERFACE . . . . . . . . . . . . . . . 4-10

4.2.1.21 POWER SUPPLY INTERFACE . . . . . . . . . . . . . 4-10

4.2.1.22 MECHANISM INTERFACE . . . . . . . . . . . . . . 4-11

Technical Service Manual iii 430-95424-002 (Rev. 01/06)

CONTENTS

4.2.2 POWER SUPPLY SUBSYSTEM . . . . . . . . . . . . . . . . 4-13

4.2.2.1 MAIN SWITCHING REGULATOR . . . . . . . . . . . 4-13

4.2.2.2 MAIN REGULATOR FAULT DETECTION . . . . . . . . 4-14

4.2.2.3 SYSTEM POWER . . . . . . . . . . . . . . . . . . 4-14

4.2.2.4 AUXILIARY SUPPLIES . . . . . . . . . . . . . . . . 4-14

4.2.2.5 POWER CONTROL . . . . . . . . . . . . . . . . . 4-15

4.2.2.6 BATTERY VOLTAGE MEASUREMENT . . . . . . . . . 4-16

4.2.2.7 BATTERY CHARGE/DISCHARGE CURRENT

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

4.2.2.8 BATTERY CHARGER . . . . . . . . . . . . . . . . 4-16

4.2.3 MECHANISM SUBSYSTEM . . . . . . . . . . . . . . . . . 4-17

4.2.3.1 MOTORS/MOTOR DRIVE . . . . . . . . . . . . . . 4-17

4.2.3.2 MOTOR POSITION SENSORS . . . . . . . . . . . . . 4-18

4.2.3.3 V2_5 REFERENCE VOLTAGE . . . . . . . . . . . . . 4-19

4.2.3.4 AIR SENSORS . . . . . . . . . . . . . . . . . . . 4-19

4.2.3.5 PRESSURE SENSORS . . . . . . . . . . . . . . . . 4-21

4.2.3.6 PRESSURE SENSOR CALIBRATION . . . . . . . . . . 4-23

4.2.3.7 CASSETTE TYPE/PRESENCE SELECTION. . . . . . . . . 4-23

4.2.3.8 SERIAL EEPROM . . . . . . . . . . . . . . . . . . 4-24

4.3 PRINTED WIRING ASSEMBLIES . . . . . . . . . . . . . . . . . 4-24

4.3.1 POWER SUPPLY PWA . . . . . . . . . . . . . . . . . . . 4-24

4.3.2 PERIPHERAL PWA . . . . . . . . . . . . . . . . . . . . 4-25

4.3.3 PERIPHERAL INTERFACE PWA . . . . . . . . . . . . . . . 4-25

4.3.4 CPU PWA . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4.3.5 DRIVER PWA . . . . . . . . . . . . . . . . . . . . . . 4-26

4.3.6 SWITCH PWA . . . . . . . . . . . . . . . . . . . . . . 4-27

4.3.7 APP PWA . . . . . . . . . . . . . . . . . . . . . . . . 4-27

4.4 REMOTE MOUNTED PERIPHERALS . . . . . . . . . . . . . . . . 4-28

4.4.1 LCD . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

4.4.2 SEALED LEAD ACID BATTERY . . . . . . . . . . . . . . . 4-28

4.4.3 BARCODE READER WAND . . . . . . . . . . . . . . . . . 4-28

4.5 MECHANICAL OVERVIEW . . . . . . . . . . . . . . . . . . . 4-28

4.5.1 CASSETTE . . . . . . . . . . . . . . . . . . . . . . . 4-29

4.5.2 MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . 4-32

4.5.2.1 MOTOR AND VALVE ASSEMBLIES. . . . . . . . . . . 4-32

4.5.2.2 A/B VALVE SUBSYSTEM . . . . . . . . . . . . . . . 4-32

4.5.2.3 INLET/OUTLET VALVE SUBSYSTEM . . . . . . . . . . 4-33

4.5.2.4 PLUNGER DRIVE SUBSYSTEM . . . . . . . . . . . . 4-33

Section 5

MAINTENANCE AND SERVICE TESTS . . . . . . . . . . . . . . . . . . 5-1

5.1 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . 5-1

5.1.1 CLEANING . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.2 SANITIZING . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 PERFORMANCE VERIFICATION TEST . . . . . . . . . . . . . . . 5-2

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

5.2.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2.3 TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.4 SELF TEST . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.5 CASSETTE ALARM TEST . . . . . . . . . . . . . . . . . . 5-6

5.2.6 FREE FLOW TEST . . . . . . . . . . . . . . . . . . . . . 5-6

5.2.7 DISPLAY TEST . . . . . . . . . . . . . . . . . . . . . . 5-6

5.2.8 KEYPAD VERIFICATION/FUNCTIONAL TEST . . . . . . . . . . 5-7

5.2.9 ALARM LOUDNESS TEST . . . . . . . . . . . . . . . . . 5-7

5.2.10 LOCKOUT SWITCH TEST. . . . . . . . . . . . . . . . . . 5-8

5.2.11 PROXIMAL OCCLUSION TEST. . . . . . . . . . . . . . . . 5-9

®

430-95424-002 (Rev. 01/06) iv Plum A+

3 Infusion System

CONTENTS

5.2.12 PROXIMAL AIR-IN-LINE TEST . . . . . . . . . . . . . . . . 5-9

5.2.13 DISTAL AIR-IN-LINE TEST . . . . . . . . . . . . . . . . . 5-10

5.2.14 DISTAL OCCLUSION TEST . . . . . . . . . . . . . . . . . 5-11

5.2.15 DELIVERY ACCURACY TEST . . . . . . . . . . . . . . . . 5-12

5.2.16 NURSE CALL TEST . . . . . . . . . . . . . . . . . . . . 5-13

5.2.17 ELECTRICAL SAFETY TEST . . . . . . . . . . . . . . . . . 5-13

5.2.18 END OF THE PVT . . . . . . . . . . . . . . . . . . . . . 5-13

5.5 PERIODIC MAINTENANCE INSPECTION . . . . . . . . . . . . . . 5-14

5.6 BATTERY OPERATION OVERVIEW . . . . . . . . . . . . . . . . 5-14

Section 6

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

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

6.2 WARNING MESSAGES . . . . . . . . . . . . . . . . . . . . . 6-1

6.3 ALARM MESSAGES AND ERROR CODES . . . . . . . . . . . . . . 6-2

6.3.1 OPERATIONAL ALARM MESSAGES . . . . . . . . . . . . . 6-2

6.3.2 ERROR CODES REQUIRING TECHNICAL SERVICE . . . . . . . . 6-7

6.4 TROUBLESHOOTING PROCEDURES. . . . . . . . . . . . . . . . 6-13

Section 7

REPLACEABLE PARTS AND REPAIRS . . . . . . . . . . . . . . . . . . 7-1

7.1 REPLACEABLE PARTS . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . 7-3

7.2.1 SAFETY AND EQUIPMENT PRECAUTIONS . . . . . . . . . . . 7-3

7.2.2 REQUIRED TOOLS AND MATERIALS . . . . . . . . . . . . . 7-3

7.2.3 RUBBER FOOT PAD REPLACEMENT . . . . . . . . . . . . . 7-4

7.2.4 BATTERY, BATTERY DOOR, AND DOOR PAD REPLACEMENT . . . 7-5

7.2.5 AC POWER CORD, RETAINER, AND VELCRO STRAP

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 7-7

7.2.6 SEPARATING THE FRONT ENCLOSURE, REAR ENCLOSURE,

AND MAIN CHASSIS ASSEMBLY . . . . . . . . . . . . . . . 7-8

7.2.7 PERIPHERAL INTERFACE ASSEMBLY REPLACEMENT . . . . . . 7-10

7.2.8 PERIPHERAL PWA REPLACEMENT . . . . . . . . . . . . . . 7-11

7.2.9 PERIPHERAL COMPONENT REPLACEMENT . . . . . . . . . . 7-13

7.2.9.1 VOLUME CONTROL KNOB REPLACEMENT . . . . . . . 7-13

7.2.9.2 PERIPHERAL COVER REPLACEMENT . . . . . . . . . . 7-14

7.2.10 FRONT/REAR ENCLOSURE GASKET REPLACEMENT . . . . . . . 7-16

7.2.11 LOWER FRONT ENCLOSURE GASKET REPLACEMENT . . . . . . 7-16

7.2.11.1 EMI GASKET REPLACEMENT . . . . . . . . . . . . . 7-17

7.2.11.2 KEYPAD GASKET REPLACEMENT . . . . . . . . . . . 7-18

7.2.11.3 TOP SEAL GASKET REPLACEMENT . . . . . . . . . . 7-18

7.2.12 REAR ENCLOSURE ASSEMBLY COMPONENT REPLACEMENT . . . 7-19

7.2.12.1 POLE CLAMP ASSEMBLY AND BACKING PLATE

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

7.2.12.2 INTERNAL AC POWER CORD REPLACEMENT . . . . . . 7-22

7.2.12.3 AC CONNECTOR REPLACEMENT . . . . . . . . . . . 7-22

7.2.12.4 FUSE REPLACEMENT . . . . . . . . . . . . . . . . 7-23

7.2.12.5 REAR ENCLOSURE GASKET REPLACEMENT . . . . . . . 7-24

7.2.13 MINIPOLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . 7-24

7.2.13.1 COTTER RING REPLACEMENT . . . . . . . . . . . . 7-25

7.2.13.2 BAG HANGER REPLACEMENT . . . . . . . . . . . . 7-26

7.2.13.3 CLUTCH HOUSING REPLACEMENT . . . . . . . . . . 7-26

7.2.13.4 CLUTCH SPRING REPLACEMENT . . . . . . . . . . . 7-27

7.2.14 MAIN CHASSIS ASSEMBLY COMPONENT REPLACEMENT. . . . . 7-27

7.2.14.1 POWER SUPPLY PWA REPLACEMENT . . . . . . . . . . 7-30

Technical Service Manual v 430-95424-002 (Rev. 01/06)

CONTENTS

7.2.14.2 KEYPAD REPLACEMENT. . . . . . . . . . . . . . . 7-30

7.2.14.3 DISPLAY ASSEMBLY REPLACEMENT . . . . . . . . . . 7-31

7.2.14.4 CPU/DRIVER CABLE REPLACEMENT . . . . . . . . . . 7-32

7.2.14.5 MOTOR POWER CABLE REPLACEMENT. . . . . . . . . 7-35

7.2.14.6 CPU PWA REPLACEMENT . . . . . . . . . . . . . . 7-35

7.2.14.7 PIEZO ALARM ASSEMBLY REPLACEMENT. . . . . . . . 7-36

7.2.14.8 MECHANISM ASSEMBLY REPLACEMENT . . . . . . . . 7-37

7.2.14.9 CASSETTE DOOR AND FLUID SHIELD REPLACEMENT . . . 7-38

7.2.14.10 OPENER HANDLE ASSEMBLY REPLACEMENT . . . . . . 7-41

Section 8

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

Section 9

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

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Figures

Figure 1-1. Display and Keypad . . . . . . . . . . . . . . . . . . . . . 1-7

Figure 1-2. Biomed Settings . . . . . . . . . . . . . . . . . . . . . . 1-9

Figure 1-3. IV Parameters . . . . . . . . . . . . . . . . . . . . . . . 1-10

Figure 1-4. Alarms Log . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Figure 1-5. Setting the Time and Date. . . . . . . . . . . . . . . . . . . 1-12

Figure 1-6. Common IV Parameters . . . . . . . . . . . . . . . . . . . 1-13

Figure 1-7. Macro IV Parameters . . . . . . . . . . . . . . . . . . . . 1-13

Figure 4-1. Electronic Functional Diagram . . . . . . . . . . . . . . . . . 4-2

Figure 4-2. Serial Interface to ADC. . . . . . . . . . . . . . . . . . . . 4-7

Figure 4-3. System Startup and Shutdown Timing, Battery Powered . . . . . . . . 4-15

Figure 4-4. Stepper Motor Coils . . . . . . . . . . . . . . . . . . . . . 4-18

Figure 4-5. Air Sensor Block Diagram. . . . . . . . . . . . . . . . . . . 4-20

Figure 4-6. Pressure Sensor Excitation and Amplifier Block Diagram . . . . . . . 4-22

Figure 4-7. Major Elements of the Dual-Channel Cassette . . . . . . . . . . . 4-30

Figure 4-8. Fluid Path in the Cassette . . . . . . . . . . . . . . . . . . . 4-31

Figure 4-9. Mechanism Valve Pins and Sensor Locations . . . . . . . . . . . . 4-33

Figure 5-1. Display and Keypad . . . . . . . . . . . . . . . . . . . . . 5-5

Figure 5-2. Rear View . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Figure 5-3. Special Cassettes with Bubble Sensor Tips Removed . . . . . . . . . 5-10

Figure 5-4. Distal Occlusion Test Setup . . . . . . . . . . . . . . . . . . 5-12

Figure 7-1. Bottom View . . . . . . . . . . . . . . . . . . . . . . . 7-4

Figure 7-2. AC Power Cord, Retainer, Velcro Strap, and Battery Assembly . . . . . 7-6

Figure 7-3. Separating the Front Enclosure, Rear Enclosure, and Main Chassis

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

Figure 7-4. Screw Placement Sequence . . . . . . . . . . . . . . . . . . 7-10

Figure 7-5. Peripheral Interface Assembly and Peripheral PWAs . . . . . . . . . 7-12

Figure 7-6. Peripheral Interface Assembly Components . . . . . . . . . . . . 7-15

Figure 7-7. Lower Front Enclosure Gaskets . . . . . . . . . . . . . . . . . 7-17

Figure 7-8. External Rear Enclosure Assembly Components . . . . . . . . . . . 7-19

Figure 7-9. Internal Rear Enclosure Assembly Components . . . . . . . . . . . 7-20

Figure 7-10. Minipole Assembly . . . . . . . . . . . . . . . . . . . . . 7-25

430-95424-002 (Rev. 01/06) vi Plum A+

®

3 Infusion System

CONTENTS

Figure 7-11. Main Chassis Components (1 of 2) . . . . . . . . . . . . . . . . 7-28

Figure 7-11. Main Chassis Components (2 of 2) . . . . . . . . . . . . . . . . 7-29

Figure 7-12. CPU/Driver Cable Routing . . . . . . . . . . . . . . . . . . 7-33

Figure 7-13. Ferrite Tape Positioning (1 of 2) . . . . . . . . . . . . . . . . . 7-34

Figure 7-13. Ferrite Tape Positioning (2 of 2) . . . . . . . . . . . . . . . . . 7-34

Figure 7-14. Fluid Shield Replacement . . . . . . . . . . . . . . . . . . . 7-39

Figure 7-15. Cassette Door and Opener Handle Assembly Replacement . . . . . . . 7-40

Figure 9-1. Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . 9-5

Figure 9-2. Front Enclosures, Rear Enclosure, and Main Chassis Assembly . . . . . 9-9

Figure 9-3. Front Enclosure Assemblies . . . . . . . . . . . . . . . . . . 9-11

Figure 9-4. Rear Enclosure Assembly . . . . . . . . . . . . . . . . . . . 9-13

Figure 9-5. Peripheral Interface Assembly . . . . . . . . . . . . . . . . . 9-17

Figure 9-6. Main Chassis Assembly . . . . . . . . . . . . . . . . . . . 9-19

Figure 9-7. CPU PWA, Display, and Keypad . . . . . . . . . . . . . . . . 9-23

Figure 9-8. CPU PWA and Main Chassis . . . . . . . . . . . . . . . . . . 9-25

Figure 9-9. AC Power Cord, Retainer, Batteries, and Minipole . . . . . . . . . . 9-27

Figure 9-10. Mechanism Assembly . . . . . . . . . . . . . . . . . . . . 9-29

Figure 9-11. Power Supply PWA Schematic . . . . . . . . . . . . . . . . . 9-31

Figure 9-12. Peripheral Interface PWA Schematic . . . . . . . . . . . . . . . 9-51

Figure 9-13. Peripheral PWA Schematic . . . . . . . . . . . . . . . . . . 9-63

Figure 9-14. CPU PWA Schematic. . . . . . . . . . . . . . . . . . . . . 9-71

Figure 9-15. Driver PWA Schematic . . . . . . . . . . . . . . . . . . . . 9-91

Figure 9-16. Switch PWA Schematic . . . . . . . . . . . . . . . . . . . . 9-97

Figure 9-17. APP PWA Schematic . . . . . . . . . . . . . . . . . . . . . 9-99

Tables

Table 1-1. Conventions. . . . . . . . . . . . . . . . . . . . . . . . 1-2

Table 1-2. System Configuration Data . . . . . . . . . . . . . . . . . . 1-9

Table 4-1. Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . 4-7

Table 4-2. Keypad Map. . . . . . . . . . . . . . . . . . . . . . . . 4-8

Table 4-3. CPU-Power Supply Interface . . . . . . . . . . . . . . . . . . 4-10

Table 4-4. CPU-Mechanism Interface Signals . . . . . . . . . . . . . . . . 4-11

Table 4-5. Power Supply PWA Interface Connections . . . . . . . . . . . . . 4-24

Table 4-6. Peripheral PWA Interface Connections . . . . . . . . . . . . . . 4-25

Table 4-7. Peripheral Interface PWA Interface Connections . . . . . . . . . . . 4-25

Table 4-8. CPU PWA Interface Connections . . . . . . . . . . . . . . . . 4-26

Table 4-9. Driver PWA Interface Connections. . . . . . . . . . . . . . . . 4-27

Table 4-10. APP PWA Interface Connections . . . . . . . . . . . . . . . . 4-27

Table 5-1. Cleaning Solutions . . . . . . . . . . . . . . . . . . . . . 5-2

Table 6-1. Warning Messages . . . . . . . . . . . . . . . . . . . . . 6-2

Table 6-2. Operational Alarm Messages and Corrective Actions . . . . . . . . . 6-3

Table 6-3. Error Codes Requiring Technical Service . . . . . . . . . . . . . 6-7

Table 6-4. Troubleshooting with the PVT . . . . . . . . . . . . . . . . . 6-13

Table 9-1. Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Table 9-2. IPB for the Infuser . . . . . . . . . . . . . . . . . . . . . 9-2

Technical Service Manual vii 430-95424-002 (Rev. 01/06)

CONTENTS

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430-95424-002 (Rev. 01/06) viii Plum A+

®

3 Infusion System

Section 1

INTRODUCTION

The Hospira Plum A+®3 infusion system is designed to meet the growing demand for
hospital wide device standardization. The system consists of three component infusers,
which are designated line 1, line 2, and line 3. By incorporating three lines into one unit,
the Plum A+
delivery capabilities. The Plum A+
needs. Compatibility with the LifeCare
accessories make the Plum A+

1.1

SCOPE

This manual is organized into the following sections:

❏ Section 1 Introduction

❏ Section 2 Warranty

❏ Section 3 System Operating Manual

❏ Section 4 Theory of Operation

❏ Section 5 Maintenance and Service Tests

❏ Section 6 Troubleshooting

❏ Section 7 Replaceable Parts and Repairs

❏ Section 8 Specifications

❏ Section 9 Drawings

❏ Appendices

❏ Index

❏ Technical Service Bulletins

®

3 provides three primary lines, three secondary lines, and piggyback fluid

®

3 serves a wide range of general floor and critical care

®

3 infusion system convenient and cost-effective.

®

5000 PlumSet® administration sets and

If a problem in device operation cannot be resolved using the information in this manual,

contact Hospira (see Section 6.1).

Specific instructions for operating the device are contained in the Plum A+
System Operating Manual. Provision is made for the inclusion of the system operating
manual in Section 3 of this manual.

®

and Plum A+®3

 Note: The terms “infusion system”, “infuser”, and “device” are used interchangeably

throughout the manual.

 Note: Figures are rendered as graphic representations to approximate actual product.

Therefore, figures may not exactly reflect the product.

 Note: Screen representations are examples only, and do not necessarily reflect the

most current software version.

Technical Service Manual 1 - 1 430-95424-002 (Rev. 01/06)

SECTION 1 INTRODUCTION

1.2

CONVENTIONS

The conventions listed in Table 1-1 are used throughout this manual.

Table 1-1. Conventions

Convention Application Example

Italic Reference to a section, figure,

table, or publication

[ALL CAPS] In-text references to keys

and touchswitches
ALL CAPS Screen displays CASSETTE TEST IN PROGRESS
Bold Emphasis CAUTION: Use proper ESD grounding

Throughout this manual, warnings, cautions, and notes are used to emphasize important
information as follows:

WARNING:

CAUTION: A CAUTION usually appears in front of a procedure or statement.
It contains information that could prevent hardware failure, irreversible damage
to equipment, or loss of data.

A WARNING CONTAINS SPECIAL SAFETY EMPHASIS AND MUST
BE OBSERVED AT ALL TIMES. FAILURE TO OBSERVE A WARNING
MAY RESULT IN PATIENT INJURY AND BE LIFE-THREATENING.

(see Section 6.1)

[START]

techniques when handling components.

 Note: A note highlights information that helps explain a concept or procedure.

1.3

COMPONENT DESIGNATORS

Components are indicated by alpha-numeric designators, as follows:

Battery BT Diode D Resistor R

Capacitor C Fuse F Switch SW

Crystal Y Integrated Circuit U Transistor Q

The number following the letter is a unique value for each type of component (e.g., R1, R2).

 Note: Alpha-numeric designators may be followed with a dash (-) number that

indicates a pin number for that component. For example, U15-13 is pin 13 of the
encoder chip [U15] on the interface PWA.

®

430-95424-002 (Rev. 01/06) 1 - 2 Plum A+

3 Infusion System

1.4 ACRONYMS AND ABBREVIATIONS

1.4

ACRONYMS AND ABBREVIATIONS

Acronyms and abbreviations used in this manual are as follows:

A Ampere

AC Alternating current

A/D Analog-to-digital

ADC Analog-to-digital converter

APP Air, pressure, and pin

BCR Barcode reader

CCA Clinical care area

CCFT Cold cathode fluorescent tube

CMOS Complementary metal-oxide semiconductor

CPU Central processing unit

DAC Digital-to-analog converter

DC Direct current

DIP Dual in-line package

DMA Direct memory access

DMM Digital multimeter

DPM Digital pressure meter

ECG Electrocardiograph

EEG Electroencephalogram

EEPROM Electrically erasable/programmable read-only memory

EMG Electromyogram

EMI Electromagnetic interference

ESD Electrostatic discharge

ETO Ethylene oxide

FPGA Field programmable gate array

FSR Force sensing resistor

hr Hour

Hz Hertz

ID Identification

I/O Input/output

IPB Illustrated parts breakdown

IV Intravenous

KB Kilobyte

kHz Kilohertz

KVO Keep vein open

lbs Pounds

Technical Service Manual 1 - 3 430-95424-002 (Rev. 01/06)

SECTION 1 INTRODUCTION

MOSFET Metal-oxide semiconductor field-effect transistor

Op-amp Operational amplifier

LCD Liquid crystal display

LED Light emitting diode

L/S Line select

MB Megabyte

MHz Megahertz

min Minute

mL Milliliter

mL/hr Milliliter per hour

MMIO Memory-mapped input/output

ms Millisecond

nF nanofarad

pF picofarad

PROM Programmable read-only memory

PVT Performance verification test

PWA Printed wiring assembly

PWM Pulse width modulator

RAM Random-access memory

rms Root-mean-square

RTC Real-time clock

SCC Serial communication controller

SCP Serial communication port

SMT Surface mount technology

SPI Serial peripheral interface

SRAM Static random access memory

TQFP Thin quad flat pack

V Volt

V

Volts AC

AC

V

Collector supply voltage

CC

VCO Voltage-controlled oscillator

Volts DC

V

DC

VSC 5 V

supply circuitry

DC

VSO Voltage sweep oscillator

VTBI Volume to be infused

WDI Watchdog input

µA Microampere

µL Microliter

µV Microvolt

µsec Microsecond

430-95424-002 (Rev. 01/06) 1 - 4 Plum A+

®

3 Infusion System

1.5 USER QUALIFICATION

1.5

USER QUALIFICATION

The infusion system is intended for use at the direction or under the supervision of licensed
physicians or certified healthcare professionals who are trained in the use of the infusion
system and the administration of parenteral and enteral fluids and drugs, and whole blood
or red blood cell components. Training should emphasize preventing related IV
complications, including appropriate precautions to prevent accidental infusion of air.
The epidural route can be used to provide anesthesia or analgesia.

1.6

ARTIFACTS

Nonhazardous, low-level electrical potentials are commonly observed when fluids are
administered using infusion devices. These potentials are well within accepted safety
standards, but may create artifacts on voltage-sensing equipment such as ECG, EMG,
and EEG machines. These artifacts vary at a rate that is associated with the infusion rate.
If the monitoring machine is not operating correctly or has loose or defective connections
to its sensing electrodes, these artifacts may be accentuated so as to simulate actual
physiological signals. To determine if the abnormality in the monitoring equipment
is caused by the infuser instead of some other source in the environment, set the device
so that it is temporarily not delivering fluid. Disappearance of the abnormality indicates
that it was probably caused by electronic noise generated by the infuser. Proper setup and
maintenance of the monitoring equipment should eliminate the artifact. Refer to the
appropriate monitoring system documentation for setup and maintenance instructions.

1.7

INSTRUMENT INSTALLATION PROCEDURE

CAUTION: Infusion system damage may occur unless proper care is exercised
during product unpacking and installation. The battery may not be fully charged
upon receipt of the infuser. Do not place the infuser in service if it fails the self test.

CAUTION: Infusion system performance may be degraded by electromagnetic
interference (EMI) from devices such as electrosurgical units, cellular phones,
and two-way radios. Operation of the infusion system under such conditions should
be avoided.

Accessory equipment connected to the analog and digital interfaces must be certified
according to the respective IEC standards (e.g., IEC 60950 for data processing equipment,
and IEC 60601-1 for medical equipment). Furthermore, all configurations shall comply
with the system standard IEC 60601-1-1. Any person who connects additional equipment
to the signal input or output part configures a medical system, and is therefore responsible
for ensuring that the system complies with the requirements of IEC 60601-1-1. If in doubt,

contact Hospira Technical Support Operations (see Section 6.1).

The instrument installation procedure consists of unpacking, inspection, and self test.

Technical Service Manual 1 - 5 430-95424-002 (Rev. 01/06)

SECTION 1 INTRODUCTION

1.7.1

UNPACKING

Inspect the shipping container as detailed in Section 1.7.2. Use care when unpacking the
infusion system. Retain the packing slip and save all packing material in the event it is
necessary to return the infuser to the factory. Verify the shipping container contains a copy
of the system operating manual.

1.7.2

INSPECTION

Inspect the shipping container for damage. Should any damage be found, contact the
delivering carrier immediately.

CAUTION: Inspect the infuser for evidence of damage. Do not use the device if it
appears to be damaged. Should damage be found, contact Hospira (see Section 6.1).

Inspect the infusion system periodically for signs of defects such as worn accessories,
broken connections, or damaged cable assemblies. Also inspect the infuser after repair
or during cleaning. Replace any damaged or defective external parts.

1.7.3

SELF TEST

CAUTION: Do not place the infuser in service if the self test fails.

 Note: Do not place the infuser in service if the battery is not fully charged. To make

certain the battery is fully charged, connect the infuser to AC power for six hours

(see Section 8).

 Note: If an alarm condition occurs during the self test, cycle the power and repeat the

self test. If the alarm condition recurs, note the message and take corrective action

(see Section 6). Repeat the self test. If the alarm condition continues to recur, remove

the infuser from service and contact Hospira.

 Note: Records prior to the date the infuser is received may be from the manufacturing

process. Disregard any events from dates prior to receipt of the infuser.

 Note: When performing the self test, line 1, line 2, and line 3 must be tested.

However, if appropriate, the test may be performed on all lines concurrently.

To perform the self test, see Figure 1-1, and proceed as follows:

1. Connect the AC power cord to a grounded AC outlet. Verify the charging/line

indicator CHARGE illuminates and an alarm beep sounds.

2. Without a cassette installed, press [ON/OFF] to turn on the infuser.

3. The LCD screen briefly displays the SELF TEST screen (see Figure 1-1).

 Note: If the SELF TEST screen does not appear, contact Hospira.

4. After the self test is complete, the message “INSERT PLUM SET CLOSE LEVER”
appears.

5. Verify the time and date. To set the time and date, see Section 1.8.3.

®

430-95424-002 (Rev. 01/06) 1 - 6 Plum A+

3 Infusion System

1.7 INSTRUMENT INSTALLATION PROCEDURE

ON/OFF

6. Open the cassette door and insert a primed cassette. Close the cassette door.
The cassette test is complete when the “CASSETTE TEST IN PROGRESS” message
disappears.

 Note: The message “MECHANISM INITIALIZATION IN PROGRESS” may briefly

appear prior to the “CASSETTE TEST IN PROGRESS” message.

7. The “CLEAR SETTINGS?” message may appear. Press the [YES] softkey.

8. Press [ON/OFF] to turn off the infuser.

LINE FLOW

INDICATORS

A B

HOSPIRA Plum A+

STATUS
REGION

MESSAGE
REGION

SOFTKEY
LABEL REGION

LINE
INDICATOR

Version X.XX MM/DD/YY

START

STOP

CHARGE

ON/OFF

Copyright Hospira Inc.

2005

System Self Test

In Progress

1

4

2
5

78

CLEAR

0

3
6

9

.

WORKING

REGION

SOFTKEYS

SELECT

KEYPAD

SILENCE

05K01002

Figure 1-1. Display and Keypad

Technical Service Manual 1 - 7 430-95424-002 (Rev. 01/06)

SECTION 1 INTRODUCTION

1.8

BIOMED SETTINGS

The biomed settings screens contain the following options that can be changed or reviewed
by qualified personnel:

- IV screen parameters

- Alarms log

- Set time and date

All infusers (new or refurbished) are shipped with factory settings (see Table 1-2).

 Note: Biomed screens do not time out for the Infuser Idle alarm or No Action alarm.
 Note: The battery will not be detected in the biomed service mode.

To access the biomed settings, proceed as follows:

1. Open the door and turn on the device. The infusion system will perform a self test.

2. After the self test is complete, the message “INSERT PLUM SET CLOSE LEVER”

appears. Press the decimal [.] key, then [START], and verify the BIOMED SETTINGS
screen is displayed (see Figure 1-2)

.

 Note: The [CHANGE BATTERY] softkey does not appear on earlier versions

of the Plum A+

®

3.

430-95424-002 (Rev. 01/06) 1 - 8 Plum A+

®

3 Infusion System

1.8 BIOMED SETTINGS

Table 1-2. System Configuration Data

Data Options Range Factory Setting

Maximum macro IV mode delivery rate 0.1 - 99.9 mL/hr and

100 - 999 mL/hr

Macro distal occlusion alarm
(pressure level)

Deliver together enable Concurrent or Piggyback Piggyback
Delayed start/standby enable Yes or No Yes
Continue rate Rate or KVO KVO
Nurse callback default Yes or No No
Time (24 hr) 00:00 - 23:59 in

Date 1/1/2002 - 12/31/2098 Factory date

1 to 15 psi 6 psi

one minute increments

999 mL/hr

Factory time

BIOMED SETTINGS

IV Screen Parameters

Alarm Log

Set Time and Date

Select, then Choose

Change
Battery

Figure 1-2. Biomed Settings

Choose

05K03010

Technical Service Manual 1 - 9 430-95424-002 (Rev. 01/06)

SECTION 1 INTRODUCTION

1.8.1

IV PARAMETERS

The IV parameters screen contains common IV parameters and macro IV parameters

(see Figure 1-3).

To change the IV parameters, see Figure 1-6 and Figure 1-7, then proceed as follows:

1. Access the biomed settings screen as described in Section 1.8.

2. Select IV Screen Parameters, and press [CHOOSE].

3. Select the parameters to be changed, and press [CHOOSE].

4. Using the [CHANGE VALUE] softkey, select the desired value, and press [ENTER].

5. Repeat step 3 and step 4 for each parameter to be changed.

6. If there are no other changes, turn off the infuser.

BIOMED SETTINGS

IV Parameters

Common IV Parameters

Macro IV Parameters

Select, then Choose

Choose Back

Figure 1-3. IV Parameters

00H03003

430-95424-002 (Rev. 01/06) 1 - 10 Plum A+

®

3 Infusion System

1.8 BIOMED SETTINGS

1.8.2

ALARMS LOG

 Note: The alarms log will retain the latest 40 alarm and malfunction codes, listed

in order from the most current to the oldest.

To view the alarms log, see Figure 1-2 and Figure 1-4, then proceed as follows:

1. Access the biomed settings screen as described in Section 1.8.

2. Select Alarms Log, and press [CHOOSE}.

3. Use the [PAGE UP] and [PAGE DOWN] softkeys to view the alarms log.

4. Press the [BACK] softkey to exit the alarms log and return to the main biomed
settings screen.

ALARMS LOG

6/23/04 01:43:01 E437 S/W Failure # 202
6/23/04 09:18:10 N190 Neg. Prox. Occl. A
6/22/04 23:44:11 N102 Infuser Idle 2 minutes
6/22/04 21:43:14 N161 Line A VTBI complete
6/22/04 11:44:20 N106 Distal occlusion
6/22/04 09:43:07 N161 Line A VTBI complete
6/22/04 06:23:20 N160 Line B VTBI complete
6/22/04 03:40:13 N101 No action alarm

Page

Up

Figure 1-4. Alarms Log

Page

Down

Back

05K03008

Technical Service Manual 1 - 11 430-95424-002 (Rev. 01/06)

SECTION 1 INTRODUCTION

1.8.3

SETTING THE TIME AND DATE

 Note: The infusion system will automatically display February 29 on leap years.
 Note: Daylight savings and time zone changes must be made manually.

To set the time and date, see Figure 1-5, then proceed as follows:

1. Access the biomed settings screen as described in Section 1.8.

2. Select Set Time and Date, and press [CHOOSE].

3. Select the parameter to be changed.

4. Enter the desired value.

5. Repeat step 3 and step 4 for each parameter to be changed.

6. Verify the time and date are correct, then press [ENTER] to return to the biomed
settings screen.

7. If there are no other changes, turn off the infuser.

BIOMED SETTINGS

Set Time and Date

Time : 22 hr:min
Year 2005
Month 02
Day 14

Enter value using keypad

Figure 1-5. Setting the Time and Date

14

Enter

Cancel/

Back

05K13004

430-95424-002 (Rev. 01/06) 1 - 12 Plum A+

®

3 Infusion System

BIOMED SETTINGS

Common IV Parameters

1.8 BIOMED SETTINGS

Continue Rate
Deliver Together

KVO

Concurrent

Enable Delay/Standby
Callback Default

Select using Change Value

Change

Value

Figure 1-6. Common IV Parameters

Enter

Cancel/

BIOMED SETTINGS

Yes

No

Back

02K03004

Macro IV Parameters

Default Distal Press
Max Rate

Enter Value using keypad

Enter

Figure 1-7. Macro IV Parameters

6.0 psi

999 mL/hr

Cancel/

Back

00K13005

Technical Service Manual 1 - 13 430-95424-002 (Rev. 01/06)

SECTION 1 INTRODUCTION

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430-95424-002 (Rev. 01/06) 1 - 14 Plum A+

®

3 Infusion System

Section 2

WARRANTY

Subject to the terms and conditions herein, Hospira, Inc., herein referred to as Hospira,
warrants that (a) the product shall conform to Hospira's standard specifications and be
free from defects in material and workmanship under normal use and service for a period
of one year after purchase, and (b) the replaceable battery shall be free from defects
in material and workmanship under normal use and service for a period of 90 days after
purchase. Hospira makes no other warranties, express or implied, as to merchantability,
fitness for a particular purpose, or any other matter.

Purchaser's exclusive remedy shall be, at Hospira's option, the repair or replacement
of the product. In no event shall Hospira's liability arising out of any cause whatsoever
(whether such cause be based in contract, negligence, strict liability, other tort,
or otherwise) exceed the price of such product, and in no event shall Hospira be liable for
incidental, consequential, or special damages or losses or for lost business, revenues,
or profits. Warranty product returned to Hospira must be properly packaged and sent
freight prepaid.

The foregoing warranty shall be void in the event the product has been misused, damaged,
altered, or used other than in accordance with product manuals so as, in Hospira's
judgment, to affect its stability or reliability, or in the event the serial or lot number has
been altered, effaced, or removed.

The foregoing warranty shall also be void in the event any person, including the Purchaser,
performs or attempts to perform any major repair or other service on the product without
having been trained by an authorized representative of Hospira and using Hospira
documentation and approved spare parts. For purposes of the preceding sentence,
“major repair or other service” means any repair or service other than the replacement
of accessory items such as batteries, flow detectors, detachable AC power cords, and
patient pendants.

In providing any parts for repair or service of the product, Hospira shall have no
responsibility or liability for the actions or inactions of the person performing such repair
or service, regardless of whether such person has been trained to perform such repair
or service. It is understood and acknowledged that any person other than an Hospira
representative performing repair or service is not an authorized agent of Hospira.

Technical Service Manual 2 - 1 430-95424-002 (Rev. 01/06)

SECTION 2 WARRANTY

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430-95424-002 (Rev. 01/06) 2 - 2 Plum A+

®

3 Infusion System

Section 3

SYSTEM OPERATING MANUAL

A copy of the system operating manual is included with every Plum A+®3 infusion system.
Insert a copy here for convenient reference. If a copy of the system operating manual is not
available, contact Hospira Technical Support Operations (see Section 6.1).

Technical Service Manual 3 - 1 430-95424-002 (Rev. 01/06)

SECTION 3 SYSTEM OPERATING MANUAL

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430-95424-002 (Rev. 01/06) 3 - 2 Plum A+

®

3 Infusion System

Section 4

THEORY OF OPERATION

This section describes the Plum A+®3 theory of operation. The theory of operation details
the general description, electronic subsystem overview, printed wiring assemblies,
remote mounted peripherals, and mechanical overview of the infusion system.
Related drawings are provided in Section 9.

4.1

GENERAL DESCRIPTION

The infusion system includes the following features:

- Dose calculation

- Loading dose

-Multi-step programming

- Therapy selection

-Nurse call

- Delayed start setting

- Standby mode

- Drug label library

- Piggyback and concurrent
delivery modes

-Titration

- 0.1-99.9 mL/hr flow rate
range for both lines
(in 0.1 mL/hr increments)

- 100-999 mL/hr flow rate
range for both lines
(in 1.0 mL/hr increments)

- Anti free-flow protection

- Air removal/backpriming

- Air detection (proximal and distal)

- Serial communication

-Alarm history

- Volumes infused
(A, B, total volumes)

- KVO at dose end (1.0 mL/hr
or less depending on delivery rate)
or continue rate to continue

- Variable distal pressure setting

- Nonpulsatile volumetric accuracy

- Microprocessor control

-Large display

- Panel back illumination
on mains power

- Lockout switch

- Standard fullfill, partfill, syringe,
and vial use

- Enteral and parenteral fluid delivery

- Blood and blood product delivery

- Battery gauge

Technical Service Manual 4 - 1 430-95424-002 (Rev. 01/06)

- Wide range of standard and specialty
administration sets

SECTION 4 THEORY OF OPERATION

Alarms include the following:

- Distal occlusion

- Proximal occlusion

- Proximal air-in-line

- Distal air-in-line

-Low battery

- Door open while pumping

- Lockout violation

-VTBI complete

- Valve/cassette test failure

-Nurse call

- No action alarm

- Infuser idle for two minutes

4.2

ELECTRONIC SUBSYSTEM OVERVIEW

This section describes the function and electronic circuitry of three main subsystems
in the infusion system: CPU subsystem, power supply subsystem, and mechanism
subsystem (see Figure 4-1). Schematic diagrams of PWAs are located in Section 9.

 Note: An asterisk (*) denotes an active low or negative true logic signal.

Battery

Power Supply PWA

Peripheral PWA

Pressure Sensors

SYSTEM 1

Pressure Sensors

SYSTEM 2

Pressure Sensors

SYSTEM 3

Plunger, LS, & IO Motors

MECHANISM

Battery

Plunger, LS, & IO Motors

MECHANISM

Battery

Plunger, LS, & IO Motors

MECHANISM

APP PWA

Switches PWA

Flex FSR

Power Supply PWA

APP PWA

Switches PWA

Flex FSR

Power Supply PWA

APP PWA

Switches PWA

Flex FSR

Driver
PWA

Driver

PWA

Driver

PWA

CPU
PWA

CPU
PWA

CPU
PWA

LCD Display

Keypad

LEDs

On/Off Switch

FRONT PANEL

Main Piezo Buzzer

Peripheral PWA

LCD Display

Keypad

LEDs

On/Off Switch

FRONT PANEL

Main Piezo Buzzer

Peripheral Interface PWA

LCD Display

Keypad

LEDs

On/Off Switch

FRONT PANEL

Main Piezo Buzzer

Figure 4-1. Electronic Functional Diagram

430-95424-002 (Rev. 01/06) 4 - 2 Plum A+

05K07015

®

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.1

CPU SUBSYSTEM

The CPU subsystem contains the main microcontroller, which is responsible for controlling
the display/keyboard interface, external communications interfaces, barcode reader (BCR)
interface, and system management.

The CPU subsystem provides the following functions:

- External memory devices access

-LCD interfaces

-Real-time clock generator interface

-System watchdog

- Analog-to-digital and digital-to-analog converter interface

- Keypad interfaces

- Control and monitor status signals, such as LEDs, audible alarms,
volume control, nurse call switch, and lockout switch

- Serial communication with host computer (DataPort) and barcode reader

- Power supply subsystem interface

- Mechanism subsystem interface

4.2.1.1

CPU

The central processing unit is a Motorola MC68302 CPU. The CPU has a closely coupled
16 bit data bus and 24 bit address bus, MC68000 microprocessor core, a system
integration block for peripherals, and an RISC communications processor. The MC68302
is packaged in a 144 pin thin quad flat pack (TQFP) package and operates from a 3.3 V
power supply. The on-chip peripheral devices are isolated from the system through the
dual port RAM. The 1152 byte dual port RAM has 576 bytes of system RAM and 576 bytes
of parameter RAM, which contains various peripheral registers, parameters, and the buffer
descriptors for each of the three serial communication controller (SCC) channels and the
serial communication port (SCP) channels. The 24 bit address bus is capable of accessing
up to 16 MB of data.

4.2.1.2

DC

SYSTEM MEMORY ADDRESS MAP

The CPU has a 24 bit address bus when combined with UDS*/A0. The address bus
is a bi-directional, three state bus capable of addressing 16 MB of data that is configured
as 16 bits per word (including the IMP internal address space). Each of the four
programmable chip-select lines has two registers that define the starting address
of a particular address space and the block size.

Technical Service Manual 4 - 3 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

4.2.1.3

PROGRAMMABLE READ-ONLY MEMORY

The CPU subsystem has two 512 K x 8 bit programmable read-only memory (PROM)
memory devices, which provide a total of 1024 KB. The PROM space is expandable up to
2 MB. The PROM memory devices operate off the 3.3 V

supply. The CPU chip-select

DC

0 pin (CS0*), is connected to the PROM chip-enable (CE*) pin (signal CSROM*). This special
chip-select signal can support bootstrap operation after reset. The interface to the CPU is
the 16 bit data bus, and a 19 bit address bus. The address bus is connected to the
ADDR<19:1> lines, and the data bus is connected to the DATA<15:0> lines.

4.2.1.4

STATIC RANDOM ACCESS MEMORY

There are two 512 K x 8 bit CMOS static random access memory (SRAM) devices, which
provide a total of 1024 KB of data memory. During an SRAM read or write cycle, the
chip-enable (CE*) is controlled by the CPU chip-select pin 1 (CS1*, signal name (CSRAM*)).
The SRAM space is expandable up to 2 MB. The SRAM operates off the 3.3 V
The CPU subsystem includes the additional SRAM for video buffer and real-time clock

(see Section 4.2.1.6 and Section 4.2.1.9).

supply.

DC

4.2.1.5

CONTROL LOGIC

The CPU PWA uses field programmable gate arrays (FPGA), which are high density, high
speed, I/O intensive general purpose devices. They are used to implement all the digital
control functions, including: memory-map address decoding; memory read-write enable;
direct memory access (DMA) request; I/O status signals; chip-select control; motor control;
sensor select; and power up/system reset control.

4.2.1.6

LCD CONTROLLER

The liquid crystal display (LCD) controller is used to interface the LCD to the CPU.
The device displays layered text and graphics, scrolls the display in any direction,
and partitions the display into multiple screens. It stores bit-mapped graphic data in
external frame buffer memory. The display controller functions include: transferring data
from the controlling microprocessor to the buffer memory; reading memory data;
converting data to display pixels; and generating timing signals for the buffer memory and
LCD panel. The LCD controller accesses 32 KB of frame buffer SRAM (video) via the
controller’s video address and data busses (VA<14:0> and VD<7:0>). The LCD controller
external clock frequency is 8 MHz. The LCD controller and the display memory are operated
off the 3.3 V
interface with the 5 V

supply. The output signal levels are shifted up to 5 VDC by buffers for

DC

LCD panel.

DC

The interface to the CPU is through the lower 8 bits of the data bus, which is connected
to DATA<7:0> lines, address line A1, and LCD chip-select signal CSLCD* (CS2*).
This controller is also configured as 8080 family compatible interface device with all the
control signals, such as WRLCD* (WR*) and RDLCD* (RD*), generated by the FPGA logic.

®

430-95424-002 (Rev. 01/06) 4 - 4 Plum A+

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.1.7

LCD BACKLIGHT CONTROL

The LCD panel is backlit by a cold cathode fluorescent tube (CCFT) lamp. The CCFT lamp
requires 300 V
to deliver a current regulated sine wave to the lamp. A switching regulator regulates the
CCFT current by monitoring feedback pin 3, and varies its output duty cycle to drive a
DC/AC inverter. Intensity control is achieved by superimposing a DC control signal with
the feedback signal. The DC control signal is sourced by a voltage divider consisting of
a digitally controlled non-volatile potentiometer and three series diodes.

The CPU can adjust LCD backlight intensity by selecting the digitally controlled
non-volatile potentiometer and controlling TUBU/D and TUBINC* signals.
The potentiometer has a five bit up/down counter with non-volatile memory. It is used to
store one of 31 settings of the potentiometer. Each count represents 323 Ω with a range
of 323 to 10 KΩ. The current counter value is stored in non-volatile memory after CSTUB*
is returned high while the TUBINC* input is also high. The current counter value is not
stored if CSTUB* is returned high and TUBINC* is low. The CCFT intensity is directly
proportional to the CCFT current, where 0 mA
is maximum intensity. The CCFT current is inversely proportional to the counter value.

to operate; a current controlled DC-to-AC voltage inverter circuit is used

rms

is minimum intensity and 5 mA

rms

rms

4.2.1.8

LCD CONTRAST CONTROL

A digitally adjustable LCD bias supply is used to control the LCD contrast over a range
of -24
converter (DAC). The CPU provides two signals, LCDADJ (ADJ) and LCDCTL (CTL),
to interface with this device. On power up or after a reset, the counter sets the DAC output
to the mid-range value. Each rising edge of LCDADJ increments the DAC output.
When incremented beyond full scale, the counter rolls over and sets the DAC to the
minimum value. Therefore, a single pulse applied to LCDADJ increases the DAC set point
by one step, and 63 pulses decrease the set point by one step.

4.2.1.9

to -8 VDC. It is digitally adjustable in 64 equal steps by an internal digital-to-analog

REAL-TIME CLOCK

The watchdog timekeeper chip includes a complete real-time clock/calendar (RTC),
watchdog timer, alarm, and interval timer. The time/date information includes
hundredths of seconds, seconds, minutes, hours, date, month, and year. The date at the
end of the month is automatically adjusted for months with less than 31 days, including
correction for leap year. The watchdog timekeeper operates in either 24-hour or 12-hour
format with an AM/PM indicator. The device can be programmed to set up an interval
timer, and it can generate an alarm every day, hour, or minute. These alarm functions
ma y be use d to schedule real-time related activities. A parallel resonant 32,768 Hz crystal
oscillator drives the internal time base.

The external interface is a separate (non-multiplexed) 8 bit data bus and 6 bit address
bus, with a contiguous address space of 64 bytes. When system power is turned off,
a battery voltage input is available, which makes the RTC data non-volatile. The address
bus is connected to the ADDR<6:1> lines, and the data bus is connected to DATA<7:0>
lines. Since the CPU accesses are 16 bits wide, the RTC data is on the lower byte of the
word. The RTC chip-enable pin (CE*) is active low enabled for read and write operations.
It is driven by the FPGA control logic, chip-select RTC signal (CSRTC*), which involves
address decoding circuitry (see Section 4.2.1.2).

Technical Service Manual 4 - 5 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

4.2.1.10

VOLTAGE MONITOR WATCHDOG TIMER

It is important to protect the system during power transitions, and the CPU is reset after
the V
automatic reset output during power up, power down, or brownout conditions. When the
V

CC

and holds the microprocessor in reset for approximately 200 ms after V
the threshold. The supervisory circuit includes a chip-select inhibit circuit, which is used
to disable access to the real-time clock’s non-volatile SRAM during power transitions and
power down mode.

This device also provides a watchdog timer function to monitor the activity of the
microprocessor. To service the watchdog timer immediately after reset, the device has
a longer time-out period (1.6 second minimum) right after a reset. The normal time-out
period (70 ms minimum) is effective after the first transition of watchdog input (WDI) after
RESET* is inactive. If the microprocessor does not toggle WDI within the time-out period,
both RESET* and watchdog out (WDO*) outputs are asserted low. The RESET* remains
active low for a minimum of 140 ms and it resets the CPU. The WDO* remains low as long
as the WDI remains either high or low for longer than the watchdog time-out period.
After a reset, the software reads this memory-mapped bit to determine if the latest reset
was a watchdog time-out.

power supply is applied. The microprocessor supervisory circuit generates an

CC

falls below the reset threshold voltage of 2.9 VDC, the reset signal (RESET*) goes low

rises above

CC

4.2.1.11

ANALOG-TO-DIGITAL CONVERTER

The analog-to-digital converter (ADC) monitors the proximal pressure sensor, distal
pressure sensor, proximal air sensor, distal air sensor, battery charge/discharge current,
battery voltage, buzzer test signal, LCD contrast voltage, CCFT test signal, and two chopper
motor drive reference voltages. The ADC is an advanced 10 bit accurate, 11 channel,
switched-capacitor, successive-approximation device. It has three inputs and a three-state
output (chip-select, I/O clock, address input, and data out) that provide a direct four-wire
interface to the serial communication port of the CPU. The ADC is designed to be used in
conjunction with multiple serial devices on a common bus; consequently, the data-out
pin is driven only when the chip-select (CS*) pin is asserted. Figure 4-2 illustrates the
serial interface between the ADC and the CPU.

In addition to a high-speed ADC and versatile control capability, this device has an on-chip
14 channel multiplexer that can select any one of 11 analog inputs or any one of three
internal self test voltages. The sample-and-hold function is automatic.
The end-of-conversion (EOC) output goes high to indicate that conversion is complete.
The CPU polls the EOC signal.

Channel selection and conversion results are transferred through the SCP pins. A serial
transfer synchronizing clock (SPCLK) must be fed into the I/O clock input pin when the
CS* pin is driven low. The address to be converted is serially transmitted into the address
pin, and the conversion results are serially shifted out the data-out pin. Typical access
time is 21 µsec. The APP PWA is the source of the 2.5 V
inputs are selected by the channel multiplexer according to the input address

(see Table 4-1). The input multiplexer is a break-before-make type to reduce input-to-input

noise injection resulting from channel switching.

reference voltage. The analog

DC

430-95424-002 (Rev. 01/06) 4 - 6 Plum A+

®

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

ANALOG
INPUTS

U4

A0

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

GND

CS*

I/O CLOCK

ADDRESS

DATA OUT

EOC

REF+

REF-

GDIG

Figure 4-2. Serial Interface to ADC

CPU

I/O

SPCLK

SPTXD SCP

SPRXD

I/O
(OR INTERRUPT)

2.5V

GANA

98K01022

Table 4-1. Analog Inputs

Signal Name Analog Input Address (hex) Description

PRPRS A0 $00 Proximal pressure sensor

DIPRS A1 $01 Distal pressure sensor

PXAIR A2 $02 Proximal air sensor

DIAIR A3 $03 Distal air sensor

IBATT A4 $04 Battery current

VBATT A5 $05 Battery voltage

BUZTST A6 $06 Buzzer test voltage

LCDTST A7 $07 LCD contrast test voltage

TUBTST A8 $08 CCFT intensity test voltage

MI_STA A9 $09 Motor current A control

MI_STB A10 $0A Motor current B control

$0B (V

$0C V

ref(+)

ref(-)

- V

ref(-)

) / 2

$0D V

Technical Service Manual 4 - 7 430-95424-002 (Rev. 01/06)

ref(+)

SECTION 4 THEORY OF OPERATION

4.2.1.12

DIGITAL-TO-ANALOG CONVERTER

The dual 8 bit digital-to-analog converter (DAC) generates two analog signals to control
the phase A and phase B motor coil currents. The interface between the DAC device and
the CPU is the 8 bit data bus, which is connected to DATA15:8. All the control signals for
this DAC are generated by FPGA logic devices. Buffer amplifier/ground compensation
circuits condition the DAC outputs.

4.2.1.13

FRONT PANEL KEYPAD MATRIX

A 5 x 5 membrane switch keypad matrix is located on the front panel. The keypad column
lines (COL4:0) are driven by open collector type memory mapped input ports, while the
keypad row lines (ROW4:0), are read by memory mapped input ports (see Table 4-2).
The keypad strobing, scanning, and switch de-bouncing is accomplished by software.
The keypad interface is designed with ESD protection.

Table 4-2. Keypad Map

COL 0 COL 1 COL 2 COL 3 COL 4

Row 4 Softkey 1 Softkey 2 Softkey 3 Softkey 4

Row 3 Start123[

Row 2 Stop456

Row 1 789[

Row 0 On/Off Clear 0

4.2.1.14

.

]

]

Silence

FRONT PANEL [ON/OFF] KEY

The [ON/OFF] key on the front panel provides a start up (STRTUP) signal to wake up the
power supply when the system is shutdown. When activated during normal operation,
the [ON/OFF] key interrupts (STRUPD*) the CPU, signaling a request for shutdown.

4.2.1.15

FRONT PANEL LED INDICATORS

The CPU drives the three light emitting diode (LED) indicators embedded in the front panel.
Two memory mapped I/O signals activate the two LED lights used to indicate which
channel is in delivery mode (LEDAE*, LEDBE*). The AC power on LED indicates the status
of AC power (LEDAC) and that the system is in the battery charge mode. A buffered AC
on signal (BACON) drives the LED and is active only when AC power is present.

430-95424-002 (Rev. 01/06) 4 - 8 Plum A+

®

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.1.16

KEYPAD LOCKOUT INTERFACE

A lockout switch (SW1) on the peripheral interface PWA locks the front panel keypad for
all three infusers. A memory mapped input port (LOTSW*) reads the switch. The switch
serves as a lockout request and software performs the lockout.

4.2.1.17

NURSE CALL INTERFACE

A nurse call relay switch on the peripheral interface PWA indicates alarm conditions to
a remote operator. A memory-mapped output signal (NURSE) activates the relay during
alarm conditions. The relay has both normally open and normally closed contacts.
A jumper on the peripheral interface board selects the contact type. The factory setting is
normally open.

4.2.1.18

AUDIBLE INDICATORS

There are two audible indicators on the CPU subsystem. Three loud, main audible
indicators are mounted on the main chassis. This main alarm is used to alert the operator
to alarm conditions. A keypad beeper, with lower power and a distinctly different tone,
is used to provide audible feedback to the operator. The keypad beeper is driven by
a memory-mapped output (KEYALM). It is used to indicate keypad activation,
and confirmation to the operator.

The main alarm has an adjustable volume control on the peripheral interface PWA,
mounted on the rear of the device. The main alarm can be activated by either
a memory-mapped control (MAINALM), the reset pulse(s), or by a power failure alarm latch.
The main alarm will sound a chirp for every reset pulse sent by the watchdog timer IC.
Continuous chirping indicates a stuck processor.

The alarm is activated continuously during power failure. If the control software does not
shut down power in a proper sequence, a latch on the CPU PWA, powered by a backup
supply (0.1 F supercap), will activate a continuous alarm. This continuous alarm sounds
until either the backup supply is discharged or the user resets the latch by pressing the
[ON/OFF] key. Reliable operation of the main alarm is assured by software monitoring
of a buzzer test signal (FBUZTST) via the ADC.

4.2.1.19

BARCODE READER INTERFACE

 Note: The barcode reader feature will not be present on later versions of the Plum A+

®

3.

The CPU communicates with a barcode wand that is connected to the peripheral PWA
from the rear of the infuser. The barcode wand reads and decodes a Code 128 barcode
symbology and outputs the barcode data via an RS-232 port using an asynchronous, serial
ASCII format.The software controls power to the barcode reader and to the interface
circuits via memory-mapped outputs BARPWR and COMPWR*. The barcode reader
is isolated from the main system by an optical data path on the peripheral PWA and an
isolated power supply.

Technical Service Manual 4 - 9 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

4.2.1.20

DATAPORT INTERFACE

The CPU communicates with an external computer by way of a DataPort interface.
The DataPort interface provides for remote monitoring of up to four infusers using a host
computer with a modified RS-232-D serial interface. Infusers are either connected directly
to the host or in a daisy chain configuration using junction boxes that provide a 5 bit hard
ID via DIP switches on the junction box. The DIP switches are buffered and read by the
CPU via the memory-mapped input/output (MMIO) port.

The DataPort system conforms to the EIA-232-D standard, with the following exceptions:

- DataPort uses non-standard DB-15 and 6 pin modular connectors in addition
to the standard DB-25 and DB-9 connectors

- With DataPort, more than one infuser is allowed on the line

- The minimum line impedance is 2 KΩ (EIA-232-D standard: 3 KΩ min.)

- The maximum line impedance is 30 KΩ (EIA-232-D standard: 7 KΩ max.)

- The maximum line capacitance is 13 nF (EIA-232-D standard: 2,500 pF)

The communications default is 1200 BAUD, no parity, 8 data bits and 1 stop bit. The BAUD
rate is selectable (1200, 2400, 4800, and 9600). The data format on the serial port is
a 10 bit frame with asynchronous start and stop. The CTS line is held high and the RTS
line is disconnected.

The DataPort is isolated from the main system by an optical data path on the peripheral
PWA and an isolated power supply.

4.2.1.21

POWER SUPPLY INTERFACE

The CPU subsystem interfaces the power supply subsystem by providing the MMIO signals
needed for power control and battery management. Additionally, the CPU subsystem
measures the battery terminal voltage and charge/discharge current via the ADC.

See Table 4-3 for CPU-power supply interface signals.

Table 4-3. CPU-Power Supply Interface

Signal Name Typ e Description

PWRHLD D, O Holds system power on

STRTUP A, I Startup pulse from the [ON/OFF] key

STRUPD* D, I Digital startup pulse, used as interrupt to the CPU

V3_3 P 3.3 V system power

V5_0/VANA P 5 V analog and interface power

VMOT P Raw, unregulated charger voltage or battery voltage

V2_7 P 2.7 V backup power for RTC and non-volatile SRAM

VSC P Full time 5 V supply, backed up by supercap

®

430-95424-002 (Rev. 01/06) 4 - 10 Plum A+

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

Table 4-3. CPU-Power Supply Interface

Signal Name Typ e Description

V12_0 P 12 V, low current supply for audio alarm

OVRVLT* D, I Signal that indicates overvoltage, regulation problem

on the power supply main regulator

BACON D, I Buffered AC on signal

IBATT A, I Voltage proportional to integration of battery

charge/discharge current

VBATT A, I Divided battery terminal voltage

CHG* D, O Battery charger enable

VFLOAT* D, O Set the main regulator voltage to battery float charge level

ITGRST D, O Reset the charge current integrator

Legend: P = Power; A = Analog; D = Digital; I = Input; O = Output

4.2.1.22

MECHANISM INTERFACE

The CPU subsystem provides the MMIO ports for interface to the mechanism subsystem,
in addition to the analog interface mentioned in the ADC and DAC sections

(see Section 4.2.1.11 and Section 4.2.1.12).

See Table 4-4 for CPU-mechanism interface signals.

Table 4-4. CPU-Mechanism Interface Signals

Signal Name Type Description

MI_STA A, O Motor current set for phase A

MI_STB A, O Motor current set for phase B

GDAC A, O Ground signal from chopper (for compensation)

M_PHA D, O Motor phase A

M_PHB D, O Motor phase B

M_SEL1, M_SEL0 D, O Motor select bits

FLCAME D, O I/O and L/S cam flag sensors enable

FLPINE D, O L/S pin motion detectors enable

FLPLE D, O Plunger motor sensor pair enable

FLLS_C D, I Flag, L/S valve cam sensor

FLIO_C D, I Flag, I/O valve cam sensor

FLLS_A D, I Flag, L/S valve A pin detector

Technical Service Manual 4 - 11 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

Table 4-4. CPU-Mechanism Interface Signals

Signal Name Type Description

FLLS_B D, I Flag, L/S valve B pin detector

FLPLRO D, I Flag, plunger rotation sensor

FLPLTR D, I Flag, plunger translation sensor

PXPRE D,O Proximal pressure sensor enable

PXPRS A, I Proximal pressure sensor

DIPRE D, O Distal pressure sensor enable

DIPRS D, O Distal pressure sensor

PXARE D, O Proximal air sensor enable

PXAIR A, I Proximal air sensor

DIARE D, O Distal air sensor enable

DIAIR A, I Distal air sensor

CASPR* D, I Cassette present

CASS2*, CASS1*, CASSO* D, I Cassette type coding: Macro (111), Micro (010),

all others are invalid

SPCLK D, O SCP clock output

SPRXD D, I SCP receive data

SPTXD D, O SCP transmit data

CSSEP* D, O Chip select, EEPROM

V5_0 P 5 V supply for interface power

V3_3 P 3.3 V supply for logic power

GDIG P Digital ground

VANA P 5 V supply for analog power

GANA P Analog ground

VMOT, GMOT P Motor power is directly from power supply PWA

V2_5 A, I Reference voltage for ADC and DAC

Legend: P = Power; A = Analog; D = Digital; I = Input; O = Output

430-95424-002 (Rev. 01/06) 4 - 12 Plum A+

®

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.2

POWER SUPPLY SUBSYSTEM

The power supply subsystem provides DC power to system circuits and interface software
controlled power and battery management.

The power supply subsystem provides for the following functions:

- Main switching regulator

-AC power detection

- Main regulator fault detection

- System power (secondary regulators)

- Auxiliary supplies

-Power control

- Battery charging circuitry

- Battery terminal voltage measurement

- Battery charge/discharge current measurement

4.2.2.1

MAIN SWITCHING REGULATOR

The main source of power for the infuser is the AC line. The main switching regulator is
a pulse width modulated, AC-to-DC converter which provides the system an isolated DC
voltage of 6.9 V
preceded by line fuses F1 and F2, surge suppressor VR1, and a line filter. The bridge
rectifier U14 and capacitors C52 and C53 provide the DC voltage required for the switching
circuit. Voltage regulator U13 provides the pulse width modulator (PWM) device U12
startup supply voltage. After startup, supply voltage for U12 is supplied by half wave
rectifier circuitry CR14, R76, and C51.

The PWM oscillation frequency is approximately 40 kHz, determined by external resistor
R72 and capacitor C45. U12 controls the power delivered by varying the duty cycle of the
power metal-oxide-semiconductor field-effect transistor (MOSFET) Q9, which drives T2.
A half-wave rectifier rectifies the transformer’s secondary voltage, which provides the raw
DC voltage for the battery charger and system power. There are three feedback
mechanisms that maintain control: a main loop for normal control, a secondary loop for
overvoltage protection, and a current limit loop.

4.2.2.1.1

(or 7.5 VDC in battery charger boost mode). The main regulator is

DC

Main Loop

The main loop uses an optical feedback path to regulate the charger voltage (BATPOS)
at 6.9 V
control of the VFLOAT* line). A shunt regulator and opto-isolator provide feedback to the
PWM error amplifier.

Technical Service Manual 4 - 13 430-95424-002 (Rev. 01/06)

(except during boost charge, when the limit is raised to 7.5 VDC by software

DC

SECTION 4 THEORY OF OPERATION

4.2.2.1.2

Secondary Loop

Diode CR10 and opto-isolator U10 provide overvoltage protection. CR10 conducts and
activates U10 when secondary voltage exceeds approximately 10 V

. The duty cycle of

DC

U12 is reduced until the excessive voltage is removed.

4.2.2.1.3

Current Limit Loop

The current limit loop is activated when the primary current, sensed by R71, exceeds 3 A.
Resistor R70 and capacitor C46 filter the voltage across R71 and feed it back to the current
sense input (1.5 V

threshold) of U12. The duty cycle of U12 is reduced until the excessive

DC

load is removed.

4.2.2.2

MAIN REGULATOR FAULT DETECTION

If the switching regulator’s main loop fails, the secondary voltage limit loop takes over.
However, the battery charger and motors must be disabled, and an alarm must be
generated. A comparator is used to monitor the raw DC (+BUSS) for overvoltage. A 3.3 V
logic signal (OVRVLT*) is provided to the CPU subsystem.

DC

4.2.2.3

SYSTEM POWER

Along with the unregulated VMOT supply, a secondary switching regulator provides
system power. The secondary switching regulator includes IC U4, transformer T1,
and transistors Q4 and Q5. The regulator is a triple output, wide supply range, fly-back
converter that provides regulated 3.3 V
transformer T1. The regulator operates over an input range of 4 V

, 5 VDC, and 12 VDC outputs from the five winding

DC

to 10 VDC and provides

DC

output current limit as well as voltage overshoot limit. Primary feedback is metered
through a bias arrangement on transistor Q3. A Schottky rectifier diode CR4 provides
feedback in the event of V3_3 or V12_0 failure, and transistor Q10 provides feedback in
the event of V5_0 failure. The positive terminal of the battery provides the raw DC voltage,
VMOT, for the motors and backlight of the display.

4.2.2.4

AUXILIARY SUPPLIES

The power supply subsystem provides full time 5 V
active when battery or AC voltage is present. The full time 5 V
low dropout voltage regulator U6, whose power source is directly from the battery and is
backed up by a 0.1 F capacitor. VSC is used for the ON/OFF switch and a power failure
alarm latch. The full time 2.7 V

supply (V2_7) is derived from VSC and is used to supply

DC

the ultra-low current needed to power the real-time clock and non-volatile SRAM during
shutdown.

and 2.7 VDC supplies, which are

DC

supply (VSC) uses a linear

DC

430-95424-002 (Rev. 01/06) 4 - 14 Plum A+

®

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.2.5

POWER CONTROL

The infuser will operate in one of three modes: normal, standby, or shutdown.
During normal operation, the user interface is active and either on battery or AC line
power. During standby mode the user interface is inactive while the CPU is still operating,
servicing the battery management and waiting for a startup interrupt. Shutdown mode
iswhen system power is off. Shutdown mode only occurs during battery operation;
otherwise, +BUSS holds the system power on.

The infuser is activated when the [ON/OFF] key is pressed or the AC line is plugged in.
The [ON/OFF] key activates the STRTUP signal, triggering a three second one-shot circuit
that will temporarily turn the system power on. This three second one-shot period allows
the CPU enough time to power up, initialize, and turn on the PWRHLD signal. The CPU
monitors the STRTUP signal, via interrupt, to signal a user request for turning off the
infuser.

Figure 4-3 illustrates the system startup/shutdown sequence while battery powered.

System power is always on while AC powered.

STRTUP

ONE-SHOT

V3_3, V5_0, V12V

PWRHLD

Figure 4-3. System Startup and Shutdown Timing, Battery Powered

3 SEC

98K01021

Technical Service Manual 4 - 15 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

4.2.2.6

BATTERY VOLTAGE MEASUREMENT

The battery terminal voltage (BATPOS - BATNEG) is measured with a differential amplifier
consisting of U1, R1, R2, R4, R7, and R8. It has a gain of 0.317 to generate a single ended
VBATT signal. The VBATT signal is then provided to the CPU A/D converter as input for
the battery management algorithms.

4.2.2.7

BATTERY CHARGE/DISCHARGE CURRENT MEASUREMENT

The battery management algorithms measure battery charge/discharge current for battery
capacity estimation and charger control. The charge/discharge current is measured by
integrating the voltage across current sense resistor R57. An operational amplifier
(op-amp) integrator circuit, consisting of U2, C5, R12, R13, R19, and R20, provides
a voltage proportional to the integration of battery current (IBATT) over a CPU controlled
measurement period. The IBATT signal is fed to the CPU A/D converter, where it is sampled
at the end of the measurement period. The battery management algorithm further
accumulates the charge/discharge current for battery capacity estimation. The op-amp
integrator is reset by the CPU system at the beginning of each measurement period by
parallel analog switches U3, controlled by the CPU’s ITGRST signal. The battery
management algorithm periodically calibrates the op-amp integrator.

4.2.2.8

BATTERY CHARGER

The software battery management algorithm controls the battery charger. The charging
scheme is a current limit/two stage voltage limit charger. The charge current is limited to

1.3 A and the voltage is limited to either 6.9 V

The source of the charge current is power MOSFET transistor Q7 operating in the linear
mode. Charge current passes through a current sense resistor R57, where it develops
a feedback signal for the charger control amplifier consisting of U7, Q6, and associated
parts. The feedback signal is compared against a 2.5 V
A .5 A fuse (F4) protects against damage due to a short circuit. The battery management
algorithm maintains on/off control of the charger by the charger enable signal CHG*.
When set high, CHG* activates a comparator U7, which overrides the feedback signal and
disables the charger. Excessive voltage on the BATNEG terminal indicates that there is
a shorted battery cell, and will disable the charger through the same comparator.

or 7.5 VDC.

DC

voltage reference U8.

DC

430-95424-002 (Rev. 01/06) 4 - 16 Plum A+

®

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.3

MECHANISM SUBSYSTEM

The mechanism subsystem includes the electronics and electromechanical components
that interface with the pumping mechanism.

The mechanism subsystem provides the following functions:

- Chopper motor drive for three stepper motors (plunger, L/S valve, I/O valve)

- Four motor position sensors (flag detectors)

- Precision voltage reference

- Two air sensors (distal, proximal)

- Two pressure sensors (distal, proximal)

- Cassette presence and type detection

- Serial electrically erasable PROM (EEPROM)

See Table 4-4 for mechanism interface signals.

4.2.3.1

MOTORS/MOTOR DRIVE

The infuser uses three stepper motors for pumping: one for fluid displacement and two
for cassette valve actuation. The stepper motors are driven, under step-by-step control
from software, by a unipolar chopper drive.

4.2.3.1.1

Stepper Motors

Each motor is named by its function:

- Plunger motor for driving the plunger screw

- I/O valve motor for moving the input-output valve pins

- L/S valve motor for moving the line select valve pins A and B

All three motors are four phase stepper types. One electrical revolution is accomplished
after four motor steps (phases) are completed. The step-angle (the number of steps
per shaft revolution) resolutions are 3.6
and 7.5

The unipolar motor windings have a center tap connected on each of the two coils as shown
in Figure 4-4. Unidirectional current enters the center tap and is steered to one end of the
coil or the other end by the driver electronics, creating positive or negative flux lines in
the motor coil. With two coils each with a choice of flux polarity, four electrical
combinations or phases are possible.

° /step (48 steps/rev) for the I/O and L/S valve motors.

° /step (100 steps/rev) for the plunger motor,

Technical Service Manual 4 - 17 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

A

ACOM

A

BCOM

B B

98K01020

Figure 4-4. Stepper Motor Coils

4.2.3.1.2

Chopper Motor Drive

The infuser stepper motor drive is a chopper drive, which is a pulse width modulation
of the coil current in each motor winding. Current is switched on and off to maintain
a predetermined coil current independent of supply voltage and motor speed. The motor
winding inductance acts as a filter to smooth out the switching currents, slowing the
current rise when turned on and storing a decaying current when turned off. Each motor
coil is modulated independently, allowing different coil currents in the two motor windings.
The coil current is sensed and compared to a reference input for each winding. Modulation
circuits correct for any error between the sensed current and the reference. This reference
input can be changed to set a different coil current.

4.2.3.2

MOTOR POSITION SENSORS

Motor position is estimated by counting the motor steps, relative to a position reference.
Optical switches and flags serve as position references, which are used to find the motor
home positions and to verify proper motion. Flag positions are anticipated by software.

Optical switch flag sensors are used for tracking the following:

- Plunger motor rotational position (coupler flag)

- Plunger translational (linear) position

- I/O valve motor rotational position (cam flag)

- L/S valve motor rotational position (cam flag)

430-95424-002 (Rev. 01/06) 4 - 18 Plum A+

®

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

Each optical switch consists of an infrared LED, which shines through a rectangular
aperture, across a slot, to illuminate a photo-transistor. The photo-transistor is activated
as long as the beam is on and not blocked (by a flag in the slot). The optical switches are
distributed throughout the mechanism, near their associated flags. The motor rotational
optical switches are mounted on the driver PWA along with the control circuitry.
The plunger translational optical switch is mounted remotely on the switch PWA.
The switches are used intermittently to save power.

There are two control signals that enable associated switch pairs:

- FLCAME flag valve motor cam sensor enable

- FLPLE flag plunger motor rotation and translation sensors enable

Each of these control signals enables a constant current source which turns on the
associated switch’s infrared LEDs. The photo transistor states are sensed by Schmidt
trigger inverters (U11 on driver PWA) which provide a 3.3 V logic high when the optical
path is blocked or a logic low when the optical path is clear. The Schmidt trigger output
is high when the sensor is disabled.

The following output signals are provided to the CPU subsystem:

- FLIO_C flag I/O valve motor cam sensor

- FLLS_C flag L/S valve motor cam sensor

- FLPLRO flag plunger motor rotation sensor

- FLPLTR flag plunger motor transition sensor

4.2.3.3

V2_5 REFERENCE VOLTAGE

A precision 2.5 VDC reference voltage is generated on the APP PWA for use by the pressure
sensor excitation circuits, the air sensor amplifier circuits, and the ADC and DAC reference
voltage. The precision 2.5 V
is V2_5.

4.2.3.4

reference is buffered by a voltage follower. The signal name

DC

AIR SENSORS

The mechanism subsystem includes two air sensors, used to detect air passage into
(proximal) or out of (distal) the cassette. Both sensors are piezoelectric crystal transmitter
receiver pairs. Liquid between the transmitter and receiver will conduct the ultrasonic
signal, while air will not (see Figure 4-5).

Technical Service Manual 4 - 19 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

VSO

CPU

VCO/PLL

Figure 4-5. Air Sensor Block Diagram

4.2.3.4.1

Transmitter Circuitry

A/D

G_TX

OUTPUT

AMP

XTL
TX

XTL
RX

G_RX

PEAK

DETECTOR

98K01019

The transmitter circuitry consists of a voltage sweep oscillator, a voltage-controlled
oscillator (VCO), and a transmitter amplifier, and are located on the APP PWA.

The voltage sweep oscillator circuit oscillates at approximately 12 kHz at 50 percent duty
cycle. The output of the sweep oscillator is between +2 V

and +3 VDC, and is used to

DC

sweep the VCO. The VCO sweeps through the sensor’s peak coupling frequency, which is
between 3 MHz and 6 MHz. A resistor and capacitor are used to configure the VCO center
frequency. The VCO is enabled when the CPU asserts either DIARE or PXARE control
signals.

The transmitter amplifier consists of a push-pull, emitter-follower, complementary pair
of transistors. The transmitter amplifier drives both proximal and distal sensors
simultaneously.

4.2.3.4.2

Receiver Circuitry

When the cassette’s test port is filled with fluid, the transmitted signal will be coupled to
an identical piezoelectric crystal, where it is amplified and detected by the receiver
circuitry. The receiver circuitry consists of an amplifier, a peak detector, and an adjustable
gain buffer stage. There is a separate, symmetrical receiver circuit for each channel
(proximal and distal). Component references (called out in this design description) will be
made to the distal channel only.

430-95424-002 (Rev. 01/06) 4 - 20 Plum A+

®

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

The first amplifier includes two, directly coupled common emitter stages, biased from the
V2_5 supply. DIARE and PXARE are used to enable the distal and proximal sensors,
respectively. The detector stage consists of an emitter follower, charging a 400 µsec time
constant, refreshed every 40 microseconds (twice per VCO sweep).

The peak detector output is buffered by an op-amp configured as a basic non-inverting
amplifier with a trimming potentiometer (R31) for gain adjustment. Each sensor has an
independent gain adjustment. The two air sensor, gain-trimming potentiometers are
accessible for calibration in an assembled mechanism.

These final signals are read by the CPU subsystem via the ADC.

- PXAIR proximal air sensor output

- DIAIR distal air sensor output

4.2.3.5

PRESSURE SENSORS

The mechanism subsection contains two strain gauge-type pressure sensors, one at the
proximal and the other at the distal cassette ports. Electrically, the strain gauge is a
Wheatstone bridge made of four strain gauge resistors. When the bridge is electrically
excited, the bridge will output a millivolt level signal proportional to the applied pressure.
The output signal is amplified and offset adjusted before being read by the ADC.
Each pressure sensor circuit includes an excitation voltage supply, sensor amplifiers,
and a low pass filter.

The pressure sensor circuitry is on the APP PWA. Each of the two channels has an identical
topology, but different gain and filter response. A block diagram of this circuit is shown
in Figure 4-6.

 Note: Component references are made to the distal channel only.

Technical Service Manual 4 - 21 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

PRESSURE

SENSOR

ENABLE

(FROM CPU)

BRIDGE

EXCITATION

3.75 V

REFERENCE

2.5 V

WHEATSTONE

BRIDGE

DIFFERENTIAL

AMPLIFIER

AND OFFSET

ADJUST

OUTPUT

AMPLIFIER

AND FILTER

PRESSURE
SIGNAL OUTPUT
(TO CPU)

Figure 4-6. Pressure Sensor Excitation and Amplifier Block Diagram

430-95424-002 (Rev. 01/06) 4 - 22 Plum A+

05K01018

®

3 Infusion System

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.3.5.1

Bridge Excitation Supply

The bridge excitation voltage is 3.75 VDC, and is derived from the 2.5 VDC reference signal
(V2_5), gained 1.5 times by an amplifier. The CPU subsystem may independently enable
power to each pressure sensor bridge.

These enable signals are active high 3.3 V logic level inputs:

- PXPRE proximal pressure sensor enable

- DIPRE distal pressure sensor enable

4.2.3.5.2

Amplifier and Low Pass Filter

The pressure sensor amplifiers include a high gain differential pre-amplifier, followed by
a second stage non-inverting amplifier with low gain. A trimming potentiometer is adjusted
to minimize any offset in the impedance of the bridge.

A two-pole filter is used to filter the pressure signals. The first pole is formed by a capacitor
(C39, multiplied by 230 due to Miller effect) and a Thevenin resistance (seen at U4-2).
The second pole is the RC filter at the ADC input, which is located on the CPU PWA.

These output signals to the A/D converter in the CPU PWA are:

- PXPRS proximal pressure signal

- DIPRS distal pressure signal

4.2.3.6

PRESSURE SENSOR CALIBRATION

Pressure sensors are calibrated for offset and gain during mechanism calibration.
A trimming potentiometer is used to adjust the initial, zero pressure offset. The proximal
and distal pressure sensors have independent offset adjustments. The final system gain
(cassette pressure to corrected amplifier output) is adjusted in software. During
mechanism calibration, each channel’s gain (amplifier output/cassette pressure) will be
measured, and stored in the serial EEPROM on the driver PWA.

4.2.3.7

CASSETTE TYPE/PRESENCE SELECTION

The mechanism subsystem includes four force sensing resistor (FSR) switches, which are
coupled to the cassette. Three FSRs are used for cassette type decoding and one is used
for cassette present detection. The FSR is a polymer thick film device, which exhibits a
decrease in resistance with any increase in force applied to the active surface. The FSRs
have a resistance that is either very large (> 1 MΩ) or relatively small (< 100 KΩ). The large
resistance is defined as a logical ‘0’, and the small resistance is defined as logical ‘1’.
Each FSR is arranged in a voltage divider configuration with a fixed resistor, followed by
a comparator with hysteresis. The comparator circuits are located on the CPU PWA.
The comparators are designed to trip as the FSR’s resistance falls below 120 KΩ.

Technical Service Manual 4 - 23 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

4.2.3.8

SERIAL EEPROM

The driver PWA holds the 8 K x 8 bit, serial EEPROM, which is used to store event, alarm,
malfunction, and calibration data specific to the pumping mechanism. It is accessed
through a serial peripheral interface (SPI) compatible interface, which is a high-speed serial
interface to the CPU. The CPU PWA accesses this device through its SCP serial interface.
This interface is a subset of the SPI, and consists of clock (SPCLK), data in (SPRXD),
and data out (SPTXD) pins. This device is in the driver PWA to allow the calibration data
to stay with the mechanism.

4.3

PRINTED WIRING ASSEMBLIES

Infusion system electronics are packaged into six printed wiring assemblies (PWA)
and several remote mounted peripherals (see Section 4.4). The following sections provide
a brief description of the functional interfaces of each PWA.

4.3.1

POWER SUPPLY PWA

The power supply PWA (see Figure 9-11) contains the following functions of the power
supply subsystem:

- Main switching regulator

-AC power detection

- Main regulator fault detection

-System power

The power supply PWA is a four layer board, with primarily surface mount technology
(SMT) components. The board is fully testable from the bottom side. An insulating tape
covers the back of the power supply PWA. Open system troubleshooting should be done
under battery power. If connection to the AC line is required, an isolation transformer
should be used since AC line potentials are present on the power supply PWA.

See Section 4.2.2 for a functional description, and see Table 4-5 for power supply PWA
interface connections.

Table 4-5. Power Supply PWA Interface Connections

Connector Type Interface

P2 30 pin receptacle Board-to-board connection to CPU PWA

- Auxiliary supplies

-Power control

- Battery management

J16 4 pin header Motor power connection to driver PWA

J21 3 pin receptacle AC power cord connection

J22 2 pin header Battery cable connection

®

430-95424-002 (Rev. 01/06) 4 - 24 Plum A+

3 Infusion System

4.3 PRINTED WIRING ASSEMBLIES

4.3.2

PERIPHERAL PWA

The peripheral PWA (see Figure 9-13) contains part of the CPU subsystem circuitry,
including system program and data memories (PROM and SRAM), and external
communication interface circuits. The peripheral PWA is designed to be field replaceable,
to facilitate software upgrades or additional external interfaces.

The peripheral PWA is a four layer board, including one ground plane, one power plane,
and two signal layers. In its initial configuration, all of the components are mounted on
the top side.

See Table 4-6 for peripheral PWA interface connections.

Table 4-6. Peripheral PWA Interface Connections

Connector Type Interface

P1 96 pin receptacle Board-to-board connection to CPU PWA

J26 15 pin D-sub DataPort

J27 9 pin D-sub Barcode reader connection

J28 3 pin phone jack Nurse call jack

4.3.3

PERIPHERAL INTERFACE PWA

The peripheral interface PWA (see Figure 9-12) contains part of the CPU subsystem
circuitry, including system program and data memories (PROM and SRAM), external
communication interface circuits, and rear instrument user controls.

See Table 4-7 for peripheral interface PWA interface connections.

Table 4-7. Peripheral Interface PWA Interface Connections

Connector Type Interface

P1 96 pin receptacle Board-to-board connection to CPU PWA

J29 and J30 50 pin plug Board-to-board connection to peripheral PWA

J26 15 pin D-sub DataPort

J27 9 pin D-sub Barcode reader connection

J28 3 pin phone jack Nurse call jack

Technical Service Manual 4 - 25 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

4.3.4

CPU PWA

The CPU PWA (see Figure 9-14) contains most of the CPU subsystem functions, with the
exception of main memory and communications ports, which are located on the peripheral
PWA. The CPU PWA also accommodates system interconnect.

The CPU PWA is an eight layer board, with one ground plane, one power plane, and six
signal layers. The CPU PWA primarily contains SMT components. Most of the components
are on the top side, while the bottom side holds wave-solder compatible SMT resistors and
capacitors.

See Section 4.2.1 for a functional description, and see Table 4-8 for CPU PWA interface
connections.

Table 4-8. CPU PWA Interface Connections

Connector Type Interface

J7 96 pin header Connection to peripheral PWA (CPU bus,

rear panel I/O, and communication ports)

J2 30 pin header Connection to power supply PWA

J3 50 pin SMT Ribbon cable connection to driver PWA

(mechanism)

J4 21 pin header Front panel connector (keypad, LEDs,

on/off switch)

J5 14 pin SMT Flat flex cable to LCD panel

J20 4 pin header CCFT backlight connector

J24 2 pin header Main audible alarm connector

4.3.5

DRIVER PWA

The driver PWA (see Figure 9-15) contains the mechanism subsystem’s motor drive
circuitry, motor position sensors, and serial EEPROM. The driver PWA is mounted in the
mechanism sub-chassis.

The driver PWA is a four-layer PWB, with one ground plane, one power plane, and two
signal layers. The driver PWA primarily uses SMT components. Most of the components
are located on the top side of the board, while the bottom side holds wave-solder compatible
resistors and capacitors.

See Table 4-9 for driver PWA interface connections.

430-95424-002 (Rev. 01/06) 4 - 26 Plum A+

®

3 Infusion System

4.3 PRINTED WIRING ASSEMBLIES

Table 4-9. Driver PWA Interface Connections

Connector Type Interface

J7 6 pin header Plunger motor

J8 6 pin header Input/output motor

J9 6 pin header Line select motor

J10 20 pin SMT Flat flex cable to APP PWA

J11 50 pin header Ribbon cable to CPU PWA

J12 6 pin SMT FSR flex circuit

J13 4 pin header Motor power, from power supply PWA

J14 8 pin SMT Flat flex cable to switch PWA

4.3.6

SWITCH PWA

The switch PWA (see Figure 9-16) contains the plunger translation position sensor, which
is one of four position sensors in the system. The switch PWA is located at the side of the
mechanism sub-chassis, and connects to the driver PWA.

4.3.7

APP PWA

The APP PWA (see Figure 9-17) is mounted in the mechanism sub-chassis, and contains
the following mechanism subsystem circuitry:

- Proximal and distal air sensors and circuitry

- Proximal and distal pressure sensor amplifiers and excitation

- V2_5 precision voltage reference

- Pin detector optical switch module

The APP PWA is a four layer board, with one ground plane, one power plane, and two
signal layers. The APP PWA uses SMT components, mounted on both sides of the board.
The air sensors and the pin detector module are board mounted.

See Table 4-10 for APP PWA interface connections.

Table 4-10. APP PWA Interface Connections

Connector Type Interface

J15 20 pin SMT Flat flex cable to driver PWA

J11 10 pin SMT Pressure sensor connector

Technical Service Manual 4 - 27 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

4.4

REMOTE MOUNTED PERIPHERALS

The following sections describe the major remote mounted peripherals.

4.4.1

LCD

The infuser uses a graphic LCD module with a CCFT. The CCFT provides a backlight
source for the LCD. The LCD requires a nominal -16 V
is controlled by the CPU. The infuser’s graphic display data is shifted out to the LCD by
the CPU LCD controller, which interfaces directly with the CPU (see Section 4.2.1.6).
The display is configured as a 240 x 240 dot matrix with a viewing angle
of approximately 60

° .

4.4.2

SEALED LEAD ACID BATTERY

supply for contrast control, which

DC

The infuser uses a nominal 6 VDC rechargeable sealed lead acid battery with 4 amp-hour
capacity.

4.4.3

BARCODE READER WAND

 Note: The barcode reader feature will not be present on later versions of the Plum A+

The barcode reader wand connects to the BCR port J27 on the peripheral PWA. The BCR
wand interfaces through the infuser’s optically isolated, TTL logic level, asynchronous
interface. The BCR wand is also capable of interfacing at RS-232 levels. The infuser
provides an isolated +5 V
of the BCR wand is swiped across a barcode label, the reflected light is scanned and
processed. After a successful scan, the data is sent over the communication interface to
the CPU.

regulator to power the BCR wand. When the LED at the tip

DC

®

3.

4.5

MECHANICAL OVERVIEW

The principal mechanical elements of the infuser include the cassette and the mechanism
assembly. When a cassette is locked into the operating position and the [ON/OFF] switch
is pressed, the infuser performs a self test to verify the integrity of the internal systems.
The operation of the mechanism assembly moves a plunger, causing a pumping action.
A valve motor selects the A or B valve, depending on the command. An additional valve
motor alternately opens and closes an inlet valve and outlet valve to control fluid flow
through the cassette pumping chamber.

The following sections detail the cassette and the mechanism assembly.

430-95424-002 (Rev. 01/06) 4 - 28 Plum A+

®

3 Infusion System

4.5 MECHANICAL OVERVIEW

4.5.1

CASSETTE

The cassette (see Figure 4-7 and Figure 4-8) operates on a fluid displacement principle
to volumetrically deliver fluid. See the system operating manual for a description of the
major cassette functions.

The pumping cycle begins when the outlet valve is opened and the inlet valve is closed.
The plunger extends to deflect the cassette diaphragm and expel fluid. At the end of the
pumping stroke, the outlet valve is closed, the inlet opens, the appropriate A or B valve
opens, and the plunger retracts to allow fluid to refill the pumping chamber. After the
pumping chamber is filled, the inlet and outlet valves are reversed, the A and B valves are
closed, and the cycle repeats.

The cassette contains two chambers: an upper air trap chamber and a pumping chamber.
The two chambers are separated by an inlet valve and operate together to detect air. The air
trap chamber receives fluid from the intravenous (IV) container through either the A or B
valve. The air trap chamber collects air bubbles from the IV line and container to prevent
them from entering the pumping chamber and can collect a substantial amount of air.

A proximal air-in-line sensor (bubble detector) is located between the A/B valves and the
upper air-trap chamber. The proximal air-in-line sensor detects air entering the upper
air-trap chamber and initiates an audible alarm if the predetermined air collection
threshold is exceeded. Similarly, a second air-in-line sensor located distal to the pumping
chamber initiates an audible alarm if a predetermined amount of air is detected.

The pumping chamber receives fluid from the upper air-trap chamber through an inlet
valve. A pressure sensor located in the upper air-trap chamber monitors pressure on the
proximal side of the cassette. When the diaphragm covering the pumping chamber is
deflected by the plunger, the pumping chamber expels fluid through an outlet valve.
A pressure sensor located distal to the pumping chamber monitors pressure on the distal
side of the cassette.

A flow regulator is incorporated into the cassette distal end. This flow regulator is used to
manually control flow when the cassette is not inserted in the infuser. When the cassette
is properly inserted into the infuser and the door is closed, a mechanism opens the flow
regulator to allow the infuser to control fluid flow. When the door is opened, the same
mechanism closes the flow regulator to disable fluid flow.

Technical Service Manual 4 - 29 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

RIGHT VIEW

SECONDARY PORT
(Y-RESEAL OR
LOCKING CAP)

B VALVE

AIR-IN-LINE

SENSOR

(PROXIMAL)

PRESSURE SENSOR

(PROXIMAL)

AIR TRAP

CHAMBER

INLET VALVE

FROM PRIMARY

CONTAINER

REAR VIEW

(CONTROL NOT SHOWN)

A VALV E

AIR-IN-LINE

SENSOR
(DISTAL)

PRESSURE SENSOR

(DISTAL)

OUTLET VALVE

PUMPING CHAMBER

PRECISION GRAVITY

FLOW REGULATOR

FINGER

GRIP

OUTLET

TO

PATIENT

LEFT VIEW

Figure 4-7. Major Elements of the Dual-Channel Cassette

430-95424-002 (Rev. 01/06) 4 - 30 Plum A+

05K13017

®

3 Infusion System

LINE A

4.5 MECHANICAL OVERVIEW

A VALV E

AIR TRAP CHAMBER

INLET VALVE

OUTLET VALVE

LINE B

B VALVE

AIR-IN-LINE SENSOR (PROXIMAL)

PRESSURE SENSOR (PROXIMAL)

PUMPING CHAMBER

PRESSURE SENSOR (DISTAL)

AIR-IN-LINE SENSOR (DISTAL)

PRECISION GRAVITY

FLOW REGULATOR (AND SHUT OFF)

98G01001

Figure 4-8. Fluid Path in the Cassette

Technical Service Manual 4 - 31 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

4.5.2

MECHANISM ASSEMBLY

The mechanism assembly is a fully self-contained unit consisting of the motor and valve
assemblies, A/B valve subsystem, inlet/outlet valve subsystem, plunger drive subsystem,
air bubble (ultrasonic) sensor assemblies, cassette door, and pressure sensor assemblies.
The motor and valve assemblies, A/B valve subsystem, inlet/outlet valve subsystem,
and plunger drive subsystem are detailed in the following sections.

During infuser operation, the mechanism assembly plunger motor drives a lead screw that
is coupled to the plunger. The motor action and lead screw move the plunger forward to
cause the delivery of approximately 0.33 mL of fluid per cycle. The plunger motion is
synchronized to the valve motors to provide controlled fluid delivery.

4.5.2.1

MOTOR AND VALVE ASSEMBLIES

The mechanism assembly pumping action is controlled by three stepper motors. The first
stepper motor, in conjunction with an associated valve assembly, activates the A or B valve
of the cassette, depending on the command. The second stepper motor alternately opens
and closes the inlet and outlet valve to control fluid delivery through the cassette pumping
chamber. A third stepper motor controls plunger movement.

4.5.2.2

A/B VALVE SUBSYSTEM

The A/B valve subsystem includes a motor designed to rotate a cam. When the cam is
positioned at top-dead-center (home position), both valves are closed. Clockwise rotation
(when viewed from the motor side) from the home position opens the A valve, while the
B valve remains closed. Counterclockwise rotation opens the B valve, while the A valve
remains closed (see Figure 4-9).

The A/B valve subsystem consists of a stepper motor with attached cam and integral cam
flag, A and B rockers and valve pins, and a pin detector assembly. The cam flag passes
through an interrupter module as it rotates with the cam. Valve home position is
determined by this cam flag/interrupter module combination through predetermined
factory calibration data. During operation, if the cam flag passes through the interrupter
module at the incorrect time sequence, a motor phase loss is detected. The rocker is the
connecting link between the cam and the valve pin.

430-95424-002 (Rev. 01/06) 4 - 32 Plum A+

®

3 Infusion System

4.5 MECHANICAL OVERVIEW

A VALV E

REGULATOR ACTUATOR

AIR-IN-LINE SENSOR
(DISTAL)

PRESSURE SENSOR
(DISTAL)

CASSETTE LOCATOR

OUTLET VALVE

PLUNGER

INLET VALVE

Figure 4-9. Mechanism Valve Pins and Sensor Locations

4.5.2.3

INLET/OUTLET VALVE SUBSYSTEM

B VALVE

AIR-IN-LINE SENSOR

(PROXIMAL)

PRESSURE SENSOR

(PROXIMAL)

FORCE SENSING

RESISTOR

02K01023

The inlet/outlet valve subsystem is similar in function and build to the A/B valve
subsystem (see Section 4.5.2.2).

4.5.2.4

PLUNGER DRIVE SUBSYSTEM

The main components of the plunger drive subsystem are: plunger, lead screw and coupler,
and stepper motor. When the infuser is turned on, the plunger moves from the retracted,
PARK position to the HOME position. The cassette diaphragm is engaged. The stepper
motor rotates approximately 1 2/3 revolutions per pump cycle to permit a 0.33 mL fluid
displacement every pump cycle. The stepper motor then reverses and the plunger returns
to HOME position. This cycle repeats for the duration of fluid administration.

The screw/coupler assembly links the motor and the plunger. This assembly includes
a flag that passes through an interrupter module. This screw/coupler, flag/interrupter
module combination is used in conjunction with predetermined factory calibration data
to determine the plunger position. During operation, if the screw/coupler flag passes
through the interrupter module at the incorrect time sequence, a motor phase loss
is detected.

Technical Service Manual 4 - 33 430-95424-002 (Rev. 01/06)

SECTION 4 THEORY OF OPERATION

This page intentionally left blank.

430-95424-002 (Rev. 01/06) 4 - 34 Plum A+

®

3 Infusion System

Section 5

MAINTENANCE AND SERVICE TESTS

A complete maintenance program promotes infusion system longevity and trouble-free
operation. Such a program should include routine maintenance, periodic maintenance
inspection, and following any repair procedure, performance verification testing.

5.1

ROUTINE MAINTENANCE

Routine maintenance consists of basic inspection and cleaning procedures. As a minimum
requirement, inspect and clean the infuser after each use. In addition, establish a regular
cleaning schedule for the device.

5.1.1

CLEANING

Accumulation of dust or spilled fluids on the cassette door and housing can affect proper
operation. The following cleaning procedures are designed to sustain longevity and
promote trouble-free operation.

Follow hospital protocol for establishing the infuser cleaning schedule.

WARNING:

CAUTION: Do not immerse the infuser in liquids. Immersion could damage the
device. Do not allow liquids to enter the electronics compartment. Do not spray
cleaning solutions toward any openings in the device.

CAUTION: Certain cleaning and sanitizing compounds may slowly degrade
components made from some plastic materials. Using abrasive cleaners or cleaning
solutions not recommended by Hospira may result in product damage and,
potentially, void the product warranty. Do not use compounds containing
combinations of isopropyl alcohol and dimethyl benzyl ammonium chloride. Do not
use solvents that are harmful to plastic.

CAUTION: To avoid damage to the device, cleaning solutions should be used only
as directed in Table 5-1. The disinfecting properties of cleaning solutions vary;
consult the manufacturer for specific information.

DISCONNECT THE INFUSER FROM AC POWER PRIOR TO
CLEANING THE DEVICE. FAILURE TO COMPLY WITH THIS
WARNING COULD RESULT IN ELECTRICAL SHOCK.

Technical Service Manual 5 - 1 430-95424-002 (Rev. 01/06)

SECTION 5 MAINTENANCE AND SERVICE TESTS

Table 5-1. Cleaning Solutions

Cleaning Solution Manufacturer Preparation

Coverage

Dispatch

Manu-Klenz

Precise

Sporicidin

Household bleach Various Per hospital procedures;

TM

HB Steris Corporation Per manufacturer's

recommendation

TM

®

TM

®

Caltech Industries Per manufacturer's

recommendation

Steris Corporation Per manufacturer's

recommendation

Caltech Industries Per manufacturer's

recommendation

Sporicidin International Per manufacturer’s

recommendation

do not exceed one part
bleach in ten parts water

1. Clean the exposed surfaces of the infusion system with a soft, lint-free cloth

dampened with one of the cleaning solutions listed in Table 5-1, or a mild solution
of soapy water.

2. Remove soap residue with clear water.

5.1.2

SANITIZING

Sanitize the external surfaces of the infuser using a cleaning solution listed in Table 5-1.

 Note: Not all cleaning solutions are sanitizers. Check product labeling.

CAUTION: Do not sterilize the infuser using heat, steam, ethylene oxide (ETO),
or radiation. These methods may cause the device to malfunction.

5.2

PERFORMANCE VERIFICATION TEST

The performance verification test (PVT) consists of the tests described in the following
sections. The PVT can be used for diagnostic purposes during the troubleshooting
of a malfunctioning infuser. The PVT should be used for performance verification before
an infuser is placed back in service after repair. If any malfunction is detected as a result
of the PVT, see Table 6-4.

 Note: Perform the PVT exactly as described in this manual to assure effective

and reliable product evaluation information.

 Note: When performing the PVT, all lines must be tested. However, if appropriate,

the test may be performed on all lines concurrently.

®

430-95424-002 (Rev. 01/06) 5 - 2 Plum A+

3 Infusion System

5.2 PERFORMANCE VERIFICATION TEST

5.2.1

EQUIPMENT REQUIRED

The PVT requires the following equipment, or equivalents:

- Graduated cylinder, 25 mL, with 0.2 mL graduations (Type A)

- Sterile water or tap water in an IV bag/container

- Digital pressure meter (DPM), 0 to 50 psi (Fluke

- Three-way stopcock, latex-free (List No. 3233-01)

- IV Set (List No. 11419)

- 21-gauge butterfly needle, latex-free (List No. 4492-01),
or 18-gauge blunt cannula

®

- Safety analyzer (Fluke

- Digital multimeter (DMM), (Fluke

- Nurse call test cable (P/N 561-88416-001) (optional)

Biomedical 232D)

®

187) (optional)

®

Biomedical DPM3)

5.2.2

INSPECTION

Inspect the infusion system periodically for signs of defects such as worn accessories,
broken connections, or damaged cables. In addition, inspect the infusion system after
repair or during cleaning. Replace any damaged or defective external parts.

Inspect the following areas for missing or damaged parts:

-Labels

- AC power cord, retainer, and straps

- Rubber foot pads

- Door assembly and handle

- Keypad and display

-LEDs

- External screws

- Pole clamp assembly

- Front and rear enclosures

- Battery doors

- Peripheral interface assembly
and components

Technical Service Manual 5 - 3 430-95424-002 (Rev. 01/06)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.2.3

TEST SETUP

WARNING:

To set up the infuser for the PVT, proceed as follows:

1. Confirm the infuser and appropriate accessories are assembled.

2. Hang two sterile water containers at a height of 18 ± 6 inches above the pumping
chamber of the infuser.

3. Connect the infuser to AC power, and press [ON/OFF] to turn on the device.

4. Verify the infuser is in the unlocked mode. Toggling the [LOCKOUT] switch
alternates between unlocked [DOWN] and locked [UP] modes.

5. Turn off the infuser.

A PATIENT SHOULD NEVER BE CONNECTED TO THE INFUSER
DURING DEVICE TESTING.

5.2.4

SELF TEST

CAUTION: Do not place the infuser in service if the self test fails.

 Note: Conduct all tests with the infuser connected to AC power unless otherwise

specified.

 Note: If an alarm condition occurs during the self test, cycle the power and repeat the

self test. If the alarm condition recurs, note the message and take corrective action

(see Section 6). Repeat the self test. If the alarm condition continues to recur, remove

the infuser from service and contact Hospira.

To perform the self test, see Figure 5-1, and proceed as follows:

1. Connect the AC power cord to a grounded AC outlet. Verify the charge/line indicator
CHARGE illuminates and an alarm beep sounds.

2. Without a cassette installed, turn on the infuser.

3. The LCD screen briefly displays the SELF TEST screen (see Figure 5-1).

 Note: If the SELF TEST screen does not appear, contact Hospira.

4. After the self test is complete, the message “INSERT PLUM SET CLOSE LEVER”
appears.

5. Verify the time and date. To set the time and date, see Section 1.8.3.

6. Open the cassette door and insert a primed cassette. Close the cassette door.
The cassette test is complete when the “CASSETTE TEST IN PROGRESS” message
disappears.

 Note: The message “MECHANISM INITIALIZATION IN PROGRESS” may briefly

appear prior to the “CASSETTE TEST IN PROGRESS” message.

7. The “CLEAR SETTINGS?” message may appear. Press [YES], then turn off the
infuser.

430-95424-002 (Rev. 01/06) 5 - 4 Plum A+

®

3 Infusion System

5.2 PERFORMANCE VERIFICATION TEST

LINE FLOW

INDICATORS

A B

HOSPIRA Plum A+

STATUS
REGION

MESSAGE
REGION

SOFTKEY
LABEL REGION

LINE
INDICATOR

Version X.XX MM/DD/YY

START

STOP

CHARGE

ON/OFF

Copyright Hospira Inc.

2005

System Self Test

In Progress

1
4

2
5

78

CLEAR

0

3

6

9

.

WORKING

REGION

SOFTKEYS

SELECT

KEYPAD

SILENCE

05K01002

Figure 5-1. Display and Keypad

Technical Service Manual 5 - 5 430-95424-002 (Rev. 01/06)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.2.5

CASSETTE ALARM TEST

To perform the cassette alarm test, proceed as follows:

1. Verify the infuser is on. Insert an empty cassette and close the door.

2. Verify the “CASSETTE TEST FAIL” message is flashing on the display and the alarm
sounds after the cassette test is complete.

3. Open the door and remove the cassette.

4. Turn off the infuser.

5.2.6

FREE FLOW TEST

To perform the free flow test, proceed as follows:

1. With a primed cassette installed, turn on the infuser.

2. After the self test, press [YES] to clear settings.

3. Place the distal end of tubing into a collection container a minimum of 36 inches
below the cassette.

4. With the cassette door closed, check the distal end of the tubing for fluid flow.
Verify a minimal flow of fluid occurs (a few drops maximum).

5. Open the cassette door and check the distal end of the tubing for fluid flow.
Verify a minimal flow of fluid occurs (a few drops maximum).

 Note: A small amount of fluid may be expelled from the cassette when opening

or closing the door.

6. Close the cassette door.

5.2.7

DISPLAY TEST

To perform the display test, see Figure 5-1, then proceed as follows:

1. Verify the LCD backlight is illuminated and the display is clearly legible at eye level
from approximately 18 inches.

2. With the infuser in the DELIVERY screen, press the [OPTIONS/VOL INF] softkey
to select the OPTIONS screen.

3. Select Lighting/Contrast, and press [CHOOSE].

4. Press the [DECREASE SETTING] and [INCREASE SETTING] softkeys to change
backlight intensity. Verify intensity decreases and increases.

5. Select Display Contrast.

6. Press [DECREASE SETTING] and [INCREASE SETTING] to change display contrast.
Verify the display contrast decreases and increases.

7. Press the [CANCEL] softkey to return to the OPTIONS screen.

8. Press the [BACK] softkey to return to the DELIVERY screen.

430-95424-002 (Rev. 01/06) 5 - 6 Plum A+

®

3 Infusion System

5.2 PERFORMANCE VERIFICATION TEST

5.2.8

KEYPAD VERIFICATION/FUNCTIONAL TEST

To perform the keypad verification/functional test, see Figure 5-1, then proceed as follows:

1. With the infuser in the DELIVERY screen, press the [A] softkey to select line A.

2. Verify the PROGRAM screen is displayed.

3. Enter a rate of 123 mL/hr and VTBI of 4567 mL.

4. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

5. Verify fluid is pumping, the message “PUMPING” is displayed in the line A status
bar, and the line A LED flashes.

6. Press [STOP], then press and hold the [BACKPRIME] softkey.

7. Verify the “BACKPRIMING” and “RELEASE BACKPRIME TO STOP” messages
are displayed, and verify the infuser is actually backpriming.

8. Release the [BACKPRIME] softkey, press [START], and verify normal pumping
operation.

9. Press the [B] softkey.

10. Verify PIGGYBACK is the displayed delivery mode. If necessary, change the delivery

mode by pressing the [CHANGE MODE] softkey.

11. Enter a rate of 890 mL/hr and VTBI of 2 mL.

12. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

13. Verify fluid is pumping, the message “PUMPING” is displayed in the line B status
bar, and the line B LED flashes.

14. After 20 seconds, verify pumping has switched to line A.

15. Press [STOP].

16. Press [OPTIONS/VOL INF]. Select Volume Infused, and press [CHOOSE].

17. Select line A.

18. Press [CLEAR]. Verify the line A volume is 0 mL and press [ENTER].

5.2.9

ALARM LOUDNESS TEST

To perform the alarm loudness test, see Figure 5-2, then proceed as follows:

1. Press the [A] softkey to select line A.

2. Enter a rate of 400 mL/hr and VTBI of 1 mL.

3. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

4. Verify fluid is pumping, the message “PUMPING” is displayed in the line A status
bar, and the line A LED flashes.

5. Verify the alarm sounds when the dose has been delivered.

6. Turn the volume control knob between HIGH and LOW (see Figure 5-2). Verify the
alarm loudness changes.

7. Press [SILENCE], and verify the alarm is silenced.

8. Press [STOP].

Technical Service Manual 5 - 7 430-95424-002 (Rev. 01/06)

SECTION 5 MAINTENANCE AND SERVICE TESTS

VOLUME
CONTROL
KNOB

LOCKOUT
SWITCH

NURSE
CALL JACK

ROUND

SEAL (2)

POLE CLAMP

ASSEMBLY

RECTANGLE
SEAL

DATAPORT
CONNECTOR

PERIPHERAL
INTERFACE
ASSEMBLY

EQUIPOTENTIAL

POST

05K07016

Figure 5-2. Rear View

5.2.10

LOCKOUT SWITCH TEST

To perform the lockout switch test, proceed as follows:

1. Press the [A] softkey to select line A.

2. Enter a rate of 400 mL/hr and VTBI of 50 mL.

3. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

4. Verify fluid is pumping, the message “PUMPING” is displayed in the line A status
bar, and the line A LED flashes.

5. Toggle the lockout alarm switch up (ON) to engage the alarm (see Figure 5-2).

6. Press any key except [STOP], and verify an alarm sounds and the “HARD LOCKOUT
ENABLED” message is displayed. Verify the infuser continues to operate until
[STOP] is pressed.

7. Press [STOP] and verify the “HARD LOCKOUT VIOLATION” message appears.

8. Toggle the lockout alarm switch down (OFF). Verify the “HARD LOCKOUT
VIOLATION” message disappears and the alarm stops.

9. Press [START].

10. Open the door and verify the “DOOR OPEN WHILE PUMPING” message is displayed
and the audio alarm activates.

11. Close the cassette door.

12. Press [NO] at the “CLEAR SETTINGS?” prompt.

430-95424-002 (Rev. 01/06) 5 - 8 Plum A+

®

3 Infusion System

5.2 PERFORMANCE VERIFICATION TEST

5.2.11

PROXIMAL OCCLUSION TEST

To perform the proximal occlusion test, proceed as follows:

1. Press the [A] softkey to select line A.

2. Enter a rate of 400 mL/hr and VTBI of 50 mL.

3. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

4. Verify fluid is pumping, the message “PUMPING” is displayed in the line A status
bar, and the line A LED flashes.

5. After several pumping cycles, clamp line A tubing proximal to the cassette.
Verify the “PROX OCCL A/AIR” message flashes and the alarm sounds before three
pumping cycles are completed.

6. Press [SILENCE] and verify the alarm stops while the message on the display
continues to flash.

7. Unclamp the proximal line and press [START]. Verify pumping resumes.

8. Press [STOP].

5.2.12

PROXIMAL AIR-IN-LINE TEST

To perform the proximal air-in-line alarm test, see Figure 5-3, then proceed as follows:

1. Install the special cassette marked proximal, and close the cassette door.

 Note: Confirm the special cassette proximal bubble sensor tips are removed.

2. Press [YES] to clear settings.

3. Press the [A] softkey to select line A.

4. Enter a rate of 400 mL/hr and VTBI of 50 mL.

5. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

6. Verify fluid is pumping, the message “PUMPING” is displayed in the line A status
bar, and the line A LED flashes.

7. Before 1 mL of fluid is delivered, verify the alarm sounds and the “PROX AIR
A. BACKPRIME” message is flashing on the display.

8. Open the door, and remove the special cassette.

Technical Service Manual 5 - 9 430-95424-002 (Rev. 01/06)

SECTION 5 MAINTENANCE AND SERVICE TESTS

PROXIMAL BUBBLE SENSOR BULB TIPS
(REMOVED FOR PROXIMAL-AIR-IN-LINE ALARM TEST)

(REMOVED FOR DISTAL-AIR-IN-LINE ALARM TEST)

CASSETTE CENTERING DEVICE

DISTAL BUBBLE SENSOR BULB TIPS

98G01024

Figure 5-3. Special Cassettes with Bubble Sensor Tips Removed

5.2.13

DISTAL AIR-IN-LINE TEST

To perform the distal air-in-line alarm test, see Figure 5-3, then proceed as follows:

1. Install the special cassette marked distal, and close the cassette door.

 Note: Confirm the special cassette proximal bubble sensor tips are removed.

2. Press [YES] to clear settings.

3. Press the [A] softkey to select line A.

4. Enter a rate of 400 mL/hr and VTBI of 50 mL.

5. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

6. Verify fluid is pumping, the message “PUMPING” is displayed in the line A status
bar, and the line A LED flashes.

7. Before 1 mL of fluid is delivered, verify the alarm sounds and the “DISTAL AIR”
message is flashing on the display.

8. Open the door, and remove the special cassette.

430-95424-002 (Rev. 01/06) 5 - 10 Plum A+

®

3 Infusion System

5.2 PERFORMANCE VERIFICATION TEST

5.2.14

DISTAL OCCLUSION TEST

To perform the distal occlusion test, see Figure 5-4, then proceed as follows:

1. Install the cassette and connect the distal tubing to the DPM through a three-way
stopcock as illustrated in Figure 5-4. Close the cassette door.

 Note: A reflux valve may be attached between the stopcock and the DPM

to keep moisture out of the DPM.

 Note: The height of the DPM must be 0 ± 12 inches from the midline of the

pumping chamber.

2. Turn on the infuser.

3. Press [YES] to clear settings.

4. Press [OPTIONS/VOL INF] to select the OPTIONS screen.

5. Select Pressure/Post Infusion Rate, and press [CHOOSE].

6. Verify the distal pressure limit is set at 6 psi. If the pressure limit is not 6 psi, enter 6
and press [ENTER].

7. Press the [A] softkey to select line A.

8. Enter a rate of 40 mL/hr and VTBI of 50.0 mL.

9. Open the three-way stopcock to air.

10. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

11. Verify fluid is pumping, the message “PUMPING” is displayed in the line A status
bar, and the line A LED flashes.

12. Set the three-way stopcock to measure pressure.

13. Verify the distal occlusion audible alarm occurs at 6 ± 3 psi. Verify the DISTAL
OCCLUSION message is flashing on the screen.

14. Open the three-way stopcock to air.

15. Open and close the door. Press [NO] at the “CLEAR SETTINGS?” prompt.

16. Press [OPTIONS/VOL INF] to select the OPTIONS screen.

17. Select Pressure/Post Infusion Rate, and press [CHOOSE].

18. Select Distal Pressure Limit. Enter 10 psi, and press [ENTER].

19. Set the three-way stopcock to measure pressure, then press [START].

20. Verify the distal occlusion audible alarm occurs at 10 ± 3 psi. Verify the DISTAL
OCCLUSION message is flashing on the screen.

21. Open the door and remove the cassette.

Technical Service Manual 5 - 11 430-95424-002 (Rev. 01/06)

SECTION 5 MAINTENANCE AND SERVICE TESTS

OFF

mmHg

cmOFHO

-13.5T O1 5

-13.5T O7 5

PSI

INCHES OFH O

UNIVERSAL

PRESSUREMETER

PRESSUREINPUT

OFF

mmHg

cmOFHO

-13.5T O1 5

-13.5T O7 5

PSI

INCHES OFH O

UNIVERSAL

PRESSUREMETER

PRESSUREINPUT

FROM FLUID
CONTAINERS

1

23

THREE-WAY
STOPCOCK

UNIVERSAL

UNIVERSAL

PRESSUREMETER

PRESSUREMETER

cmOFHO

2

cmOFHO

2

mmHg

mmHg

OFF

OFF

PRESSUREINPUT

PRESSUREINPUT

0.00

0.00

INCHES OFH O

INCHES OFH O

-13.5T O1 5

-13.5T O1 5

-13.5T O7 5

-13.5T O7 5

2

2

PSI

PSI

DPM

01K07018

Figure 5-4. Distal Occlusion Test Setup

5.2.15

DELIVERY ACCURACY TEST

 Note: Accuracy testing is for informational purposes only, and is not to be used

as a re-release test. If there is any concern as to infuser accuracy, contact Hospira.

CAUTION: Do not remove the protective cover from the 21-gauge needle.

To perform the delivery accuracy test, proceed as follows:

1. Open the cassette door and insert a primed cassette. Close the cassette door.

2. Install an 18-gauge blunt cannula or a 21-gauge needle to the distal end of the
tubing. Verify the fluid container is 18 to 24 inches above the pumping chamber.
Verify all lines are unclamped.

3. Place the distal output end of tubing into the graduated cylinder.

4. Press the [A] softkey to select line A.

5. Enter a rate of 200 mL/hr and VTBI of 10 mL.

6. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

7. Verify fluid is pumping, the message “PUMPING” is displayed in the line A status
bar, and the line A LED flashes.

8. Press the [B] softkey to select line B.

9. Verify the infuser is in the PIGGYBACK delivery mode. If necessary, press
[CHANGE MODE] to change the delivery mode.

10. Enter a rate of 200 mL/hr and VTBI of 10 mL.

430-95424-002 (Rev. 01/06) 5 - 12 Plum A+

®

3 Infusion System

5.2 PERFORMANCE VERIFICATION TEST

11. Press [START] and verify the “CONFIRM PROGRAM?” message is displayed. If rate
and VTBI are correct, press [YES].

12. Verify fluid is pumping, the message “PUMPING” is displayed in the line B status
bar, and the line B LED flashes.

13. Verify the “KVO” message flashes on the display and an audible alarm sounds when
total delivery is complete on line A.

14. Press [STOP] and verify the volume delivered is 20 ± 1 mL.

5.2.16

NURSE CALL TEST

 Note: The nurse call test may be bypassed if the nurse call function is not used.

To perform the nurse call test, attach the nurse call test cable and proceed as follows:

1. Set the primary delivery rate to 400 mL/hr, and the primary dose limit to 1 mL.

2. Connect the DMM to the nurse call test cable.

3. Press [START] and verify pumping action.

4. After “DOSE END” and “KVO” appear on the display, observe a short circuit on the
DMM (approximately 1 Ω on a scale of 0 to 100 Ω).

5.2.17

ELECTRICAL SAFETY TEST

To perform the electrical safety test, proceed as follows:

1. Connect the AC power cord to a safety analyzer.

2. Connect the safety analyzer ground lead to the ground test-point located on the
rear of the infuser.

3. Check the leakage current with the safety analyzer. Leakage current (both open
and closed ground) must not exceed 100 microamperes AC

4. Measure the resistance of the AC connector ground lug with the safety analyzer.
Resistance should not exceed 0.1 Ω.

rms

.

5.2.18

END OF THE PVT

If all performance verification tests have been successful, proceed as follows:

1. Press [OPTIONS/VOL INF]. Select Volume Infused, and press [CHOOSE].

2. Press [CLEAR] to clear the volume infused.

3. Press [ENTER].

4. Press the [A] softkey.

5. Press [YES] at the “CLEAR LINE A SETTINGS?” prompt.

6. Press [CANCEL/BACK] to return to the delivery screen.

7. Press the [B] softkey.

8. Press [YES] at the “CLEAR LINE B SETTINGS?” prompt

9. Reset the infuser to the original configuration.

10. Turn off the infuser and return the device to service.

 Note: If any tests fail, see Section 6, or contact Hospira.

Technical Service Manual 5 - 13 430-95424-002 (Rev. 01/06)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.3

PERIODIC MAINTENANCE INSPECTION

Periodic maintenance inspections should be performed per hospital procedures for
compliance to accreditation requirements. It is recommended that JCAHO and/or hospital
protocol be followed for establishing a periodic maintenance inspection schedule.
Product specifications for this inspection are listed in Section 8.

To perform the periodic maintenance inspection, complete the PVT in Section 5.2.

5.4

BATTERY OPERATION OVERVIEW

The infusion system is intended to operate on battery power on an exception basis only,
such as emergency backup or temporary portable operation. Examples of emergency
backup include AC power failure or inadvertent disconnection of the AC power cord.
An instance of temporary portable operation includes patient transfer from one location
to another.

The device should be connected to AC power whenever possible to allow the battery
to remain fully charged. The line power indicator turns off when the infuser is operating
on battery power. The backlight extinguishes after approximately one minute of operation
on battery power.

Factors that most commonly affect battery life are the depth and frequency of discharge
and the length of the recharge period. As a general rule, the more often the battery
is discharged and recharged, the sooner it will need replacement. The primary cause
of damage is leaving the battery in a less than fully charged state for any period of time.
Battery damage can occur in a matter of hours and cause a permanent loss of battery
capacity. The amount of lost capacity depends on the degree of discharge, the storage
temperature, and the length of time the battery was stored in a discharged state.

 Note: A permanently damaged battery cannot be recharged to full capacity.

When the battery discharges below the acceptable level while the infuser is operating,
the audio indicator is activated and the “WARNING: LOW BATTERY” message displays.
Although it is not recommended to continue operating the infuser on battery power at this
point, the battery continues providing power until it is depleted. When the battery is
depleted, delivery stops, a continuous alarm tone sounds, and, after three minutes,
the infuser automatically turns off.

CAUTION: As soon as the low battery alarm occurs, connect the infuser
to AC power.

When the infuser detects that the battery has reduced capacity, it will register a Replace
Battery condition. For the first two occurrences of a Replace Battery condition, the
“WARNING: LOW BATTERY” message will appear and the audio indicator will activate.
The message and audio indicator can be cleared only when the device is plugged in or
turned off. For the third and subsequent occurrences, the “WARNING: REPLACE
BATTERY” message will appear, and the audio indicator will activate and persist over
power cycles. The message and audio indicator are cleared by replacing the battery,
accessing the biomed settings screen, and pressing the [CHANGE BATTERY] softkey.

430-95424-002 (Rev. 01/06) 5 - 14 Plum A+

®

3 Infusion System

5.4 BATTERY OPERATION OVERVIEW

Recharging can occur any time the infuser is connected to AC power. It is recommended
that the infuser be connected to AC power whenever practical to maximize available battery
charge during transport or ambulation. The infuser does not have to be on for the battery
to recharge.

 Note: The infuser should be operated on battery power for three continuous hours

at least once every six months for optimum battery performance and life.

Technical Service Manual 5 - 15 430-95424-002 (Rev. 01/06)

SECTION 5 MAINTENANCE AND SERVICE TESTS

This page intentionally left blank.

430-95424-002 (Rev. 01/06) 5 - 16 Plum A+

®

3 Infusion System

Section 6

TROUBLESHOOTING

This section contains information on technical assistance, warning messages,
alarm messages and error codes, and troubleshooting procedures for the Plum A+
infusion system.

®

6.1

TECHNICAL ASSISTANCE

For technical assistance, product return authorization, and to order parts, accessories,
or manuals within the United States, contact Hospira Technical Support Operations.

1-800-241-4002

For additional technical assistance, technical training, and product information, visit the
website at www.hospira.com.

Send all authorized, prepaid returns within the United States to the following address:

Hospira, Inc.

Technical Support Operations

755 Jarvis Drive

Morgan Hill, California 95037

For technical assistance, product return authorization, and to order parts, accessories,
or manuals from outside the United States, contact the nearest Hospira sales office.

3

6.2

WARNING MESSAGES

Table 6-1 lists warning messages, possible causes, and corrective actions. These warning

messages are captured in the Error Log.

 Note: When the infuser detects that the battery has reduced capacity, it will register

a Replace Battery condition. For the first two occurrences of a Replace Battery
condition, the “WARNING: LOW BATTERY” message will appear and the audio
indicator will activate. The message and audio indicator can be cleared only when the
device is plugged in or turned off. For the third and subsequent occurrences,
the “WARNING: REPLACE BATTERY” message will appear, and the audio indicator will
activate and persist over power cycles. The message and audio indicator are cleared
by replacing the battery, accessing the biomed settings screen, and pressing the
[CHANGE BATTERY] softkey.

 Note: If the device is not plugged in, and turned on with a previously depleted battery,

the infuser will display a “DEPLETED BATTERY” message for 16 seconds,
then power off.

Technical Service Manual 6 - 1 430-95424-002 (Rev. 01/06)

SECTION 6 TROUBLESHOOTING

Message Possible Cause Corrective Action

Table 6-1. Warning Messages

Stop delivery, then turn off Attempting to turn off the

infuser while a delivery
is in progress

Warning: Low Battery Battery is discharged so

that only approximately 30
minutes of battery life
remains

Warning: Replace Battery Battery service needed

Battery voltage is less than
the depleted threshold and
the charge level is higher
than the low charge
threshold

Warning: Charger Service A hardware problem with

the battery charging circuit
is detected; charging
circuitry is not behaving
as expected

Stop all lines, then turn off
the infuser

Plug into AC power

Replace the battery

Press [SILENCE]

6.3

ALARM MESSAGES AND ERROR CODES

Under most alarm conditions the infuser ceases normal operation, generates an audible
alarm, and displays an alarm message or error code on the LCD screen.

There are two types of alarm conditions:

- alarm codes that can be cleared by the operator

- error codes that require qualified service personnel

6.3.1

OPERATIONAL ALARM MESSAGES

Table 6-2 lists infuser alarm codes that can be cleared by the operator. Also listed in
Table 6-2 are the alarm messages, descriptions, possible causes, and corrective actions.

 Note: Operational alarm messages are displayed on the LCD screen. Associated error

codes are displayed in the alarms log (see Section 1.8.2).

430-95424-002 (Rev. 01/06) 6 - 2 Plum A+

®

3 Infusion System

6.3 ALARM MESSAGES AND ERROR CODES

Table 6-2. Operational Alarm Messages and Corrective Actions

Alarm

Code

N100

(URC)

N101

(NAA)

N102

(RL)

N103

(SEEP

CRC)

N104

(NC2)

Alarm Description Possible Cause

Unrecognizable
cassette

Incorrect cassette
type

An incorrect
cassette is
inserted

No action No operator action

and no delivery
for two minutes

Interruption or a
partial change to

a program
during delivery
parameters entry

Infuser idle
2 minutes

NV RAM lost
thrpy data

Infuser in reset
or idle for over
two minutes

Programming

set without start

for two minutes

Therapy data is lost Infuser did not

complete the

previous

non-volatile

memory write

successfully

Nurse callback B Delivery line B

has changed
(if alarm is enabled)

End of delivery

step on line B

other than VTBI

complete while

callback is

enabled

Corrective

Action

Insert proper
cassette

Complete
programming
of the infuser

Press [START]

Re-enter all
programmed
data

Press [SILENCE]

N105

(NC1)

N160

or

E160

(VTB2)

N161

or

E161

(VTB1)

N180

or

E180

(OD1)

N181

or

E181

(OD1)

Nurse callback A Delivery line A

has changed
(if alarm is enabled)

Line B VTBI
complete

Programmed
volume to be
infused completed
on line B

Line A VTBI
complete

Programmed
volume to be
infused completed
on line A

Distal Occl Peak distal

occlusion,
non-delivery

Distal Occl Negative distal

occlusion,
non-delivery

End of delivery

step on line A

other than VTBI

complete while

callback is

enabled

VTBI is complete

on line B

VTBI is complete

on line A

Distal occlusion

detected during

non-delivery

Distal occlusion

detected during

non-delivery

Press [SILENCE]

Press [SILENCE]
and replace
IV bag, and
restart line B

Press [SILENCE]
and replace
IV bag, and
restart line A

Backprime the
cassette and
restart the infuser

Backprime the
cassette and
restart the infuser

Technical Service Manual 6 - 3 430-95424-002 (Rev. 01/06)

SECTION 6 TROUBLESHOOTING

Table 6-2. Operational Alarm Messages and Corrective Actions

Alarm

Code

N182

or

E182

(OP2)

N183

or

E183

(OP2)

N184

or

E184

(OP1)

Alarm Description Possible Cause

Prox. Occl B, Air
or
Prox. Occl B

Negative proximal
occlusion B,
non-delivery

Proximal
occlusion
detected on
line B during
non-delivery

Prox. Occl B, Air
or
Prox. Occl B

Peak proximal
occlusion B,
non-delivery

Proximal
occlusion
detected on
line B during
non-delivery

Prox. Occl A, Air
or
Prox. Occl A

Negative proximal
occlusion A,
non-delivery

Proximal
occlusion
detected on
line A during
non-delivery

Corrective

Action

Backprime the
cassette and
restart line B
or
Stop all lines,
backprime the
cassette, and
restart all lines

Backprime the
cassette and
restart line B
or
Stop all lines,
backprime the
cassette, and
restart all lines

Backprime the
cassette and
restart line A
or
Stop all lines,
backprime the
cassette, and
restart all lines

N185

or

E185

(OP1)

N186

or

E186

(OD1)

N187

or

E187

(OD1)

N188

or

E188

(OP2)

Prox. Occl A, Air
or
Prox. Occl A

Peak proximal
occlusion A,
non-delivery

Distal Occl Peak distal

occlusion,
delivery

Distal Occl Negative distal

occlusion,
delivery

Prox. Occl B, Air Negative proximal

occlusion B,
delivery

Proximal
occlusion
detected on
line A during
non-delivery

Distal occlusion
detected during
delivery

Distal occlusion
detected during
delivery

Proximal
occlusion
detected during
delivery on line B

Backprime the
cassette and
restart line A
or
Stop all lines,
backprime the
cassette, and
restart all lines

Fix occlusion
and restart
the infuser

Fix occlusion
and restart
the infuser

Fix occlusion
and restart line B
or
Stop all lines,
fix occlusion
and restart
the infuser

430-95424-002 (Rev. 01/06) 6 - 4 Plum A+

®

3 Infusion System

6.3 ALARM MESSAGES AND ERROR CODES

Table 6-2. Operational Alarm Messages and Corrective Actions

Alarm

Code

N189

or

E189

(OP2)

N190

or

E190

(OP1)

N191

or

E191

(OP1)

Alarm Description Possible Cause

Prox. Occl B, Air Peak proximal

occlusion B,
delivery

Proximal

occlusion

detected during

delivery on line B

Prox. Occl A, Air Negative proximal

occlusion A,
delivery

Proximal

occlusion

detected during

delivery on line A

Prox. Occl A, Air Peak proximal

occlusion A,
delivery

Proximal

occlusion

detected during

delivery on line A

Corrective

Action

Fix occlusion
and restart line B
or
Stop all lines,
fix occlusion
and restart
the infuser

Fix occlusion
and restart line A
or
Stop all lines,
fix occlusion
and restart
the infuser

Fix occlusion
and restart line A
or
Stop all lines,
fix occlusion
and restart
the infuser

N230

or

E230

(APT)

N231

or

E231

(APB)

N232

or

E232

(APA)

Prox. Air Total Proximal

air-in-line total

Prox. Air on B,
backprime

Proximal
air-in-line
on line B

Prox. Air on A,
backprime

Proximal
air-in-line
on line A

500 µL of air

has entered

the cassette

500 µL of air

has entered

the cassette

on line B

500 µL of air

has entered

the cassette

on line A

Backprime
the cassette
and restart
the infuser
or
Remove and
manually reprime
the cassette,
and restart
the infuser

Backprime
the cassette
and restart line B
or
Remove and
manually reprime
the cassette
and restart
the infuser

Backprime
the cassette
and restart line A
or
Remove and
manually reprime
the cassette
and restart
the infuser

Technical Service Manual 6 - 5 430-95424-002 (Rev. 01/06)

SECTION 6 TROUBLESHOOTING

Table 6-2. Operational Alarm Messages and Corrective Actions

Alarm

Code

N233

or

E233

(ADC)

N234

or

E234

(ADB)

N250

or

E250

(DCO1)

N251

or

E251

(CS1)

Alarm Description Possible Cause

Distal air
cumulative

Distal air
cumulative

500 µL of air
detected in
the last 5.3 mL
of fluid delivered

Distal air bolus Distal air bolus 100 µL bolus

of air detected
at distal sensor

Door opened
while pumping

Valve/cass
test fail

Door opened
while pumping

Valve/cassette
test failure

Door opened
while pumping

Valve/cassette
fails the leak test

Corrective

Action

Remove and
manually reprime
the cassette
and restart
the infuser

Remove and
manually reprime
the cassette
and restart
the infuser

Turn off the
infuser
or
Insert the
cassette and
close the door

Replace cassette
and retest
or
Backprime
and retest

N252

or

E252

(BDP)

N253

or

E253

(LOV)

N254

or

E254

(FPL)

Depleted battery Low battery The battery

terminal voltage
is less than

5.45 V

Lockout violation Hard lockout

violation

The use of the
[STOP] key or an
attempt to open
the door while
lockout switch
is locked

Lockout Enabled Keypad locked Any action not

resulting in
stopping of the
delivery while
the lockout
switch is locked

Connect the
infuser to
AC power
or
Recharge
or replace
the battery

Unlock the
lockout switch

Unlock the
lockout switch

430-95424-002 (Rev. 01/06) 6 - 6 Plum A+

®

3 Infusion System

6.3 ALARM MESSAGES AND ERROR CODES

Table 6-2. Operational Alarm Messages and Corrective Actions

Alarm

Code

N255

(SLV)

N256

(SLE)

Alarm Description Possible Cause

Lockout violation Soft lockout

violation

Lockout enabled Soft lockout

enabled

The use of the

[STOP] key or an

attempt to open

the door while the

lockout switch

is locked

Any action not

resulting in

stopping of

delivery while

the lockout

switch is locked

Corrective

Action

Unlock the
software lockout
switch

Unlock the
software lockout
switch

6.3.2

ERROR CODES REQUIRING TECHNICAL SERVICE

Table 6-3 lists infusion system error codes that require technical service. Also listed

in Table 6-3 are malfunction descriptions, possible causes, and corrective actions.

Table 6-3. Error Codes Requiring Technical Service

Error

Code Malfunction Possible Cause Corrective Action

E300 ADC failure Analog to digital

converter failure

E301 Audio alarm

failure

E302 Backlight failure Backlight (CCFT tube) is

Piezo is off but sensed on
or
Piezo is on but sensed off

not at the expected range

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date,
if required

(see Section 1.8.3)

Turn power off, then on,
to reset the infuser

Replace piezo alarm

(see Section 7.2.14.7)

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date,
if required

(see Section 1.8.3)

Turn power off, then on,
to reset the infuser

Replace display

(see Section 7.2.14.3)

Reset time and date,
if required

(see Section 1.8.3)

Technical Service Manual 6 - 7 430-95424-002 (Rev. 01/06)

SECTION 6 TROUBLESHOOTING

Table 6-3. Error Codes Requiring Technical Service

Error

Code

Malfunction Possible Cause Corrective Action

E320 Battery charge

current out
of range

E321 Battery not

charging

E322 Battery current

calibration value
out of range

E323 Battery trickle

charge current
out of range

E324 Supply

overvoltage

E325 Battery

overvoltage

Battery charge current is
out of range after 8 hours

Battery charging timed out
Complete battery discharge

has occurred

Battery integrator calibration
value is out of range

Battery trickle charge
current is out of range

An overvoltage condition
is detected in the charging
circuit

An overvoltage condition
is detected in the battery

Replace battery

(see Section 7.2.4)

Replace power supply PWA

(see Section 7.2.14.1)

Reset time and date,
if required

(see Section 1.8.3)

Charge battery for
additional 8 hours

Replace battery

(see Section 7.2.4)

Replace power supply PWA

(see Section 7.2.14.1)

Reset time and date,
if required

(see Section 1.8.3)

E326 Battery

disconnected

E327 Brownout

condition

E340 Critical

instruction
failure

E341 Critical data

memory failure

Battery disconnected
while the infuser is on

Check for loose battery
connections

Replace battery

(see Section 7.2.4)

Reset time and date,
if required

(see Section 1.8.3)

Brownout condition detected Replace power supply PWA

(see Section 7.2.14.1)

Reset time and date,
if required

(see Section 1.8.3)

Power-up CPU
register test failed
(no malfunction
message displayed)

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date,
if required

(see Section 1.8.3)

Critical data memory failure Replace mechanism

assembly

(see Section 7.2.14.8)

Reset time and date,
if required

(see Section 1.8.3)

430-95424-002 (Rev. 01/06) 6 - 8 Plum A+

®

3 Infusion System

6.3 ALARM MESSAGES AND ERROR CODES

Table 6-3. Error Codes Requiring Technical Service

Error

Code

Malfunction Possible Cause Corrective Action

E342 Display failure Defective display Replace display

(see Section 7.2.14.3)

Reset time and date,
if required

(see Section 1.8.3)

E343 Distal air sensor

failure 1

E344 Distal air sensor

failure 2

E345 Distal pressure

sensor failure 1

E346 Distal pressure

sensor failure 2

E347 Hardware

watchdog
failure

E378 I/O valve

phase loss

With the cassette removed,
the distal air sensor self test
detects liquid

With the cassette inserted,
the distal air sensor self test
detects sensor out of range

Replace mechanism
assembly

(see Section 7.2.14.8)

Reset time and date,
if required

(see Section 1.8.3)

Distal air sensor failed
while the infuser is off

Distal air sensor failed
while the infuser is on

Hardware watchdog failure Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date,
if required

(see Section 1.8.3)

Generic I/O valve failure Turn power off, then on,

to reset the infuser
Replace mechanism

assembly

(see Section 7.2.14.8)

Reset time and date,
if required

(see Section 1.8.3)

E379 L/S valve

phase loss

E380 Plunger motor

phase loss

Generic L/S valve failure Turn power off, then on,

to reset the infuser

Generic plunger motor failure

Replace mechanism
assembly

(see Section 7.2.14.8)

Reset time and date,
if required

(see Section 1.8.3)

Technical Service Manual 6 - 9 430-95424-002 (Rev. 01/06)

SECTION 6 TROUBLESHOOTING

Table 6-3. Error Codes Requiring Technical Service

Error

Code

Malfunction Possible Cause Corrective Action

E430 Proximal

air sensor
failure 1

E431 Proximal

air sensor
failure 2

E432 Proximal

pressure

Proximal air sensor ongoing
test detects liquid with
cassette removed

Proximal air sensor self test
detects liquid with cassette
removed

Proximal pressure sensor
failed while the infuser is off

Replace mechanism
assembly

(see Section 7.2.14.8)

Reset time and date,
if required

(see Section 1.8.3)

sensor 1

E433 Proximal

pressure

Proximal pressure sensor
failed while the infuser is on

sensor 2

E434 RAM failure RAM failure Turn power off, then on,

to reset the infuser
Replace peripheral

assembly

(see Section 7.2.7)

Reset time and date,
if required

(see Section 1.8.3)

E435 RTC failure Real-time clock failure Turn power off, then on,

to reset the infuser
Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date,
if required

(see Section 1.8.3)

E436 ROM failure ROM checksum failure Turn power off, then on,

to reset the infuser
Replace peripheral

assembly

(see Section 7.2.7)

Reset time and date,
if required

(see Section 1.8.3)

E437 Software failure Generic software failure Turn power off, then on,

to reset the infuser

E438 Stack

out-of-range
failure

Stack out-of-range failure

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date,
if required

(see Section 1.8.3)

430-95424-002 (Rev. 01/06) 6 - 10 Plum A+

®

3 Infusion System

Error

Code

6.3 ALARM MESSAGES AND ERROR CODES

Table 6-3. Error Codes Requiring Technical Service

Malfunction Possible Cause Corrective Action

E439 Stuck key A key is sensed as pressed

for over two minutes

E440 Power hold stuck Power hold signal stuck

Power cannot be turned off

Replace keypad

(see Section 7.2.14.2)

Reset time and date,
if required

(see Section 1.8.3)

E443 LCD failure LCD bias is out of range Replace display

(see Section 7.2.14.3)

Reset time and date,
if required

(see Section 1.8.3)

E444 CPU timebase

inaccurate

CPU timer 2 and RTC
measured times disagree

Turn power off, then on,
to reset the infuser

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date,
if required

(see Section 1.8.3)

E445 RTC memory

failure

Real-time clock memory
is corrupt

Turn power off, then on,
to reset the infuser

Reset time and date,
if required

(see Section 1.8.3)

E446 CPU timer failure CPU timer 1 and timer 2

measured times disagree

E447 Battery ADC

reading failure

16 consecutive readings
have been either all zero
or the max value

E448 SEEP write

SEEP data write failed Replace mechanism

failure

E449 SEEP calibration

data corrupted

E450 MMIO port

Calibration data
block corrupted

I/O port read/write failure Replace CPU PWA

read/write
failure

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date,
if required

(see Section 1.8.3)

assembly

(see Section 7.2.14.8)

Replace CPU PWA

(see Section 7.2.14.6)

Replace CPU/driver cable

(see Section 7.2.14.4)

Reset time and date,
if required

(see Section 1.8.3)

(see Section 7.2.14.6)

Reset time and date,
if required

(see Section 1.8.3)

Technical Service Manual 6 - 11 430-95424-002 (Rev. 01/06)

SECTION 6 TROUBLESHOOTING

Table 6-3. Error Codes Requiring Technical Service

Error

Code

Malfunction Possible Cause Corrective Action

E451 Inaccurate

delivery

E452 Software failure Miscellaneous

E453 Two SEEP

CRC errors

E454 NVRAM over

capacity

E455 Invalid device

configuration

E456 Invalid drug

library

Over/under delivery detected Turn power off, then on,

software failures

NVRAM data block corrupted Replace mechanism

Software trying to write into
non-existent NVRAM space

Incorrect flash memory
on peripheral PWA

A drug library install was
started but not completed
successfully

to reset the infuser
Reset time and date,

if required

(see Section 1.8.3)

If error codes recur,

contact Hospira

assembly

(see Section 7.2.14.8)

Replace CPU PWA

(see Section 7.2.14.6)

Replace CPU/driver cable

(see Section 7.2.14.4)

Reset time and date,
if required

(see Section 1.8.3)

Turn power off, then on,
to reset the infuser

Replace peripheral PWA

(see Section 7.2.8)

Attempt to reinstall
the library install

(see the system
operating manual)

Replace peripheral
assembly

(see Section 7.2.7)

E457 Drug library

corrupted

CRC failure on drug library Reload the library

(see the system
operating manual)

 Note: The following error codes are not generated in the biomed service mode:

E320

E321

E322

E323

E324

E325

E326

E343

E345

E346

E371

E372

E373

E374

E375

E376

E377

E378

E379

E380

E430

E431

E432

E433

E441

E447

 Note: Some error codes include sub-ID codes. These sub-ID codes are intended for

Hospira internal use only, and should be included when contacting Hospira Technical

Support Operations (see Section 6.1).

®

430-95424-002 (Rev. 01/06) 6 - 12 Plum A+

3 Infusion System

6.4 TROUBLESHOOTING PROCEDURES

6.4

TROUBLESHOOTING PROCEDURES

This section details recommended procedures for problems not associated with
malfunction alarms. Before performing any troubleshooting procedure, turn the infuser
off, then on.

Allow the self test to complete and proceed as follows:

1. If a malfunction exists, carefully inspect the infuser for damage as described
in Section 5.2.2.

2. If an infuser inspection has not disclosed a malfunction, perform the PVT
in Section 5.2. See Table 6-4 for section reference, probable cause, and corrective
actions.

3. If, after completing step 1 and step 2, a malfunction has not been located, or if the
infuser persistently fails, contact Hospira (see Section 6.1).

Table 6-4. Troubleshooting with the PVT

Test Failure Probable Cause Corrective Action

Self test

Section 5.2.4

Cassette alarm test

Section 5.2.5

Free flow test

Section 5.2.6

Display test

Section 5.2.7

Keypad verification/
functional test

Section 5.2.8

Cassette not properly
installed

Defective CPU PWA Replace CPU PWA

Cassette not properly
seated

Defective cassette Replace cassette

Cassette not properly
seated

Defective cassette Replace cassette

Defective or dirty valve pins Clean valve pins

Defective display assembly Replace display

Defective keypad Replace keypad

Reseat cassette

(see Section 7.2.14.6)

Reseat cassette

Reseat cassette

Replace mechanism assembly

(see Section 7.2.14.8)

(see Section 7.2.14.3)

(see Section 7.2.14.2)

Alarm loudness test

Section 5.2.9

Technical Service Manual 6 - 13 430-95424-002 (Rev. 01/06)

Defective CPU Replace CPU PWA

(see Section 7.2.14.6)

Defective peripheral PWA Replace peripheral PWA

(see Section 7.2.8)

Defective piezo alarm
assembly

Replace piezo alarm assembly

(see Section 7.2.14.7)

SECTION 6 TROUBLESHOOTING

Table 6-4. Troubleshooting with the PVT

Test Failure Probable Cause Corrective Action

Lockout switch test

Section 5.2.10

Proximal occlusion test

Section 5.2.11

Proximal air-in-line test

Section 5.2.12

Distal air-in-line test

Section 5.2.13

Defective peripheral PWA Replace peripheral PWA

(see Section 7.2.8)

Closed proximal clamp Open clamp

Cassette not properly

Re-prime cassette

primed

Defective cassette Replace cassette

Dirty sensor pin Clean sensor pin

Defective APP PWA Replace mechanism assembly

(see Section 7.2.14.8)

Defective special cassette Replace special cassette

Dirty sensors Clean sensors

Defective APP PWA Replace mechanism assembly

(see Section 7.2.14.8)

Defective special cassette Replace special cassette

Dirty sensors Clean sensors

Defective APP PWA Replace mechanism assembly

(see Section 7.2.14.8)

Distal occlusion test

Section 5.2.14

Delivery accuracy test

Section 5.2.15

Electrical safety test

Section 5.2.16

Cassette not properly

Re-prime cassette

primed

Defective cassette Replace cassette

Dirty sensor pin Clean sensor pin

Defective APP PWA Replace mechanism assembly

(see Section 7.2.14.8)

Set not properly primed Re-prime cassette

Damaged or faulty cassette Replace cassette

Defective mechanism
assembly

Replace mechanism assembly

(see Section 7.2.14.8)

Defective AC power cord Replace AC power cord

(see Section 7.2.5)

430-95424-002 (Rev. 01/06) 6 - 14 Plum A+

®

3 Infusion System

Section 7

REPLACEABLE PARTS AND REPAIRS

This section itemizes all parts and subassemblies of the infusion system that are repairable
within the scope of this manual. In addition, this section details replacement procedures
for all listed parts.

7.1

REPLACEABLE PARTS

Replaceable parts for the infusion system are itemized in the spare parts price list and are
identified in Figure 9-1. Table 9-2 identifies each part by an index number that correlates
to Figure 9-1.

To request a copy of the current spare parts price list, contact Hospira Technical Support

Operations (see Section 6.1), or to view the catalog online, visit the website at:

www.hospiraparts.com

For convenient reference, insert a copy of the spare parts price list here.

Technical Service Manual 7 - 1 430-95424-002 (Rev. 01/06)

SECTION 7 REPLACEABLE PARTS AND REPAIRS

This page intentionally left blank.

430-95424-002 (Rev. 01/06) 7 - 2 Plum A+

®

3 Infusion System

7.2 REPLACEMENT PROCEDURES

7.2

REPLACEMENT PROCEDURES

This section contains safety and equipment precautions, required tools and materials,
and step-by-step procedures for replacing parts in the infuser. Unless otherwise stated,
always perform the PVT after a replacement procedure.

7.2.1

SAFETY AND EQUIPMENT PRECAUTIONS

Before opening the front enclosure of the infuser, take all necessary precautions for
working on high-voltage equipment.

WARNING: POSSIBLE EXPLOSION HAZARD EXISTS IF THE INFUSER

WARNING: UNLESS OTHERWISE INDICATED, DISCONNECT THE INFUSER

CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store PWAs
in antistatic bags before placing them on any surface.

IS SERVICED IN THE PRESENCE OF FLAMMABLE ANESTHETICS.

FROM AC POWER BEFORE PERFORMING ADJUSTMENT
OR REPLACEMENT PROCEDURES.

7.2.2

REQUIRED TOOLS AND MATERIALS

The following tools and materials, or equivalents, are required for the replacement
procedures in this section. In addition, the beginning of each procedure lists tools and
materials required for that specific procedure.

- Set of flat blade screwdrivers

- Set of Phillips

- Set of standard and metric nutdrivers

®

screwdrivers

- Wide head pliers

- Diagonal cutters

-X-acto

®

knife

- Metric 10 mm wrench

- Custom nutdriver (P/N 519-95056-001)

- Long needle nose pliers

Technical Service Manual 7 - 3 430-95424-002 (Rev. 01/06)

- Mild solvent

- Lint-free cloth

SECTION 7 REPLACEABLE PARTS AND REPAIRS

7.2.3

RUBBER FOOT PAD REPLACEMENT

The recommended tool for this procedure is a #2 Phillips screwdriver.

The replacement parts for this procedure are:

Pad, Rubber Foot
Screw, 6-32 x 1/2, Pan Head, Phillips

To replace a rubber foot pad, see Figure 7-1, then proceed as follows:

1. Turn off the infuser, and disconnect the device from AC power.

2. Place the infuser face down on a soft flat surface.

3. Using the Phillips screwdriver, remove the screw that secures the rubber foot pad.

4. Install the replacement rubber foot pad in the exact reverse order of removal.

Replacement of a rubber foot pad is routine maintenance and no verification procedure
is normally required. However, if the infuser may have been damaged during rubber foot
pad replacement, perform the PVT in Section 5.2.

Figure 7-1. Bottom View

RUBBER FOOT PAD (4)

BATTERY DOOR

PAN HEAD SCREW (4)

05K06006

(3)

6-32 x 1/2

430-95424-002 (Rev. 01/06) 7 - 4 Plum A+

®

3 Infusion System

7.2 REPLACEMENT PROCEDURES

7.2.4

BATTERY, BATTERY DOOR, AND DOOR PAD REPLACEMENT

Recommended tools for this procedure are a medium size flat blade screwdriver,
mild solvent, and a lint-free cloth.

The replacement parts for this procedure are:

Assembly, Battery, with Wire Harness
Door, Battery
Pad, Door
Ring, Retaining
Screw, 6-32 x 1/2, Hex Head, Slotted, with Washer

To replace a battery, battery door, and door pad, see Figure 7-2, then proceed as follows:

1. Turn off the infuser, and disconnect the device from AC power.

2. Place the infuser face down on a soft flat surface.

3. Using the flat blade screwdriver, remove the screw and retaining ring that attach
the battery door to the infuser, and remove the door.

4. Inspect the battery door and door pad for damage. Replace the door, if required.

5. If the battery door pad is defective, remove it and clean the door with mild solvent.
Dry the battery door thoroughly, and install the replacement pad on the door.

6. Disconnect the battery harness from the charger circuit cable. Carefully pull the
battery harness wires and connector outside the enclosure, and remove the battery.

7. Connect the replacement battery harness to the charger circuit cable, and insert
the replacement battery into the enclosure.

 Note: The cable connectors are keyed so that cables cannot be connected

incorrectly.

 Note: Confirm the battery harness is not pinched between the battery and the

enclosure.

8. Replace the battery door using the screw and retaining ring that were removed
in step 3.

9. Press [ON/OFF] with the infuser disconnected from AC power, and verify the front
panel battery symbol illuminates.

10. Access the BIOMED SETTINGS screen and press [CHANGE BATTERY].

 Note: The [CHANGE BATTERY] softkey will not appear on earlier versions

of the Plum A+

Replacement of the battery door and door pad is routine maintenance and no verification
procedure is normally required. However, if the infuser may have been damaged during
these procedures, perform the PVT in Section 5.2.

®

3.

Technical Service Manual 7 - 5 430-95424-002 (Rev. 01/06)

SECTION 7 REPLACEABLE PARTS AND REPAIRS

AC POWER CORD

BATTERY
ASSEMBLY (3)

DOOR PAD (3)

RETAINING RING (3)

BATTERY DOOR (3)

VELCRO STRAP

EQUIPOTENTIAL

TERMINAL

POWER CORD

6-32 x 1/2
HEX HEAD
SCREW (3)

Figure 7-2.

AC Power Cord, Retainer, Velcro Strap, and Battery Assembly

4-40 x 3/8

FLAT HEAD

SCREW

RETAINER

05K06001

430-95424-002 (Rev. 01/06) 7 - 6 Plum A+

®

3 Infusion System

7.2 REPLACEMENT PROCEDURES

7.2.5

AC POWER CORD, RETAINER, AND VELCRO STRAP REPLACEMENT

The recommended tool for this procedure is a #2 Phillips screwdriver.

The replacement parts for this procedure are:

Cordset, AC Power, Hospital Grade, Detachable
Retainer, AC Power Cord
Strap, Velcro, AC Power Cord
Screw, 4-40 x 3/8, Pan Head, Phillips

To replace the AC power cord, retainer, or Velcro strap, see Figure 7-2, then proceed
as follows:

1. Turn off the infuser, and disconnect the device from AC power.

2. Remove the batteries as described in Section 7.2.4.

3. Using the Phillips screwdriver, remove the screw from the AC power cord retainer.
Turn the power cord retainer approximately 1/8 turn counterclockwise.

4. Unplug the power cord, and slide the plug through the retainer.

 Note: Remove the AC power cord from its receptacle by grasping the plug.

Do not pull the cord.

5. Remove the Velcro strap from the power cord. Inspect the Velcro strap for wear and
replace the strap, if required. Attach the strap to the replacement power cord.

6. Install the replacement AC power cord in the exact reverse order of removal.

7. Reinstall the batteries and connect the infuser to AC power.

8. Press [ON/OFF] and verify the infuser powers on.

Replacement of the AC power cord, retainer, and Velcro strap is routine maintenance and
no verification procedure is normally required. However, if the infuser may have been
damaged during these procedures, perform the PVT in Section 5.2.

Technical Service Manual 7 - 7 430-95424-002 (Rev. 01/06)

SECTION 7 REPLACEABLE PARTS AND REPAIRS

7.2.6

SEPARATING THE FRONT ENCLOSURE, REAR ENCLOSURE, AND MAIN CHASSIS ASSEMBLY

The recommended tool for this procedure is a #2 Phillips screwdriver.

 Note: The front enclosure consists of an upper assembly and a lower assembly.

The main chassis assembly consists of an upper chassis and a lower chassis.

The replacement parts for this procedure are:

Enclosure, Upper Front
Enclosure, Lower Front
Enclosure, Rear
Chassis, Upper
Chassis, Lower
Screw, 6-32 x 1/2, Pan Head, Phillips
Screw, 6-32 x 1 1/4, Pan Head, Phillips
Screw, 6-32 x 2 3/4, Pan Head, Phillips
Screw, 8-32 x 3 1/2, Pan Head, Phillips
Washer, Flat, #6
Washer, Flat #8

CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store PWAs
in antistatic bags before placing them on any surface.

To separate the front enclosure, rear enclosure, and main chassis assembly, see Figure 7-3,
then proceed as follows:

1. Turn off the infuser, and disconnect the device from AC power.

2. Remove the battery doors and batteries as described in Section 7.2.4.

3. Remove the AC power cord and retainer as described in Section 7.2.5.

4. Using the Phillips screwdriver, remove the screws from the rear enclosure.

5. Remove the rear enclosure by lifting it up and to the side.

6. Disconnect the three internal power connectors.

7. Using the Phillips screwdriver, remove the screws from the bottom corners of the
center mechanism.

8. Set the infuser upright and remove the front upper enclosure by pulling it away
from the upper chassis.

9. Remove the lower front enclosure by tilting the infuser back approximately 10
and pull the lower front enclosure away from the lower chassis.

10. Reassemble the front enclosure, rear enclosure, and main chassis assembly in the
exact reverse order of disassembly. Follow the screw placement sequence as
illustrated in Figure 7-4.

° ,

 Note: When reassembling the upper front enclosure, lift all three door

handles first.

To verify successful assembly, perform the PVT in Section 5.2.

430-95424-002 (Rev. 01/06) 7 - 8 Plum A+

®

3 Infusion System