retains all the exclusive rights of dissemination, reproduction, manuf act ure, an d sale. Any part y
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.
Table 9-2. IPB for the Infusion System . . . . . . . . . . . . . . . . . . 9-2
Table A-1. Guidance and Manufacturer’s Declaration - Electromagnetic Emissions . . A-1
Table A-2. Guidance and Manufacturer’s Declaration - Electromagnetic Immunity . . A-2
Table A-3. Guidance and Manufacturer’s Declaration - Electromagnetic Immunity for
Life-Supporting Equipment and Systems . . . . . . . . . . . . . A-3
Table A-4. Recommended Separation Distances Between Portable and Mobile RF
Communications Equipment and the LifeCare XLM with DataPort . . . . A-5
430-00587-008 (Rev. 2/05)viiiPlum XL Series
Page 11
Section 1
INTRODUCTION
The Plum XL™, XL Micro/Macro, and XL Micro/Macro with DataPort Infusion Systems are
dual-line volumetric infusion systems designed to meet the growing demand for
hospital-wide device standardization. The infusion system provides primary line,
secondary line, and piggyback fluid delivery capabilities to furnish a wide range of general
floor, critical care, and home care applications. Compatibility with LifeCare
PlumSet
cost-effective. The Plum XL Micro/Macro is herein refe rred t o as X LM. T he Pl um XL Micr o /
Macro with DataPort is herein referred to as Plum XLM with DataPort.
®
administration sets and accessories make the infusion system convenient and
Note: References to the Plum XL and XLM Infusion Systems apply to the LifeCare
XL and XLM Infusion Systems as well.
Note: Unless otherwise stated, references to the Plum XLM include the Plum XLM
with DataPort.
Note: Do not connect DataPort when infusing.
®
5000
1.1
SCOPE
This Technical Service Manual applies to Plum XL series infusion systems only. It is
organized into the following sections:
❏ Section 1Introduction
❏ Section 2Warranty
❏ Section 3System Operating Manual
❏ Section 4Theory of Operation
❏ Section 5Maintenance and Service Tests
❏ Section 6Troubleshooting
❏ Section 7Replaceable Parts and Repair
❏ Section 8 Specifications
❏ Section 9 Drawings
❏ Appendices
❏ Index
❏ Technical Service Bulletins
If a problem in device operation cannot be resolved using the information in this manual,
contact Hospira (see Section 6.1, Technical Assistance).
Technical Service Manual1 - 1430-00587-008 (Rev. 2/05)
Page 12
SECTION 1 INTRODUCTION
Specific instructions for operating the device are contained in the Plum XL System
Operating Manual, Plum XL Micro/Macro System Operating Manual, and Plum XL Micro/
Macro with DataPort System Operating Manual. Provision is made for the inclusion of the
system operating manual in Section 3 of this manual.
Note: In this manual, the terms “device” and “infusion system” refer to all
configurations of the Plum XL series infusion system unless otherwise specified.
Display messages and key labels may vary slightly, depending on the configuration
of the infusion system in use.
Note: Figures are rendered as graphic representations to approximate actual
product; therefore, figures may not exactly reflect the product.
1.2
GLOBAL PRODUCT CONFIGURATIONS
The design of the infusion system facilitates its operation in many countries with slight
modification to the product. Three configurations presented in this manual are detailed
in Table 1-1, Global Product Configurations. The front panels of the English language and
icon based system are shown in Figure 1-1, Plum XL Icon Based and English Language
Front Panels and Figure 1-2, Plum XLM Icon Based and English Language Front Panels.
Group
Icon
115V
220V
Table 1-1. Global Product Configurations
List NumberCountry
11555-04
11846-04
11859-04
12570-04
11555-13 French
11555-88
11846-88
11859-88*
11555-27
11846-27
11859-27*
11555-54
11846-54
11859-54*
11555-09
11846-09
11859-09*
USA100-130
Canadian
Spanish
Australia210-260
UK
Spanish
(Latin
America)
Power
Supply
VAC
100-130
VAC
VAC
210-260
VAC
Rear CaseLCD
Nondetachable AC
(mains) power cord
Nondetachable AC
(mains) power cord
Detachable AC
(mains) power cord
Detachable AC
(mains) power cord
English
Icons
English
Icons
430-00587-008 (Rev. 2/05)1 - 2Plum XL Series
Page 13
Group
Icon
Table 1-1. Global Product Configurations
List NumberCountry
11555-29
French
11846-29
11859-29*
11555-36
Europe
11846-36
11859-36*
11846-42
Italy
11859-42*
11555-46
Swedish
11846-46
11859-63*Poland
11859-69*Hungary
11859-71*Czech
Republic
Power
Supply
1.2 GLOBAL PRODUCT CONFIGURATIONS
Rear CaseLCD
* Complies with IEC/EN 60601-1-2: 2001
EN-2
Technical Service Manual1 - 3430-00587-008 (Rev. 2/05)
Page 14
SECTION 1 INTRODUCTION
mL / H
mL
ICON BASED
0000 mL
PRI
SEC
SET VTBI
SET RATE
OFF
CHARGE
ENGLISH LANGUAGE
RUN
HOLD/RESET
TITRATE
BACK
PRIME
CLEAR
VOL
SILENCE
04K01021
Figure 1-1. Plum XL Icon Based and English Language Front Panels
ENGLISH LANGUAGE
PRI
SEC
SET VTBI
SET RATE
OFF
CHARGE
RUN
QUICKSET
TITRATE
BACK
PRIME
HOLD/RESET
CLEAR
VOL
SILENCE
1
mL/H
ICON BASED
2
mL
0000 mL
04K01022
Figure 1-2. Plum XLM Icon Based and English Language Front Panels
430-00587-008 (Rev. 2/05)1 - 4Plum XL Series
Page 15
1.3 CONVENTIONS
1.3
CONVENTIONS
The conventions listed in Table 1-2, Conventions, are used throughout this manual.
Table 1-2.Conventions
ConventionApplicationExample
ItalicReference to a section, figure,
table, or publication
[ALL CAPS]In-text references to keys are
described in all caps and
enclosed in brackets
ALL CAPS
Initial Caps with lowercase
BoldEmphasisCAUTION: Use proper ESD
Screen displaysDOOR/CASSETTE
(see Figure 5-4, Distal
Occlusion Test Setup)
[TITRATE]
Self test in progress
grounding techniques
when handling
components.
Throughout this manual, warnings, cautions and notes are used to emphasize important
information.
WARNING:A WARNING CONTAINS SPECIAL SAFETY EMPHASIS AND
MUST BE OBSERVED AT ALL TIMES. FAILURE TO OBSERVE
A WARNING MAY RESULT IN PATIENT INJURY AND IS
POTENTIALLY LIFE THREATENING.
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.
Note: A note highlights information to help clarify a concept, procedure or statement.
: Information applies to IEC/EN 60601-1-2: 2001 compliant devices.
EN-2
Technical Service Manual1 - 5430-00587-008 (Rev. 2/05)
Page 16
SECTION 1 INTRODUCTION
1.4
COMPONENT DESIGNATORS
Components are indicated by alpha-numeric designators, as follows:
BatteryBTDiodeDResistorR
CapacitorCFuseFSwitchSW
CrystalYIntegrated CircuitUTransistorQ
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.
1.5
ACRONYMS AND ABBREVIATIONS
Acronyms and abbreviations used in this manual are as follows:
The Plum XL series infusion system is 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.
Technical Service Manual1 - 7430-00587-008 (Rev. 2/05)
Page 18
SECTION 1 INTRODUCTION
1.7
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 infuser 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.
1.8
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 infusion system. Do not place the infusion system 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.
CAUTION: Before operating the infusion system next to, or in a stacked
configuration with other electrical equipment, confirm the infusion system’s
operational performance in that configuration.
CAUTION: The use of any accessory, transducer or cable with the LifeCare XLM
with DataPort other than those specified may result in increased emissions or
decreased immunity of the LifeCare XLM with DataPort.
The instrument installation procedure consists of unpacking, inspecting, and self test.
Note: Do not place the infusion system in service if the battery is not fully charged.
To make certain the battery is fully charged, connect the infusion system to AC
(mains) power for eight hours (see Section 8, Specifications).
1.8.1
UNPACKING
Inspect the infusion system shipping container as detailed in Section 1.8.2, Inspection.
Use care when unpacking the infusion system. Retain the packing slip and save all packing
materials in the event it is necessary to return the infusion system to the factory. Verify
that the shipping container includes a copy of the system operating manual.
430-00587-008 (Rev. 2/05)1 - 8Plum XL Series
Page 19
1.8 INSTRUMENT INSTALLATION PROCEDURE
1.8.2
INSPECTION
Inspect the infusion system for shipping damage. Should any damage be found, contact
the delivering carrier immediately.
CAUTION: Do not use the infusion system if it appears to be damaged. Should
damage be found, contact Hospira (see Section 6.1, Technical Assistance). Do not use
the infusion system if it appears to be damaged.
Inspect the infusion system periodically for signs of defects such as worn accessories,
broken connections, or damaged cable assemblies. Also inspect the infusion system after
repair or during cleaning. Replace any damaged or defective external parts.
1.8.3
SELF TEST
CAUTION: Do not place the infusion system in service if the self test fails.
To perform the self test, refer to Figure 1-3, Plum XL LCD Test Screens and Figure 1-4, Plum
XLM LCD Test Screens, and proceed as follows:
1. Connect the infusion system AC (mains) power cord to a grounded AC (mains) outlet
and confirm the AC (mains) power icon (next to the OFF/CHARGE setting)
illuminates.
2. Open the door assembly (cassette door) by lifting up on the cassette door handle.
3. Hold a primed cassette by its handle and insert the cassette into the cassette door
guides. Do not force the cassette into position.
4. Close the cassette door handle to lock the cassette in place.
5. Turn the control knob to SET RATE to initiate the self test.
6. Verify the following screens display in succession:
- LCD test screen
- Four backward Cs (approximately two seconds)
- Set rate screen
7. Disconnect the infusion system from AC (mains) power and confirm BATTERY
displays on the LCD screen.
8. Turn the control knob to OFF/CHARGE and remove the administration set.
9. To allow the battery to charge fully, connect the infusion system to AC (mains) power
for a minimum of eight hours with the control knob in the OFF/CHARGE position.
Confirm the AC (mains) power icon illuminates.
Technical Service Manual1 - 9430-00587-008 (Rev. 2/05)
Page 20
SECTION 1 INTRODUCTION
Note: If the LCD test screen does not match Figure 1-3 or Figure 1-4 exactly, contact
Hospira.
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, Troubleshooting). If the alarm condition continues to recur, remove the
infusion system from service and contact Hospira.
AIR IN LINEEMPTYLOW BATTERYKVOTURN TO RUNCHECK SETTINGSOCCLUSION
SECONDARYPRIMARYBACKPRIMING
AIR IN LINEEMPTYLOW BATTERY
SET
KVO
RATE
TURN TO RUN CHECK SETTINGS OCCLUSION
VTBI
SECONDARYPRIMARY BACKPRIMING
PIGGYBACK ML/HR
SET
RATE
VTBI
PIGGYBACK ML/HR
AIR IN LINELOCKEDLOW BATTERY
KVO VTBI COMPLETEDOORCASSETTE
TURN TO RUN CHECK SETTINGS OCCLUSION
SECONDARYPRIMARY BACKPRIMING
SET
RATE
VTBI
PIGGYBACK ML/HR MICRO
VTBI COMPLETE
VTBI COMPLETE
ENGLISH LANGUAGE
ENGLISH LANGUAGE
DOOR/CASSETTE
DOOR/CASSETTE
TOTAL VOLUMEDELIVERED
TOTAL VOLUME
DELIVERED
Figure 1-3. Plum XL LCD Test Screens
TOTAL VOLUME
DELIVERED
OK
ICON BASED
KVO 2 1 mL=mL mL/H,mL?
OK
KVO 2 1 mL=mL mL/H,mL?
2 1 mL/H
2 1 mL/H
ICON BASED
KVO 2 1 ml=ml ml/hr,ml?
2 1 ml/hrm
ML
04K01024
ML
04K01024
ml
04K01025
Figure 1-4. Plum XLM LCD Test Screens
Note: All LCD screens on international infusion systems are icon-based, with the
exceptions of country codes 27 and 54.
430-00587-008 (Rev. 2/05)1 - 10Plum XL Series
Page 21
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 a Hospira
representative performing repair or service is not an authorized agent of Hospira.
Technical Service Manual2 - 1430-00587-008 (Rev. 2/05)
Page 22
SECTION 2 WARRANTY
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430-00587-008 (Rev. 2/05)2 - 2Plum XL Series
Page 23
Section 3
SYSTEM OPERATING MANUAL
A copy of the system operating manual is included with every 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
Assistance).
Technical Service Manual3 - 1430-00587-008 (Rev. 2/05)
Page 24
SECTION 3 SYSTEM OPERATING MANUAL
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430-00587-008 (Rev. 2/05)3 - 2Plum XL Series
Page 25
Section 4
THEORY OF OPERATION
This section describes the infusion system theory of operation. Related drawings are
provided in Section 9, Drawings. The theory of operation details the infusion system
general description, electronics overview for both 115 VAC and 220 VAC systems, and
mechanical overview of the system.
4.1
GENERAL DESCRIPTION
The infusion system includes the following features:
❏ Volume to be infused (VTBI) setting
❏ Safeguards to protect against overdelivery:
- Motor speed is continuously monitored
- Firmware senses malfunctions that could result in gravity flow
❏ Volume infused accumulation displays for primary and secondary solutions
❏ Flow rate selection from 1 to 999 mL/hr in 1 mL increments (XL)
❏ Flow rate selection from 0 to 99.9 mL in 0.1 mL/hr increments and 100 to 999 mL/
hr in 1 mL increments (XLM)
❏ Battery operation
❏ Self test
❏ Simple setup (one hand cassette loading)
❏ Automatic memory retention of all previous therapy settings and fluid delivery data
until cleared by user
❏ Alarms include the following:
-OCCLUSION
-AIR-IN-LINE
-TURN TO RUN
- LOW BATTERY
- DOOR/CASSETTE (XL)
- DOOR (XLM)
- CASSETTE (XLM)
- SET RATE
- CHECK SETTINGS
-VTBI COMPLETE
❏ Two-level adjustable alarm volume
❏ Remote monitoring with DataPort (XLM with DataPort)
❏ Nurse call alarm (XLM with DataPort - Nurse Call)
Technical Service Manual4 - 1430-00587-008 (Rev. 2/05)
Page 26
SECTION 4 THEORY OF OPERATION
Note: Do not connect DataPort when infusing.
Note: Nurse call alarm is not available in IEC compliant infuser.
EN-2
4.2
ELECTRONICS OVERVIEW
This section describes the function and electronic circuitry of each printed wiring assembly
(PWA) in the infusion system:
❏ Power supply PWA
❏ Micro controller unit (MCU) PWA
❏ Display PWA
❏ Buzzer PWA
❏ Sensor PWA
❏ Bubble sensor PWA
Schematic diagrams supporting the operation of infusion system PWAs are in
Section 9, Drawings.
4.2.1
POWER SUPPLY PWA
The power supply PWA provides direct current (DC) power to system circuits and
charges the battery (see Figure 9-23, Power Supply PWA Schematic (XL Domestic),
115V
switcher circuitry, voltage regulator circuitry, and battery charger circuitry. The following
sections describe these circuits.
4.2.1.1
Figure 9-25, Power Supply PWA Schematic (XLM Domestic) or Figure 9-27, Power
Supply PWA Schematic (XLM with DataPort)). The power supply PWA consists of
SWITCHER CIRCUITRY
The primary function of the switcher circuitry is to convert alternating current
AC (mains) line power to an isolated +11 volts DC (VDC). Fuses F1 and F2, and
115V
T1, and inductor L1 attenuate the conducted emissions. Bridge rectifier U1, resistor R1,
and capacitor C3 provide the DC voltage required for switcher circuit. Diodes CR1 and
CR2, R2, R3, CR4, C4, and C9 provide the supply voltage to the current mode-switcher
controller integrated circuit (IC) U2. Transistor Q1, transformer T2, IC U2, and the
associated passive components are enclosed in a shielded box to minimize radiated
electromagnetic interference (EMI). U2 controls the duty cycle of Q1 through resistors R5
and R6. Resistor R9 provides current sensing. Resistor R8 and capacitor C7 filter the ramp
voltage across R9 and feed it back to U2.
variable resistor VR1 provide protection against AC (mains) line-high voltage
spikes and excessive input power demands. Capacitors C1 and C2, transformer
430-00587-008 (Rev. 2/05)4 - 2Plum XL Series
Page 27
4.2 ELECTRONICS OVERVIEW
U2 configuration allows DC voltage at pin 9 (ERR+) to equal the peak voltage across resistor
R9. DC voltage controls the delivered power through transformer T2 to regulate the output
voltage. Voltage at U2-9 is limited to +1.25 VDC so that peak current through transistor
Q1 is limited to approximately 2 amperes (A). This limit constitutes the output short
protection.
Optocoupler U3 is part of the main regulation loop; it provides the UL-544 isolation barrier.
Resistor R61, diode CR5, and capacitor C6 provide protection from T2 windings short by
applying the higher voltage across resistor R9 to the U2 inhibit input. C6 and the input
impedance at U2-4 determine the low hiccup frequency in the event of a T2 winding short.
Diode CR3 and the clamp winding of transformer T2 provide intermediate energy transfer
to capacitor C3 and limit the peak voltage across transistor Q1. At AC (mains) power-up,
capacitor C12 provides delayed timing to permit the voltage potential at U2-14 (Vcc) to
reach its minimum level.
Diode CR11 and capacitors C23 and C24 rectify the transformer T2 voltage to create the
main DC voltage source (+BUSS) for the infusion system. Diode CR10, resistor R23, IC
U4, and capacitor C19 constitute a secondary +12 VDC control loop for protection in case
of primary loop failure. Diode CR12 and capacitor C25 create a feed-forward converted
negative voltage across capacitor C25 to switch transistor Q9 on through resistor R57 and
diode CR14. The Q9 output, housekeeping DC (HKDC), provides the necessary voltage to
power both the main regulation loop and the charger circuitry. HKDC is at ground potential
when AC (mains) is off and CR12 blocks unnecessary battery power drain. Resistors R58,
R59, and R60; capacitors C30, C31, and C32; and IC U9 filter HKDC and create a stable
+2.5 VDC reference voltage (F2.5V).
Resistors R21, R39, R44, and R45; capacitor C27; and components U8B and U3 constitute
the main control loop. Transistor Q7, resistor R42, and diode CR9 eliminate latch-up at
AC (mains) power-up by enabling voltage regulation only after +BUSS reaches +9 VDC.
4.2.1.2
VOLTAGE REGULATOR CIRCUITRY
The primary function of the voltage regulator circuitry is to provide constant DC
level output. The motor voltage (VMOT) regulator circuitry (U8A, Q5, Q4, and
115V
CR8 and resistors R11 and R12. While Q2 remains on, transistor Q3 is disabled to inhibit
POWERHOLD and SPSTIN (single-pole, single-throw in) effect on the VMOT voltage
regulator.
When AC (mains) is off, Q2 is disabled. If battery operation is required, Q4 is turned on
momentarily by the SPSTIN signal and permanently by POWERHOLD. Since Q2 is off, Q4
switches the battery voltage through the VMOT circuitry to supply voltage to the necessary
circuits, including the +5 VDC regulator U5. IC U5, the +5 VDC low-drop voltage regulator,
powers most of the digital circuits in the infusion system.
associated passive components) provides a constant +9.35 VDC output when
AC (mains) is on. Transistor Q2 remains forward-biased by HKDC through diode
Technical Service Manual4 - 3430-00587-008 (Rev. 2/05)
Page 28
SECTION 4 THEORY OF OPERATION
4.2.1.3
BATTERY CHARGER CIRCUITRY
The primary function of the battery charger circuitry is to charge the battery.
The main component of the battery charger circuitry is a constant current source
115V
When AC (mains) is off, Q8 is off and Q6 is on.
The battery is charged by two current levels and trickle current (R20). Charge current
control is achieved by controlling the voltage at U6-6 by the signals LOCHG (low charge),
CHRG_OFF (charge off), and BAT2 (battery 2). The BAT2 signal is active when a short is
introduced at battery connector J26-3 and -4 (an active BAT2 signal implies battery type
2 is connected to connector J26). In this case, the charge current is lower since Q10 is on.
Table 4-1, Battery Charge Current States, lists the charge current state as a function of
the control signals.
comprised of transistors Q6 and Q8, IC U6B, resistor R33, and associated
passive devices. Q6 is the current carrying device and R33 is the sense resistor.
Note: Table 4-1 applies to all 115 VAC and 220 VAC infusion systems.
Table 4-1. Batter y Charge Current States
LOCHG SignalCHRG_OFF SignalJ26-3 to J26-4Approximate Current
LowLowShort0.8 A
LowLowOpen1.2 A
HighLowShort0.16 A
HighLowOpen0.25 A
Don't careHighDon't careTrickle = (11-Vbat)/475
IC U7A also offers overpower protection for transistor Q6. When the voltage across Q6
generates more than +2.5 VDC at U7-4, the charge current switches to low.
The LOCHG_REQ (low charge request) signal alerts the MCU PWA of the battery voltage
level. LOCHG_REQ is generated by ICs U6A, U7B, U7C, U7D, and associated passive
components.
IC U6A, resistors R24 through R28, and capacitor C20 constitute a differential amplifier
that monitors the battery voltage as the battery is being charged. The output of the
differential amplifier is compared to a previously determined level by voltage comparator
U7C. U7C generates the LOCHG_REQ signal. The voltage level depends on whether U7-13
or -1 is low or, alternately, whether battery one or battery two is connected.
430-00587-008 (Rev. 2/05)4 - 4Plum XL Series
Page 29
4.2 ELECTRONICS OVERVIEW
4.2.2
POWER SUPPLY PWA
The power supply PWA consists of switcher circuitry, voltage regulator circuitry,
and battery charger circuitry. Refer to Figure 9-24, Power Supply PWA Schematic
220V
❏ AC (mains) off. Infusion system is not connected to mains voltage and is not operating
❏ AC (mains) off, infusion system on. Infusion system is not connected to mains voltage
❏ AC (mains) on. Infusion system is connected to mains voltage and is not operating
❏ AC (mains) on, infusion system on. Infusion system is connected to mains voltage
4.2.2.1
SWITCHER CIRCUITRY
220V
high-line voltage spikes and abnormally high input power demands. Capacitors C1, C2,
C35, C36, C37, and C38, transformer T1, and inductor L1 are designed for attenuating
the conducted emissions. IC U1, resistor R1, inductor L1, and capacitor C3 provide the
DC voltage required for conversion by the switcher. Diodes CR1, CR2, CR4, and CR15;
resistors R22, R68, R73, and R74; capacitors C4, C9, and C34; and transistors Q11 and
Q12 provide the DC voltage for IC U2, the current mode switcher controller IC.
(XL International), or Figure 9-26, Power Supply PWA Schematic (XLM
International). The power supply PWA includes the following operational modes:
and is operating
and is operating
The switcher circuitry converts AC (mains) voltage to an isolated +11 VDC power
through flyback topology.
Fuses F1 and F2, and variable resistors VR1 and VR2 provide protection against
A UL-544 isolation barrier surrounds transistor Q1, transformer T2, IC U2, and associated
passive components to minimize radiated EMI. Optocoupler U3 is part of the main
regulation loop that provides the UL-544 isolation barrier.
IC U2 oscillates at approximately 40 kHz, a frequency dictated by the values of resistor
R4 and capacitor C5. U2 controls the duty cycle of transistor switch Q1 through resistors
R5 and R6, and diode CR16. Resistor R9 provides the current sense and resistor R8 and
capacitor C7 filter the ramp voltage across R9 and feed it back to IC U2.
U2 configuration allows DC voltage at pin 9 (ERR+) to equal the peak voltage across resistor
R9. This DC voltage controls the delivered power through transformer T2 to regulate the
output voltage. Voltage at U2 pin 9 is limited to +1.25 VDC so that peak current through
transistor Q1 is limited to 1.25 VDC divided by the value of resistor R9.
Resistors R61 and R72, diode CR5, and capacitor C6 provide transformer T2 winding short
protection by applying the higher voltage across resistor R9 to the U2 inhibit input. C6
and the input impedance at U2-4 apply the low hiccup frequency to protect transistor Q1.
Diode CR3 and the clamp winding of transformer T2 provide intermediate energy transfer
to capacitor C3 and limit the peak voltage across transistor Q1.
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SECTION 4 THEORY OF OPERATION
At AC (mains) power-up, capacitor C12 provides delayed timing to permit the voltage
potential at U2-14 (Vcc) to reach its minimum level. Diode CR11, and capacitors C18, C23,
and C24 rectify the transformer T2 voltage to create the main DC voltage source for the
infusion system. Diode CR10, resistor R23, IC U4, and capacitor C19 constitute a
secondary +12 VDC control loop for protection in case of primary loop failure. Diode CR12
and capacitor C25 create a feed-forward converted negative voltage across capacitor C25
to switch transistor Q9 on through resistor R57 and diode CR14. The Q9 output,
housekeeping DC (HKDC), provides the necessary voltage to power both the main
regulation loop and the charger circuitry. HKDC is at ground level when AC (mains) is off
and diode CR14 inhibits unnecessary battery power drain. Resistors R58 through R60,
capacitors C30 through C32, and IC U9 filter HKDC and create a stable +2.5 VDC reference
voltage (F2.5V). Both HKDC and F2.5V are at ground level when AC (mains) is off.
IC U8B, with resistors R7, R21, R39, R43 through R45, capacitor C27, and IC U3 constitute
the main loop control. Transistor Q7, resistor R42, and diode CR9 eliminate latch-up at
AC (mains) power-up by enabling voltage regulation only after +BUSS reaches +9 VDC.
4.2.2.2
VOLTAGE REGULATOR CIRCUITRY
VMOT voltage regulator circuitry (U8A, Q5, and Q4 and associated passive
220V
Transistor Q2 remains forward-biased by HKDC through diode CR9 and resistors R11 and
R12. While transistor Q2 remains on, transistor Q3 is disabled to inhibit POWERHOLD
and SPSTIN from affecting the voltage regulator circuitry.
When AC (mains) is off, transistor Q2 is disabled. If battery operation is required, transistor
Q4 is turned on momentarily by the SPSTIN signal and permanently by POWERHOLD
through transistor Q3. Since Q2 is off, transistor Q4 switches the battery voltage through
the VMOT circuitry to supply voltage to the necessary circuits, including the +5 VDC
regulator U5. IC U5, the +5 VDC low-drop voltage regulator, powers most of the digital
circuits in the infusion system.
4.2.2.3
components) is at 9.35 VDC when AC (mains) is on.
BATTERY CHARGER CIRCUITRY
The primary part of the battery charger is the constant current source,
comprised of transistors Q6 and Q8, IC U6B, resistor R33, and associated
220V
Q6 is on.
The battery is charged by two current levels and trickle current (resistor R20). Current
level is achieved by controlling the voltage at U6-6. IC U7A, transistor Q10, and resistors
R31, R32, R34, R62, and R63 control the voltage at U6-6, and hence, the current level.
The BAT2 signal is high (not logic level) when a short is introduced at the battery connector
J26 pins 3 and 4, which implies that battery type 2 is connected to connector J26. In this
case, the battery charge current is low since transistor Q10 is on.
passive devices. Transistor Q6 is the current-carrying device, and resistor R33
is the sense resistor. When AC (mains) is off, transistor Q8 is off and transistor
IC U7A also serves as an overpower protection for transistor Q6. When the voltage across
Q6 generates more than 2.5V at U7-4, the charge current switches to low.
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4.2 ELECTRONICS OVERVIEW
The LOCHG_REQ signal alerts the MCU PWA of the battery voltage level; it is generated
by U6A, U7B, U7C, U7D and associated passive components.
IC U6A, resistors R24 through R28, and capacitor C20 constitute a differential amplifier
that reads the battery voltage as it is being charged. The output of the differential amplifier
is compared to a previously determined level by U7C. U7C generates the LOCHG_REQ.
The voltage level depends on whether U7-13 or U7-1 is low or, alternatively, whether
battery type 1 or battery type 2 is connected.
4.2.3
MCU PWA
The MCU PWA contains micro controller U6 (see Figure 9-15, MCU PWA Schematic (XL),
Figure 9-16, MCU PWA Schematic (XLM), or Figure 9-17, MCU PWA Schematic
(XLM with DataPort)). The MCU PWA has five digital ports and one analog port. Each port
is eight lines wide. The MCU PWA also includes the following circuitry:
❏ Watchdog
❏ Serial communication
❏ Alarm
❏ Alarm power backup
❏ Motor drivers
❏ Pin detector
❏ Universal asynchronous receiver/transmitter (UART) (XLM with DataPort)
4.2.3.1
WATCHDOG CIRCUITRY
The watchdog circuitry continuously monitors the MCU PWA and contains IC U14. U14
is strobed by micro controller U16 at a predetermined minimum frequency; otherwise, the
*RESET output becomes active. *RESET also becomes active if digital voltage (VDIG) is
out of range. *RESET causes the MCU PWA to reset, blocks any signal to the motors, and
turns the alarm on.
4.2.3.2
SERIAL COMMUNICATION CIRCUITRY
The serial communication circuitry interchanges data between the MCU PWA and either
the liquid crystal display (LCD) screen or the electrically erasable programmable read-only
memory (EEPROM).
Although data is transmitted to both the LCD screen and the EEPROM, the clock is diverted
only to the selected receiver. If EE_CS is active, then *SCK appears as EE_CLK at IC U9C.
If EE_CS is inactive, then *SCK is inverted to appear as LCD_CLK at IC U8B.
Data is read from either the LCD screen or the EEPROM. If EE_CS is active, then EE_DO
appears as RXD at IC U7C. If EE_CS is inactive, then LCD_DO is inverted to appear as
RXD at IC U7C.
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SECTION 4 THEORY OF OPERATION
4.2.3.3
ALARM CIRCUITRY (XL)
The alarm circuitry includes an oscillator circuit consisting of inverters U10C, U10B, and
U10E. The oscillator circuit generates acoustic power at a predetermined frequency based
on the BUZ1 self resonance. Normally, the BUZZER signal is low, U9-10 is high, and
resistor network RN8-7 and RN8-8 disables the oscillator. The alarm can be activated by
the BUZZER or *RESET signals becoming active and pulling RN8-7 down. When SW1 is
set to LO, resistor R13 is electronically connected to the BUZ1-3 (buzzer drive) and the
sound level decreases. U10D and U10F constitute a memory unit that disables the
oscillator circuit when the U10F output is high.
At AC (mains) power-up, POWERHOLD becomes active and changes the U10D/U10F
memory unit to enable the oscillator circuit. At a voluntary power-off, DIST_AIR_EN and
PROX_AIR_EN become momentarily active. This momentary activation of DIST_AIR_EN
and PROX_AIR_EN allows the memory unit to change to an oscillator-disabling state and
the alarm does not sound. At a catastrophic failure, however, the memory unit remains
enabled and the alarm sounds.
During a catastrophic failure, the alarm can be disabled by positioning the infusion system
control knob to OFF/CHARGE.
4.2.3.4
ALARM CIRCUITRY (XLM)
The alarm circuitry includes an oscillator circuit consisting of inverters U10C, U10B, and
U10E. The oscillator circuit generates acoustic power at a predetermined frequency based
on the BUZ1 self resonance. Normally, the BUZZER signal is low, U9-10 is high, and
resistor network RN8-7 and RN8-8 disables the oscillator. The alarm can be activated by
the BUZZER or *RESET signals becoming active and pulling RN8-7 down. U10D and U10F
constitute a memory unit that disables the oscillator circuit when the U10F output is high.
At AC (mains) power-up, POWERHOLD becomes active and changes the U10D/U10F
memory unit to enable the oscillator circuit. At a voluntary power-off, DIST_AIR_EN and
PROX_AIR_EN become momentarily active. This momentary activation of DIST_AIR_EN
and PROX_AIR_EN allows the memory unit to change to an oscillator-disabling state and
the alarm does not sound. At a catastrophic failure, however, the memory unit remains
enabled and the alarm sounds.
During a catastrophic failure, the alarm can be disabled by positioning the infusion system
control knob to OFF/CHARGE.
The alarm circuitry provides sound for low-level settings only. For high-level sound, see
Section 4.2.4, Buzzer PWA (XLM).
4.2.3.5
ALARM POWER BACKUP CIRCUITRY
The alarm power backup circuitry is provided through super capacitor C34. C34 offers
power backup in the event of a catastrophic failure. Diodes CR15, CR19, and CR20 route
the power for alarm driver U10 from VDIG or C34.
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4.2 ELECTRONICS OVERVIEW
4.2.3.6
MOTOR DRIVER CIRCUITRY
The motor driver circuitry energizes the three stepper motors: plunger, input/output, and
primary/secondary. The MCU PWA micro controller, U6, outputs MOTPHAS1 and
MOTPHAS2 to inverters U9A and U9F which generate two additional signals: *MOTPHAS1
and *MOTPHAS2. These four signals are required to step the motors. Three motor enable
signals manage the motor step width. The motor enable signals are: MOTPLN_EN (motor
plunger enable), MOTIO_EN (motor input/output enable), and MOTPS_EN (motor
primary/secondary enable). The four motor stepping signals activate ICs U2A, U3A, U3D,
and U2D; or U2B, U3B, U3C, and U2C; or U5D, U5A, U4A, and U4D to switch the power
metal-oxide semiconductor field-effect transistors (MOSFETs) Q1 through Q4, Q5 through
Q8, or Q9 through Q12. When active, *RESET disables motor activity.
4.2.3.7
PIN DETECTOR CIRCUITRY
The pin detector circuitry detects the primary and secondary valve pin motion. When
PSV_EN is active, *PSV_EN becomes active and a constant current flows through
light-emitting diode (LED) CR1 and LED CR2. CR1 and CR2 are located in the pin detector
sensor assembly mounted on the bubble sensor PWA. If *P_S_EN is active, IC U11A is
activated and U11B is de-activated, and vice versa. U11 serves as two hysteresis
comparators and its output, PS_VALVE, is edge detected by the MCU PWA. The positive
edges are detected by the MCU PWA INT1 input. The negative edges are detected by the
MCU PWA PC3 input.
4.2.3.8
UART (XLM WITH DATAPORT)
The UART used in the Plum XLM with DataPort infusion system is TL16C450 made by
Texas Instruments. It is a complementary metal-oxide semiconductor (CMOS) field-effect
transistor (FET) version of an asynchronous communication element (ACE) typically
functioning in a microcomputer system as a serial input/output interface.
The UART performs serial-to-parallel conversion on data received from the host computer
and performs parallel-to-serial conversion on data received from the MCU. The MCU can
read the status of the UART at any point in its operation. The status information includes
the type of transfer operation in progress, the status of the operation, and any error
conditions encountered.
The UART includes a programmable, on-board baud rate generator which is capable of
dividing a reference clock input by divisors from 1 to (216 -1) and producing a 16 x clock
to drive the internal transmitter logic. Provisions are also included to use this 16 x clock
to drive the receiver logic. In the Plum XLM with DataPort infusion system, data is
transmitted and received at 1,200 bits per second. The 16 x clock is running at 19,200
Hz (16 x 1,200).
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SECTION 4 THEORY OF OPERATION
The UART includes a complete modem control capacity and a processor interrupt system
that is software adjustable to user requirements to minimize the computing required to
handle the communication link. The software of the Plum XLM with DataPort infusion
system programs the UART not to use its modem control capacity, but to interrupt the
MCU when a byte of data is received from or transmitted to the host computer.
Note: Do not connect DataPort when infusing.
4.2.3.9
NURSE CALL ALARM (XLM WITH DATAPORT - NURSE CALL)
During an alarm, an isolated contact closure is made by U22, a solid-state FET relay. The
BUZZER signal from the microprocessor is filtered to maintain the contact closure between
short beeps by the diode and RC network at the input to the driver U5.
The connection to the nurse call feature is made by an adapter that mates to the 15-pin
serial port. The nurse call adapter connects to existing signalling equipment with a 1/4
inch phone plug.
Note: Nurse call alarm is not available in IEC compliant infuser.
EN-2
Note: Do not connect DataPort when infusing.
4.2.4
BUZZER PWA (XLM)
The buzzer PWA is installed on the Plum XLM and XLM with DataPort (see Figure 9-28,
Buzzer PWA Schematic). The buzzer PWA includes the following circuitry:
❏ High volume audible alarm
❏ Lockout switch
4.2.4.1
HIGH VOLUME AUDIBLE ALARM
In addition to the MCU PWA alarm circuitry, a loud piezo alarm buzzer is installed on the
buzzer PWA for high volume setting (see Section 4.2.3.4, Alarm Circuitry (XLM)). The high
volume setting is selected by lever switch SW1. Switch SW1 is located on the buzzer PWA,
and during normal operation is accessible on the rear enclosure.
The BUZZER_HI signal connects to the central processing unit (CPU) port on the MCU
PWA. The SPSTIN_BUZ signal connects to the SPSTIN (+BUSS) signal on the MCU PWA.
SPSTIN_BUZ is the battery charging voltage. When an alarm occurs, the processor
activates BUZZER_HI. When the switch SW1 is closed (high setting), the high volume piezo
buzzer and the alarm circuitry on the MCU PWA activate. When switch SW1 is open (low
setting), only the MCU PWA alarm circuitry activates.
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4.2 ELECTRONICS OVERVIEW
4.2.4.2
LOCKOUT SWITCH
The lockout switch SW2 is located on the buzzer PWA and is accessible on the rear
enclosure of the Plum XLM. The lockout switch is connected to the LOCKOUT1 signal on
the display PWA, and to the LOCKOUT2 signal on the MCU PWA. LOCKOUT1 connects to
the collector of Q7 on the display PWA. When lockout switch SW2 is closed, and Q7
saturates, LOCKOUT2 goes low and the LOCKED icon on the LCD illuminates.
4.2.5
DISPLAY PWA
The display PWA receives serial data from the MCU PWA and displays it at the LCD (see
The display PWA also includes most of the control knob functions required to operate the
infusion system. The display PWA includes the following circuitry: display,
electroluminescent (EL) panel driver (XL), LED backlight panel and driver (XLM), RUN
indicator, line power indicator, and control knob.
4.2.5.1
DISPLAY CIRCUITRY (XL)
ICs U2 and U3 are master- and slave-type serial input LCD drivers and are cascaded to
form a 92-segment (4 back-plane by 23 fore-plane) driver. LCD panel U1 is designed to
match the drivers and has 88 segments.
Display data is serially clocked into U2 at pin 21. The clocking signal, LCD CLK, is received
at U2-23 and U3-22. The drive frequency is not synchronized to the data input and is
dictated by resistor R7. To eliminate a false display during data updates, U2 and U3 are
disabled by CR3, C14, R9, R8, and Q3.
4.2.5.2
DISPLAY CIRCUITRY (XLM DISPLAY PWA -003 AND LOWER)
IC U2 is the 128 segment LCD driver that can drive the four backplanes and 32 frontplanes.
LCD panel U4 has 110 front panel segments multiplexed with the four backplanes.
Display data is clocked serially into U2 via DIN (pin 39) and DCLK (pin 38). The LCD drive
frequency (approximately 100 Hz) is set by R7 and is not synchronized to the data input
into U2.
4.2.5.3
DISPLAY CIRCUITRY (XLM DISPLAY PWA -004 AND HIGHER)
IC U13 is the 128 segment LCD driver that can drive the four backplanes and 32
frontplanes. LCD panel U4 has 110 front panel segments multiplexed with the four
backplanes.
Display data is clocked serially into U13 via DATA (pin 58) and SCL (pin 57). The LCD
drive frequency (approximately 100 Hz) is set by R31 and is not synchronized to the data
input into U13.
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SECTION 4 THEORY OF OPERATION
4.2.5.4
EL PANEL DRIVER CIRCUITRY (XL)
Transistor Q1 and transformer T1 windings 1-3 (primary) and 4-2 (feedback) constitute
the main oscillator positive feedback. The T1 output winding (5, 8) provides a large-turn
ratio (to T1 primary winding) to boost the output to 300 volts peak-to-peak (Vpp). The
capacitance of EL panel EL1 and the inductance of the T1 output winding dictates the
oscillation frequency of 300 Hz to 500 Hz. As the capacitance of EL1 decreases because
of aging, the frequency increases to maintain a constant brightness.
A control loop consisting of diode CR1; capacitors C13 and C10; resistors R13, R4, R3,
and R6; IC U10B; and transistor Q2 maintains a constant output amplitude by rectifying
the output and comparing it to the ELON signal.
4.2.5.5
LED BACKLIGHT PANEL AND DRIVER (XLM)
The display backlight panel is an array of 60 LEDs arranged as parallel elements of two
series LEDs. The required drive voltage of the panel equals two LED voltage drops of
approximately 4.2 VDC. The actual forward voltage changes with temperature and varies
from panel to panel. Driving the panel with a constant current compensates for varying
voltage requirements.
The XLM backlight panel requires approximately 200 mA for optimum brightness. The
current is controlled utilizing a current mode switching technique enabling high efficiency
operation with a wide power supply range of 7 to 11 volts. The signal VMOT is the supply
voltage for the backlight constant current regulator.
Current through U5, LED panel, is regulated by Q3 operation until the voltage across
current sensing resistors R14, R23, and R24 exceeds a reference voltage of approximately
96 mV. The voltage drop is filtered by R13 and C7 and then compared to the turn-off
threshold determined by the voltage divider R11 and R12. Comparator U3, pin 1 drives
low when the current through R14, R23, and R24 exceeds the turn-off threshold,
discharging C4. U1 senses the quick discharge of C1 and then turns off Q1.
Q1 remains off while C4 charges via resistor R9. Q3 turns on when the the charge on C4
exceeds the input voltage high threshold of U3, pin 2.
4.2.5.6
RUN INDICATOR CIRCUITRY
LEDRUN, when active, turns LED1 on. IC U10A (Q8 XLM) functions as a constant current
source to LED1 by maintaining constant voltage across resistor R20. The voltage is
approximately +3.33 VDC.
4.2.5.7
LINE POWER INDICATOR CIRCUITRY
HKDC is active when the infusion system is operating on AC (mains), and turns on the
line power indicator, LED2. HKDC brings transistor Q4 base volt age to VDIG + Vf through
R15 (Vf equals forward voltage of diode CR1). This base voltage change causes Q4 to
conduct and the current through LED2 equals approximately VDIG divided by the value
of resistor R14.
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4.2 ELECTRONICS OVERVIEW
4.2.5.8
CONTROL KNOB CIRCUITRY (XL)
The control knob circuitry consists of transistor Q5; rotary switch Hall-effect sensors U11
through U15; reed switch S7; ICs U4, U5, and U7 through U9; and associated passive
components. The control knob circuitry senses the control knob position and sends the
position code to the MCU PWA. The HSENSEN signal, when active, switches transistor Q5
on and allows the output of rotary switch Hall-effect sensors U11 through U15 to be gated
through ICs U4, U5, and U7 through U9. Resultant output conditions of rotary 0 (ROT0),
ROT1, and ROT2 at ICs U9B, U7B, and U7A are sent to the MCU PWA as a three-bit code
representing the control knob position. The S7 reed switch output, SPSTIN is transferred
to the power supply PWA. If more or less than one Hall-effect sensor position signal is
active, ROT0, ROT1, and ROT2 become active simultaneously to signify a failure. If the
control knob is set to the OFF/CHARGE position, *SESTIN is enabled.
4.2.5.9
CONTROL KNOB CIRCUITRY (XLM)
The control knob circuitry consists of transistor Q5; rotary switch Hall-effect sensors U11
through U15; reed switch S7; ICs U4, U5, U7, and U8; and associated passive components.
The control knob circuitry senses the control knob position and sends the position code
to the MCU PWA. The HSENSEN signal, when active, switches transistor Q5 on and allows
the output of rotary switch Hall-effect sensors U11 through U15 to be gated through ICs
U4, U5, U7, and U8. Resultant output conditions of rotary 0 (ROT0), ROT1, and ROT2 at
ICs U7A, U7B, and U7D are sent to the MCU PWA as a three-bit code representing the
control knob position. The S7 reed switch output, SPSTIN is transferred to the power
supply PWA. If more or less than one Hall-effect sensor position signal is active, ROT0,
ROT1, and ROT2 become active simultaneously to signify a failure. If the control knob is
set to the OFF/CHARGE position, *SESTIN is enabled.
4.2.6
SENSOR PWA
The sensor PWA consists of the following circuitry: pressure amplifier/filter, AC (mains)
amplifier, voltage reference, opto interrupter, and EEPROM (see Figure 9-21, Sensor PWA
Schematic).
4.2.6.1
PRESSURE AMPLIFIER/FILTER CIRCUITRY
The pressure amplifier circuitry (IC U7, resistors R6 and R11 through R16, and capacitors
C2 and C3) is a differential amplifier with an approximate gain of 600. Capacitors C2 and
C3 are part of an automatic-zero system within U7. The combination of resistors R13 and
R11 makes it possible for R12 (trimpot) to compensate for up to a 3 millivolt (mV) offset
input from the strain gauge. In case of larger offsets, R13 must be removed from the sensor
PWA. R12 is adjusted to approximately +0.7 VDC at distal pressure (DISTPRES) so that
negative pressure spikes can be read by the MCU PWA.
The filter circuitry (resistors R1 and R3, capacitors C4 and C5, and IC U8A) constitutes a
two-pole, 30 Hz Bessel active filter. The filter alternates the 500 Hz automatic-zero
switching frequency of U7 and other noise.
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SECTION 4 THEORY OF OPERATION
4.2.6.2
AC AMPLIFIER CIRCUITRY
The AC (mains) amplifier circuitry (IC U8A) processes negative spikes that may signify an
occlusion on DISTPRES to a level manageable by the MCU PWA analog-to-digital (A/D)
converter. The AC amplifier blocks slow pressure changes and amplifies the spikes to the
required level. The AC amplifier also divides into the logarithmic compression circuit
(resistor R7 and diodes CR1 and CR3), the bias/high-pass circuit (capacitor C8 and
resistor R10), and the amplifier circuit (IC U8B, resistors R4 and R9, and capacitor C7).
The logarithmic compression circuit limits the amplitude of the negative spikes at high
back-pressure. The bias/high pass circuit blocks the slow pressure changes and biases
the AC (mains) amplifier to +2.5 VDC.
4.2.6.3
VOLTAGE REFERENCE CIRCUITRY
The voltage reference circuitry consists of ICs U1 and U6; transistor Q1; diodes CR2 and
CR5; resistors R17 through R20, R22, and R23; and capacitors C9, C11, and C12. R22,
C11, and C12 filter VMOT. R18 biases the reference U1. U6B buffers the +2.5 VDC REF.
The +2.5 VDC REF is boosted by Q1, U6A, and associated components to generate the
main +3.75 VDC reference 3V75REF. CR2 limits 3V75REF to VDIG level to protect the
MCU PWA micro controller, U6. CR5 protects the base-emitter junction of Q1.
4.2.6.4
OPTO INTERRUPTER CIRCUITRY
When PSENSEN is active, transistors Q2 and Q3 drive all LEDs in ICs U2, U3, and U4
with a constant current of approximately 22 milliamperes (mA). Resistor R24 limits the
current.
4.2.6.5
EEPROM CIRCUITRY
The EEPROM circuitry (IC U5) communicates serially with the MCU PWA. U5 receives
commands and data through pin 3 as TXD. Stored data is transferred through pin 4 as
EE_DO. When EE_CS is active at pin 1 and EE_CLK (pin 2) is in synchronization with
TXD, U5 is enabled.
4.2.7
BUBBLE SENSOR PWA
The bubble sensor PWA consists of the following circuitry: transmitter, receiver (which
includes two channels, proximal and distal), and pin detector flex (see Figure 9-21, Sensor
PWA Schematic, and Figure 9-22, Pin Detector Flex Circuit Schematic).
Note: Both proximal and distal sensors can transmit or receive.
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4.2 ELECTRONICS OVERVIEW
4.2.7.1
TRANSMITTER CIRCUITRY
The transmitter circuitry consists of a sweep oscillator, a voltage-controlled oscillator
(VCO), and a driver.
The sweep oscillator (ICs U1A and portion of U2, capacitor C5, and resistor R15 through
R18) oscillates at approximately 12 kHz with a 50 percent duty cycle. A CMOS gate within
U2 is used for a quality rail-to-rail symmetrical signal for greater timing accuracy. The
output of the sweep oscillator (C2) is between +2 VDC and +3 VDC. The C2 output is used
to sweep the VCO at U2-9.
IC U2, capacitor C7, and resistor R21 constitute the VCO. U2 is originally a phase-lock
loop (PLL) IC with the VCO portion sweeping output frequencies from 4 MHz to 6 MHz.
The VCO center frequency is determined by R21 and C7. Activating either signal,
PROX_AIR_EN or DIST_AIR_EN, enables the VCO.
The driver consists of a push-pull, emitter-follower complementary pair of transistors: Q4
and Q5. The driver supplies input to proximal sensor X1 and distal sensor X2.
4.2.7.2
RECEIVER CIRCUITRY
The receiver consists of an amplifier, detector, and buffer.
The amplifier consists of transistors Q3, Q6, Q2, and associated passive components. The
amplifier is biased by 2V5REF and is designed for wide power supply range. Q3 is biased
by PROX_AIR_EN in order to receive from proximal sensor X1. Q6 is biased by
DIST_AIR_EN to receive from distal sensor X2.
The detector is an emitter-follower transistor Q1. Q1 allows maximum input impedance.
Capacitor C1 and resistor R4 constitute a time constant of 200 microseconds (µS). Since
the time between peaks is approximately 40 µS, the output (*AIR_OPT) remains high with
a pronounced sawtooth ripple.
The buffer (IC U1A and resistors R7 and R2) also amplifies the detected signal.
4.2.7.3
PIN DETECTOR FLEX CIRCUITRY
The pin detector flex circuitry detects movement of the primary and secondary valve pins
by optical transmitters CR1 and CR2, and optical receivers Q1 and Q2. Light interrupters
are attached to the pins and as the pins move, the appropriate valve movement signals
are transferred to the MCU PWA through the bubble sensor PWA.
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SECTION 4 THEORY OF OPERATION
4.3
MECHANICAL OVERVIEW
The principal mechanical elements of the infusion system include the cassette and the
mechanism assembly. When a cassette is locked into the operating position and the control
knob is turned on, the infusion system 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 primary or secondary 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.
4.3.1
CASSETTE
The cassette operates on a fluid displacement principle to volumetrically deliver fluid
(see Figure 4-1, Major Elements of the Dual-Channel Cassette, and Figure 4-2, Fluid Path
in the Cassette). Refer to 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 closes, the inlet opens, the appropriate primary or
secondary 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
primary and secondary valves are closed, and the cycle is repeated.
The cassette contains two chambers: an upper air trap chamber and a pumping chamber.
The two chambers are separated by an inlet valve (see Figure 4-1 and Figure 4-2) and
operate together to detect air. The upper air-trap chamber receives fluid from the
intravenous (IV) container through either the primary or secondary valve. The upper
air-trap chamber collects air bubbles from the IV line and container to prevent them from
entering the pumping chamber; the chamber can collect a substantial amount of air. The
controller tracks the amount of air collected in the upper air-trap chamber. If a
predetermined air collection threshold is exceeded, the controller starts an infusion system
backprime and initiates a secondary display.
A proximal air-in-line sensor (bubble detector) is located between the primary/secondary
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. 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 pump. When the cassette
is properly inserted into the infusion system and the infusion system door is closed, a
mechanism opens the flow regulator to allow the infusion system to control fluid flow.
When the infusion system door is opened, the same mechanism closes the flow regulator
to disable fluid flow.
430-00587-008 (Rev. 2/05)4 - 16Plum XL Series
Page 41
SECONDARY PORT
(Y-RESEAL OR LOCKING CAP)
FROM PRIMARY
CONTAINER
4.3 MECHANICAL OVERVIEW
PRECISION GRAVITY
FLOW REGULATOR
(CONTROL NOT SHOWN)
FINGER
GRIP
RIGHT VIEW
SECONDARY
PRIMARY VALVE
VALV E
AIR-IN LINE
SENSOR
(DISTAL)
AIR-IN-LINE
SENSOR
(PROXIMAL)
AIR TRAP
PRESSURE SENSOR
OUTLET VALVE
CHAMBER
INLET VALVE
REAR VIEW
PUMPING CHAMBER
LEFT VIEW
Figure 4-1. Major Elements of the Dual-Channel Cassette
OUTLET
TO
PATIENT
01K04004
Technical Service Manual4 - 17430-00587-008 (Rev. 2/05)
Page 42
SECTION 4 THEORY OF OPERATION
PRIMARY VALVE
AIR TRAP CHAMBER
INLET VALVE
OUTLET VALVE
PRIMARY
SECONDARY
SECONDARY VALVE
AIR-IN-LINE SENSOR (PROXIMAL)
PUMPING CHAMBER
PRESSURE SENSOR
AIR-IN-LINE SENSOR (DISTAL)
PRECISION GRAVITY
FLOW REGULATOR ( AND SHUT-OFF)
04K01002
Figure 4-2. Fluid Path in the Cassette
4.3.2
MECHANISM ASSEMBLY
The mechanism assembly is a fully self-contained unit consisting of the motor and valve
assemblies, primary/secondary valve subsystem, inlet/outlet valve subsystem, plunger
drive subsystem, air bubble (ultrasonic) sensor assemblies, cassette door, and pressure
sensor assembly. The motor and valve assemblies, primary/secondary valve subsystem,
inlet/outlet valve subsystem, and plunger drive subsystem are detailed in the following
sections.
During infusion system operation, the mechanism assembly plunger motor drives a lead
screw that is coupled to a nut in 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.
430-00587-008 (Rev. 2/05)4 - 18Plum XL Series
Page 43
4.3 MECHANICAL OVERVIEW
4.3.2.1
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 primary
or secondary 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.
4.3.2.2
PRIMARY/SECONDARY VALVE SUBSYSTEM
The primary/secondary valve subsystem includes a motor designed to rotate a cam
(see Figure 4-3, Mechanism Valve Pins and Sensor Locations). When the cam is positioned
at the top dead center (home position), both valves are closed. Clockwise rotation (when
viewed from the motor side) from the home position opens the primary valve, while the
secondary valve remains closed. Counterclockwise rotation opens the secondary valve,
while the primary valve remains closed.
The primary/secondary valve subsystem consists of a stepper motor with attached cam
and integral cam flag, primary and secondary 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.
The primary/secondary valve pins each have a series of interrupters that are optically
detected by the pin detector assembly to assure proper valve pin movement.
Technical Service Manual4 - 19430-00587-008 (Rev. 2/05)
Page 44
SECTION 4 THEORY OF OPERATION
PRIMARY VALVE
REGULATOR ACTUATOR
AIR-IN-LINE SENSOR
(DISTAL)
PRESSURE SENSOR
CASSETTE LOCATOR
OUTLET VALVE
PLUNGER
INLET VALVE
SECONDARY VALVE
(PIGGY BACK)
AIR-IN-LINE SENSOR
(PROXIMAL)
04K01003
Figure 4-3. Mechanism Valve Pins and Sensor Locations
4.3.2.3
INLET/OUTLET VALVE SUBSYSTEM
The inlet/outlet valve subsystem is similar in function and build to the primary/secondary
valve subsystem, but it does not contain a series of interrupters or a pin detection
assembly. Refer to Section 4.3.2.2, Primary/Secondary Valve Subsystem, for the inlet/
outlet valve subsystem theory of operation.
4.3.2.4
PLUNGER DRIVE SUBSYSTEM
The plunger drive subsystem includes a stepper motor. The stepper motor rotates
approximately 1-2/3 revolutions per infusion system cycle to permit a 0.33 mL fluid
displacement every infusion system cycle. The stepper motor then reverses and the plunger
returns to home position. This cycle repeats for the duration of fluid administration.
Excluding the stepper motor, the plunger drive subsystem includes the following
components: ball thrust bearing, screw/coupler assembly, and plunger/support system.
The ball thrust bearing is positioned against the mechanism assembly chassis. As the
plunger extends into the cassette diaphragm to displace fluid, the resulting load (due to
pumping action and back pressure) is transferred axially through the ball thrust bearing
to the mechanism assembly chassis.
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.
430-00587-008 (Rev. 2/05)4 - 20Plum XL Series
Page 45
Section 5
MAINTENANCE AND SERVICE
TESTS
A complete maintenance program promotes infusion longevity and trouble-free instrument
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 infusion pump after each use. In addition, establish
a regular cleaning schedule for the infusion pump.
5.1.1
INSPECTING THE INFUSION SYSTEM
Inspect the infusion system periodically for signs of defects such as worn accessories,
broken instrument connections, or damaged cables. In addition, inspect the infusion
system after repair or during cleaning. Replace any damaged or defective external parts.
See Section 5.2.3, Inspection.
5.1.2
CLEANING THE INFUSION SYSTEM
The following procedures are designed to maintain the infusion pump, sustain system
longevity, and promote trouble-free instrument operation.
Follow hospital protocol for establishing the infusion pump cleaning schedule.
WARNING:DISCONNECT THE INFUSION SYSTEM FROM AC (MAINS)
POWER PRIOR TO CLEANING THE INSTRUMENT. FAILURE
TO COMPLY WITH THIS WARNING COULD RESULT IN
ELECTRICAL SHOCK.
CAUTION: Do not immerse the infusion system in liquids. Immersion could damage
the instrument. Do not allow liquids to enter the infusion system electronics
compartment. Do not spray cleaning solutions toward any openings in the infusion
system.
Technical Service Manual5 - 1430-00587-008 (Rev. 2/05)
Page 46
SECTION 5 MAINTENANCE AND SERVICE TESTS
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.
CAUTION: Do not use solvents that are harmful to plastic, such as isopropyl alcohol
or acetone, on external surfaces or plastic components. Do not use abrasive cleaners.
CAUTION: To avoid infuser damage, cleaning solutions should be used only as
directed in Table 5-1, Cleaning Solutions. The disinfecting properties of cleaning
solutions vary; consult the manufacturer for specific information
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. Do not use solvents that are harmful to
plastic, such as isopropyl alcohol or acetone. Do not use abrasive cleaners.
Table 5-1.Cleaning Solutions
Cleaning SolutionManufacturerPreparation
Coverage™ HBSteris CorporationPer manufacturer's
recommendation
Dispatch
Formula C™JohnsonDiverseyPer manufacturer's
Manu-Klenz
Precise
Sporicidin
Household bleachVariousPer hospital procedures; do
®
®
Steris CorporationPer manufacturer's
®
®
Caltech IndustriesPer manufacturer's
recommendation
recommendation
recommendation
Caltech IndustriesPer manufacturer's
recommendation
Sporicidin InternationalPer manufacturer’s
recommendation
not exceed one part bleach
in ten parts water
5.1.3
SANITIZING THE INFUSION SYSTEM
Sanitize external surfaces of the infusion system using a cleaner listed in Table 5-1.
Note: Not all cleaning solutions are sanitizers. Check product labeling.
CAUTION: Do not sterilize the infusion system using heat, steam, ethylene oxide
(ETO), or radiation. These methods may cause the instrument to malfunction.
430-00587-008 (Rev. 2/05)5 - 2Plum XL Series
Page 47
5.1 ROUTINE MAINTENANCE
5.1.4
CLEANING THE BUZZER
Recommended materials are cotton swabs and pure isopropyl alcohol.
Under certain circumstances, residue will build up on the buzzer located on the MCU
board. This residue can prevent the buzzer from alarming, but can be easily removed.
To remove any residue, refer to Figure 5-1, Cleaning the Buzzer, then proceed as follows:
1. Separate the front and rear enclosures as described in Section 7.2.5, leaving the
main chassis in the rear enclosure.
2. Inspect the buzzer for any physical damage. If damage is found, discontinue this
procedure and contact Hospira.
3. Moisten the cotton swab with the isopropyl alcohol and clean any residue from the
entire rear surface of the buzzer.
4. Reassemble the pump in the exact reverse order of disassembly, and perform the
PVT in Section 5.2.
04K01046
Figure 5-1. Cleaning the Buzzer
Technical Service Manual5 - 3430-00587-008 (Rev. 2/05)
Page 48
SECTION 5 MAINTENANCE AND SERVICE TESTS
5.2
PERFORMANCE VERIFICATION TEST
The Perfomance 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 infusion system. The PVT should be used for performance verification
before an infusion pump is placed back in service after repair. If any malfunction is
detected as a result of the PVT, refer to Table 6-6, PVT Troubleshooting.
Note: The PVT must be performed exactly as described in this manual to assure
effective and reliable product evaluation information.
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 two IV bags/containers
❏ Digital pressure meter, Fluke Biomedical DPM3
❏ Safety analyzer, Fluke Biomedical 232D
❏ Three-way stopcock, latex-free, List No. 03233-01 or 03232-01
❏ Reflux valve (optional)
❏ Six inch tubing extension, List No. 42362-01 (optional)
❏ Special cassette with proximal bubble sensor tips removed
❏ Special cassette with distal bubble sensor tips removed
❏ LifeShield PlumSet, List No. 1642
❏ LifeShield secondary set, List No. 11397
❏ Digital multimeter (DMM), Fluke
❏ 21-gauge needle, List No. 04492, or 18-gauge blunt cannula
❏ Battery charger test box (optional)
❏ Computer with a terminal emulator (optional)
❏ RS-232 serial communication cable (optional)
®
187
430-00587-008 (Rev. 2/05)5 - 4Plum XL Series
Page 49
5.2 PERFORMANCE VERIFICATION TEST
5.2.2
ICONS AND ENGLISH LANGUAGE EQUIVALENTS
International infusion systems use icons in displays and labels. Refer to Figure 5-2, Icons
and English Language Equivalents.
LCD Screen Icons
TURN TO RUNOCCLUSION
EMPTY
KEEP VEIN OPEN
PRIMARY
CHECK SETTINGS
LOW BATTERY (XLM)
DOOR/CASSETTE (XL)
BATTERY
AIR IN LINE
SECONDARY
SECONDARY→PRIMARY
LOCKED (XLM)
LOW BATTERY XL
DOSE COMPLETE
BACKPRIMING
DOOR (XLM)
CASSETTE (XLM)
()
Control Dial Icons
OFF/CHARGE
RUN
HLDREET
Operating Key Icons
PRIMARY/SECONDARY
BACKPRIME
TITRATE/QUICKSET (XLM)
SET RATE
O/S
SET DOSE
0000
CLEAR VOLUME
TITRATE (XL)
ALARM SILENCE
96B03022
Figure 5-2. Icons and English Language Equivalents
Technical Service Manual5 - 5430-00587-008 (Rev. 2/05)
Page 50
SECTION 5 MAINTENANCE AND SERVICE TESTS
5.2.3
INSPECTION
Inspect the infusion system periodically for signs of defects such as worn accessories or
damaged cables. Also, inspect the infusion system after repair or during cleaning. Replace
any damaged or defective external parts.
Inspect the following areas for missing and damaged parts:
- Labels- Front panel label
- AC power cord- Control knob and all external screws
- Velcro
- Rubber foot pads- Front and rear enclosures
- Door assembly, shield, and handle- Battery access cover
- Cassette guide spring and roller- LCD screen
- Valve pins, plunger, bubble
detectors, and locator pin
®
retainer strap-Pole clamp assembly
- DataPort connector (XLM with DataPort)
Note: Do not connect DataPort when infusing.
5.2.4
TEST SETUP
WARNING:A PATIENT SHOULD NEVER BE CONNECTED TO THE
INFUSION SYSTEM DURING SYSTEM TESTING.
To set up the infusion system for the PVT, proceed as follows:
1. Confirm the infusion system and appropriate accessories are fully assembled.
2. Hang two sterile water containers at a height of 18 to 24 inches (46 to 60 cm) above
the pumping chamber of the infusion system.
3. Connect the infusion system to AC (mains) power. Conduct all tests with the
infusion system connected to AC (mains) power unless otherwise specified.
4. Verify the lockout switch is in the UNLOCKED (down) position (XLM only).
430-00587-008 (Rev. 2/05)5 - 6Plum XL Series
Page 51
5.2 PERFORMANCE VERIFICATION TEST
5.2.5
SELF TEST
CAUTION: Do not place the infusion system in service if the self test fails.
To perform the self test, refer to Figure 5-3, Plum XL LCD Test Screens and Figure 5-4, Plum
XLM LCD Test Screens, then proceed as follows:
1. Connect the infusion system AC (mains) power cord to a grounded AC (mains) outlet
and confirm the AC (mains) power icon (next to the OFF/CHARGE setting)
illuminates.
2. Open the door assembly (cassette door) by lifting up on the cassette door handle.
3. Hold a primed cassette by its handle and insert the cassette into the cassette door
guides. Do not force the cassette into position.
4. Close the cassette door handle to lock the cassette in place.
5. Turn the control knob to SET RATE to initiate the self test.
6. Verify the following screens display: the LCD test screen; four backward Cs
(approximately two seconds); set rate screen.
Note: If the LCD test screen does not match Figure 5-3 or Figure 5-4 exactly,
contact Hospira.
Note: If an alarm condition occurs during the self test, turn the control knob
to OFF/CHARGE and repeat Step 5 and Step 6. If the alarm condition recurs,
the message and take corrective action (see Section 6, Troubleshooting). Repeat
the self test. If the alarm condition recurs, remove the infusion system from
service and contact Hospira.
7. Disconnect the infusion system from AC (mains) power and confirm BATTERY
displays on the LCD screen.
8. Turn the control knob to OFF/CHARGE and remove the administration set.
9. To allow the battery to charge fully, connect the infusion system to AC (mains) power
for a minimum of eight hours with the control knob in the OFF/CHARGE position.
Confirm the AC (Mains) power icon illuminates.
ENGLISH LANGUAGE
AIR IN LINEEMPTYLOW BATTERY
KVO
TURN TO RUN CHECK SETTINGS OCCLUSION
SECONDARYPRIMARY BACKPRIMING
SET
RATE
VTBI
PIGGYBACK ML/HR
VTBI COMPLETE
DOOR/CASSETTE
TOTAL VOLUME
DELIVERED
KVO 2 1 mL=mL mL/H,mL?
2 1 mL/H
ICON BASED
OK
ML
04K01024
Figure 5-3. Plum XL LCD Test Screens
Technical Service Manual5 - 7430-00587-008 (Rev. 2/05)
Page 52
SECTION 5 MAINTENANCE AND SERVICE TESTS
ENGLISH LANGUAGE
AIR IN LINELOCKEDLOW BATTERY
KVO VTBI COMPLETEDOORCASSETTE
TURN TO RUN CHECK SETTINGS OCCLUSION
SECONDARYPRIMARY BACKPRIMING
SET
RATE
VTBI
PIGGYBACK ML/HR MICRO
TOTAL VOLUME
DELIVERED
Figure 5-4. Plum XLM LCD Test Screens
KVO 2 1 ml=ml ml/hr,ml?
2 1 ml/hrm
ICON BASED
ml
04K01025
Note: All LCD screens on international infusion systems are icon-based with the
exceptions of country codes 27 and 54.
5.2.6
KEYPAD AND CONTROL KNOB TEST
To perform the keypad and control knob test, proceed as follows:
1. Turn the control knob to SET RATE. Press the following keys to verify that each key
activates and the screen responds:
-[PRI/SEC] toggles screen between PRIMARY and SECONDARY
-[S] raises the value of the delivery rate
-[T] lowers the value of the delivery rate
-MICRO legend appears when the rate is lower than 100 mL/hr, and disappears
when the rate is above 99.9 mL/hr (XLM)
2. Turn the control knob to SET VTBI. Press the following keys to verify that each key
activates and the screen responds:
-[S] raises the value of volume delivered
-[T] lowers the value of volume delivered
3. Turn the control knob to RUN. Press and hold each key combination simultaneously
to verify that each key combination activates and the screen responds:
-[TITRATE/QUICKSET] and [S] raises the value of the delivery rate
-[TITRATE/QUICKSET] and [T] lowers the value of the delivery rate
4. Turn the control knob to SET RATE. Press the [TITRATE/QUICKSET] key and
confirm a quick rate change occurs.
5. Turn the control knob to HOLD/RESET. Press and hold [BACK PRIME] to verify
pumping occurs from the primary line up through the secondary inlet port.
430-00587-008 (Rev. 2/05)5 - 8Plum XL Series
Page 53
5.2 PERFORMANCE VERIFICATION TEST
5.2.7
OPEN DOOR ALARM TEST
To perform the open door alarm test, proceed as follows:
1. Close the clamp on the secondary line (to prevent fluid in containers from mixing).
2. Open the cassette door. Verify the DOOR/CASSETTE (XL) or DOOR (XLM) legend
appears and an alarm sounds.
3. Press [SILENCE]. Verify the alarm mutes.
4. Close the cassette door and unclamp the secondary line.
5.2.8
ALARM LOUDNESS TEST (XL)
To perform the alarm loudness test, proceed as follows:
1. Turn the control knob to SET RATE and open the cassette door. Verify the DOOR/
CASSETTE legend appears and an alarm sounds.
2. Toggle the audio switch (located on the infusion system bottom) between the high
and low settings. Verify two alarm levels sound.
3. Press [SILENCE]. Verify the alarm mutes.
4. Close the cassette door.
5.2.9
ALARM LOUDNESS AND LOCK FUNCTION TESTS
(XLM)
To perform the alarm loudness and lock function tests, proceed as follows:
1. Turn the control knob to SET RATE and open the cassette door. Verify the DOOR
legend appears and an alarm sounds.
2. Toggle the audio switch (located on the rear panel) between the high and low
settings. Verify two alarm levels sound.
3. Press [SILENCE]. Verify the alarm mutes.
4. Close the cassette door.
5. Turn the control knob to HOLD/RESET, then back to RUN.
6. Press the LOCK button (located on the rear panel). Verify LOCKED appears on the
display.
7. Turn the control knob to any other position. Verify the infusion system stops
pumping, an alarm sounds, and the display backlight and LOCKED flash.
8. Turn the control knob to RUN. Verify the infusion system starts to pump.
9. Press [SILENCE]. Verify that the alarm condition remains unchanged.
10. Press the LOCK button to clear the alarm condition.
Technical Service Manual5 - 9430-00587-008 (Rev. 2/05)
Page 54
SECTION 5 MAINTENANCE AND SERVICE TESTS
5.2.10
BATTERY LEGEND TEST
To perform the battery legend test, proceed as follows:
1. Disconnect the infusion system from AC (mains) power.
2. Turn the control knob to SET RATE. Verify the line power indicator turns off and
the BATTERY legend turns on within five seconds.
3. Reconnect the infusion system to AC (mains) power after the battery legend check.
4. Turn the control knob to OFF/CHARGE.
5.2.11
FREE FLOW TEST
To perform the free flow test, proceed as follows:
1. Insert a primed cassette into the infusion system.
2. Turn the control knob to SET RATE.
3. With the cassette door closed, check the distal end of tubing for fluid flow. Verify a
minimal flow of fluid (a few drops maximum) occurs.
4. Open the cassette door and check the distal end of tubing for fluid flow. Verify a
minimal flow of fluid (a few drops maximum) occurs.
Note: A small amount of fluid may be expelled from the cassette when opening
or closing the door.
5. Close the cassette door and check the distal end of tubing for fluid flow. Verify a
minimal flow of fluid (a few drops maximum) occurs.
6. Turn the control knob to OFF/CHARGE.
5.2.12
PROXIMAL OCCLUSION TEST
To perform the proximal occlusion test, proceed as follows:
1. Turn the control knob to SET RATE. Set the rate to a value greater than 40 mL/hr.
2. Turn the control knob to RUN to start pumping fluid.
3. After several pumping cycles, clamp the tubing proximal to the cassette. After drops
stop falling through the sight chamber, verify that an occlusion alarm occurs within
three pumping cycles.
4. Press [SILENCE] and unclamp the proximal tubing.
5. Turn the control knob to OFF/CHARGE.
430-00587-008 (Rev. 2/05)5 - 10Plum XL Series
Page 55
5.2 PERFORMANCE VERIFICATION TEST
5.2.13
DISTAL OCCLUSION TEST
To perform the distal occlusion test, refer to Figure 5-5, Distal Occlusion Test Setup, and
proceed as follows:
1. Connect the distal tubing to the DPM through a three-way stopcock as illustrated
in Figure 5-5.
Note: A reflux valve or six inch tubing extension 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 to 6 inches (0 to 15 cm) from the
midline of the cassette.
2. Turn the control knob to SET RATE.
3. Set the rate to 40 mL/hr.
4. Turn the control knob to SET VTBI.
5. Set the volume to 100 mL.
6. Open the three-way stopcock to air.
7. Turn the control knob to RUN and allow the infusion system to stabilize for one
minute. Verify all air is cleared from the tubing.
8. Set the three-way stopcock to measure pressure.
9. Verify the occlusion alarm occurs when DPM indicates 10.0 ± 2 psi
(69.0 ± 13.8 kPa).
10. Turn the control knob to HOLD/RESET to clear the occlusion alarm. Open the
three-way stopcock to air and disconnect the distal tubing.
PRI
SEC
SET VTBI
SETRATE
OFF
CHARGE
FROM FLUID
CONTAINERS
TITRATE
BACK
PRIME
RUN
HOLD/RESET
CLEAR
VOL
SILENCE
THREE-WAY
STOPCOCK
UNIVERSAL
PRESSURE METER
0.00
cm OF H O
2
mmHg
OFF
PRESSUREINPUT
DPM
INCHESOF H O
-13.5TO 15
-13.5TO 75
96B03023
2
PSI
Figure 5-5. Distal Occlusion Test Setup
Technical Service Manual5 - 11430-00587-008 (Rev. 2/05)
Page 56
SECTION 5 MAINTENANCE AND SERVICE TESTS
5.2.14
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 infusion system accuracy, return the
infusion system to Hospira Technical Support Operations.
CAUTION: Do not remove the protective cover from the butterfly needle.
To perform the delivery accuracy test, proceed as follows:
1. Attach an 18-gauge cannula, or a 21-gauge needle, to the distal end of the tubing.
Verify the fluid container is 18 to 24 inches (46 to 60 cm) above the cassette pumping
chamber. Verify all lines are unclamped.
2. Prime the tubing. Verify no air is in the tubing. Place cannula or needle in a 25 mL
graduated cylinder.
3. Turn the control knob to SET RATE and set the primary rate to 400 mL/hr.
4. Press [PRI/SEC] to display SECONDARY and set the secondary rate to 400 mL/hr.
5. Turn the control knob to SET VTBI and press [PRI/SEC] to display PRIMARY.
6. Set the primary volume to 10 mL.
7. Press [PRI/SEC] to display SECONDARY and set the secondary volume to 10 mL.
8. Turn the control knob to CLEAR VOL to clear previous value. Verify four beeps
sound.
9. Assure the graduated cylinder is dry.
10. Turn the control knob to RUN to start pumping fluid. Verify volume delivered is
20 ± 1 mL. Verify that after the VTBI is complete, the infusion system changes to
KVO mode at a rate of 1 mL/hr.
11. Turn the control knob to OFF/CHARGE.
12. Clamp both lines. Remove the distal tubing. Remove the cassette from the infusion
system.
5.2.15
EMPTY CONTAINER/AIR-IN-LINE ALARM TEST
To perform the empty container/air-in-line alarm test, proceed as follows:
1. Install the special cassette marked EMPTY in the infusion system. Confirm the
special cassette proximal bubble sensor tips are removed (see Figure 5-6, Special
Cassettes with Bubble Sensor Tips Removed).
2. Turn the control knob to SET VTBI.
3. Set the volume to 100 mL.
4. Turn the control knob to RUN to start pumping. Verify that within three pumping
cycles the audible alarm sounds and the AIR-IN-LINE and BACKPRIMING legends
display.
5. Turn the control knob to HOLD/RESET.
6. Open the cassette door and remove the cassette.
7. Install the special cassette marked AIR in the infusion system. Confirm the special
cassette distal bubble sensor tips are removed (see Figure 5-6).
8. Turn the control knob to RUN to start pumping. Verify that within three pumping
cycles the alarm sounds and the AIR-IN-LINE legend displays.
430-00587-008 (Rev. 2/05)5 - 12Plum XL Series
Page 57
9. Turn the control knob to HOLD/RESET.
10. Open the cassette door and remove the cassette.
5.2 PERFORMANCE VERIFICATION TEST
(REMOVED FOR PROXIMAL AIR IN LINE ALARM TEST)
PROXIMAL BUBBLE SENSOR BULB TIPS
DISTAL BUBBLE SENSOR BULB TIPS
(REMOVED FOR DISTAL AIR IN LINE ALARM TEST)
CASSETTE CENTERING DEVICE
Figure 5-6. Special Cassettes with Bubble Sensor Tips Removed
5.2.16
ELECTRICAL SAFETY TEST
To perform the electrical safety test, proceed as follows:
1. Connect the infusion system AC (mains) power cord to a safety analyzer.
2. Connect the safety analyzer ground lead to the infusion system ground test-point
screw located on the rear of the infusion system.
3. Check the leakage current with the safety analyzer. Leakage current must not
exceed 100 microamperes (µA) (AC RMS).
4. Measure the resistance of the AC (mains) connector ground lug with the safety
analyzer. Resistance should not exceed 0.1 Ω.
04K01027
Technical Service Manual5 - 13430-00587-008 (Rev. 2/05)
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SECTION 5 MAINTENANCE AND SERVICE TESTS
5.2.17
END OF PERFORMANCE VERIFICATION TEST
If all tests have been successful, proceed as follows:
1. Clear the dose history.
2. Reset the infusion system to the original configuration.
3. Return the infusion system to service.
Note: If any tests fail, refer to Section 6, Troubleshooting, or contact Hospira
Technical Support Operations.
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 an infusion pump periodic maintenance inspection
schedule. Product specifications for this inspection are listed in Section 8, Specifications.
To perform the periodic maintenance inspection, complete the performance verification
test 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 (mains) power failure or inadvertent disconnection of the AC (mains)
power cord. An instance of temporary portable operation includes patient transfer from
one location to another.
The infusion system should be connected to AC (mains) power whenever possible to allow
the battery to remain fully charged. The infusion system line power indicator disappears
and the BATTERY legend appears when the infusion system is operating 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 infusion system is
operating, the alarm sounds and the LOW BATTERY message displays. Although it is not
recommended to continue operating the infusion system on battery power at this point,
the battery will continue providing power until discharged. At this point, the infusion
system enters the battery discharged mode and operation ceases.
430-00587-008 (Rev. 2/05)5 - 14Plum XL Series
Page 59
5.4 BATTERY OPERATION OVERVIEW
CAUTION: As soon as the LOW BATTERY alarm occurs, connect the infusion system
to AC (mains) power.
Recharging occurs any time the infusion system is connected to AC (mains) power. It is
recommended that the infusion system be connected to AC (mains) power whenever
practicable to maximize available battery charge during transport or ambulation. The
power switch does not have to be on for the battery to recharge. Recharging while the
infusion system is operating is rate dependent.
Note: The infusion system should be operated on battery power for six continuous
hours at least once every six months for optimum battery performance and life.
5.4.1
BATTERY CHARGER CURRENT TEST (OPTIONAL)
To perform the battery charger current test, refer to Figure 5-7, Battery Charger Current
Test Configuration, then proceed as follows:
Note: Make certain the battery is in good condition and charged. If necessary, use a
second battery for this test.
1. Disconnect the infusion system from AC (mains) power. Remove the battery access
cover and disconnect the battery.
2. Connect the battery charger test circuit as illustrated in Figure 5-7. Make certain
switch S1 is in the off position.
3. Connect the infusion system to AC (mains) power and allow 20 seconds for the
current to stabilize. Read the current on the current meter.
4. Compare the measured current to the minimum and maximum values in Table 5-2,
Battery Charger Current Test Parameters.
Note: If the reading is too low, the battery may be fully charged. Close switch
S1; repeat Step 3 and verify per Table 5-2.
5. Disconnect the infusion system from AC (mains) power. Remove the battery charger
test circuit. Reconnect the battery to the infusion system. Replace the battery access
cover and secure.
Technical Service Manual5 - 15430-00587-008 (Rev. 2/05)
Page 60
SECTION 5 MAINTENANCE AND SERVICE TESTS
Y
TO CURRENT METER
TO PUMP
J1
1 +
2 -
3
4
+
RED
BLK
ORG
GRN
20 WATTS, 5%)
-
RED
S1
R1
(10 OHMS,
Figure 5-7. Battery Charger Current Test Configuration
Table 5-2. Batter y Charger Current Test Parameters
Battery
Type
Jumper between
Pins 3 and 4
Minimum ValueMaximum Value
1No1.0 Amps1.4 Amps
2Yes0.64 Amps0.92 Amps
TO BATTER
J2
+ 1
- 2
3
4
04K01030
5.5
DATAPORT CONNECTION AND GROUND
CONTINUITY TEST (OPTIONAL)
To perform the DataPort connection and continuity test, refer to Figure 5-8, DataPort
Connector, then proceed as follows:
1. Confirm the infusion system and appropriate accessories are fully assembled.
2. Measure the continuity with a DMM between the left lug of the DataPort connector
and the ground test point on the lower left corner of the rear case. The resistance
should not exceed 1 ohm.
3. Connect the infusion system to AC (mains) power.
4. Turn the control knob to the SET RATE position.
5. Measure the voltage on the DataPort connector between pin 10 (CTS) and pin 9
(COMGND). Verify the voltage is 12.25 ± 0.25 VDC.
6. Turn the control knob to the OFF position.
7. Connect the infusion system to an available RS-232 serial port in the host computer.
430-00587-008 (Rev. 2/05)5 - 16Plum XL Series
Page 61
5.5 DATAPORT CONNECTION AND GROUND CONTINUITY TEST (OPTIONAL)
8. Set the terminal emulator in the host computer with the following parameters:
- 1200 baud, 8 data bits, parity none, stop bits 1
Echo typed character locally
9. Turn the control knob to the SET RATE position.
10. Type in the following commands from the terminal emulator:
T@0;I45A4<CR> (where “<CR>” = Carriage Return)
Note: Commands are case sensitive.
11. Verify the response message is in the following format:
13. Disconnect the infusion system from the RS-232 cable DataPort Connector.
Note: Do not connect DataPort when infusing.
AUDIBLE
LEVEL SWITCH
REAR
ENCLOSURE
PIN 10 (CTS)
Figure 5-8. DataPort Connector
8
PIN 9 (COMGND)
PIN 5 (NURSE2)
PIN 4 (NURSE1)
1
04K01029
Technical Service Manual5 - 17430-00587-008 (Rev. 2/05)
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SECTION 5 MAINTENANCE AND SERVICE TESTS
5.6
NURSE CALL FUNCTION TEST (OPTIONAL)
To perform the nurse call function test, refer to Figure 5-8, then proceed as follows:
1. Confirm the infusion system and appropriate accessories are fully assembled.
2. Turn the control knob to the SET RATE position. Set the rate to a value greater than
40 mL/hr.
3. Turn the control knob to SET VTBI position. Set volume to 100 mL.
4. Turn the control knob to RUN to start pumping fluid.
5. Measure the continuity between pin 4 and pin 5 with a DMM. Verify there is an
open circuit between the two pins.
6. After several pumping cycles, clamp the tubing proximal to the cassette. After drops
stop falling in the sight chamber, verify an occlusion alarms occurs within three
pumping cycles.
7. Measure the continuity between pin 4 and pin 5 with the DMM. Verify there is a
closed circuit between the two pins.
8. Press [SILENCE] and unclamp the proximal tubing.
9. Verify the continuity between pin 4 and pin 5 changes back to an open circuit once
[SILENCE] is pressed.
10. Turn the control knob to OFF/CHARGE.
Note: The nurse call alarm is not available in IEC compliant infusers.
EN-2
430-00587-008 (Rev. 2/05)5 - 18Plum XL Series
Page 63
Section 6
TROUBLESHOOTING
This section contains information on obtaining technical assistance, and alarm messages
and error codes for the 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.
6.2
ALARM MESSAGES AND ERROR CODES
Under most alarm conditions the infusion system 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
See Table 6-1, Operational Alarm Messages and Corrective Actions, and Table 6-2, Error
Codes Requiring Technical Service.
Technical Service Manual6 - 1430-00587-008 (Rev. 2/05)
Page 64
SECTION 6 TROUBLESHOOTING
6.2.1
OPERATIONAL ALARM MESSAGES
Table 6-1 lists infusion system alarm codes that can be cleared by the operator. Also listed
in Table 6-1 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 alarm history (see Section 6.2.3.1, Alarm History).
Table 6-1. Operational Alarm Messages and Corrective Actions
Error
Code
01-1OCCLUSIONDistal
01-2Distal
01-3Distal
01-4Distal
03-1Proximal
03-2Proximal
06-1AIR IN LINE
Alarm MessageDescriptionPossible Cause
occlusion
alarm
occlusion
alarm
occlusion
alarm
occlusion
alarm
occlusion
alarm
occlusion
on secondary
during
backpriming
Air detected
BACKPRIMING
in cassette
Proximal
air-in-line
Distal pressure
above 10 psi
for five seconds
Distal pressure
above 10 psi
for two plunger
strokes
Distal pressure
above 13 psi
Excessive distal
pressure during
the valve leak test
Clamp closed;
tubing kinked;
possible occluded
tubing; defective
administration set;
or defective
pressure circuit
1000 µL of air
has entered the
cassette since
last initialization
Corrective
Action
Unkink tubing,
check IV site,
or replace
administration
set
If condition
recurs,
contact Hospira
Backprime
to expel air
07-1AIR IN LINEDistal air-in-line100 µL bolus
of air detected
at distal sensor
07-2Distal air-in-line260 µL of air
detected in
the last 2.6 mL
of fluid delivered
430-00587-008 (Rev. 2/05)6 - 2Plum XL Series
Remove and
reprime cassette
Remove and
reprime cassette
Page 65
Table 6-1. Operational Alarm Messages and Corrective Actions
Error
Code
08-1AIR IN LINE
Alarm MessageDescriptionPossible Cause
BACKPRIMING
Empty
container
alarm
6.2 ALARM MESSAGES AND ERROR CODES
Corrective
Action
500 µL of air
detected entering
the cassette in
the last two intake
strokes
Change
container
and backprime
to expel air
10-1CHECK SETTINGS
mL/H=mL?
11-1TURN TO RUNTurn to run alarmRotary control
12-1VTBI COMPLETE
Check
settings
alarm
Primary VTBI
complete alarm
mL=mL
12-2Secondary VTBI
complete alarm
13-1CASSETTE
DOOR/CASSETTE
13-2Primary/
13-3Valve leak
(XL only)
or
Input/output
valve leak
test failure
secondary
valve leak
test failure
test failure
due to excessive
signal noise
Rate and VTBI
settings not
correct
knob not in
OFF/CHARGE
or RUN position,
or no key is
pressed for
five minutes
The VTBI for
the primary
channel has
been delivered
The VTBI for
the secondary
channel has
been delivered
Defective
administration set
Cassette
improperly
loaded or
improperly
primed
Fluid spillage
around valve pins
Turn control
knob to
SET RATE
or SET VTBI
to check settings
or enter values
Turn control
knob to RUN,
OFF/CHARGE,
or HOLD/RESET
Discontinue
infusion,
or change
container and
program new
VTBI setting
Turn control
knob to
OFF/CHARGE,
open and close
cassette door,
then restart
If condition
recurs, replace
administration
set
Turn control
knob to OFF/
CHARGE or
HOLD/RESET,
reprime cassette
and restart
Clean valve pins
Technical Service Manual6 - 3430-00587-008 (Rev. 2/05)
Page 66
SECTION 6 TROUBLESHOOTING
Table 6-1. Operational Alarm Messages and Corrective Actions
Error
Code
Alarm MessageDescriptionPossible Cause
14-1LOCKEDLock
violation
alarm
Control knob
position changed
while in LOCKED
mode
Corrective
Action
Press LOCK
button and reset
settings
15-1None
UART test failureThe UART
The device does
not communicate
to the host computer
15-2None
The device does
not communicate
Excessively
frequent UART
interrupts
to the host computer
15-3None
The device does
not communicate
The UART
receiver buffer
has overflowed
to the host computer
16-1TURN TO RUNControl knob in
between valid
states for five
minutes
17-1LOW BATTERYLow
battery
alarm
17-2Low battery
re-alarms after
15 minutes
18-1LOW BATTERYDischarged
battery alarm
Replace
loop-back test
during power-up
MCU PWA
(Section 7.2.9.1)
failed
The MCU does
not have enough
time to process
Replace
MCU PWA
(Section 7.2.9.1)
UART hardware
due to UART
hardware failure
The MCU does
not have enough
time to process
Replace
MCU PWA
(Section 7.2.9.1)
the received data
due to UART
hardware failure
Control knob not
in OFF/CHARGE
or RUN position
Turn control
knob to RUN,
OFF/CHARGE,
or HOLD/RESET
position
Defective control
knob assembly
Replace control
knob assembly
(Section 7.2.7.3)
Low batteryConnect to AC
power or turn
control knob to
HOLD/RESET,
then to RUN
Low batteryConnect to AC
power or turn
control knob to
HOLD/RESET,
then to RUN
Fully
discharged
battery
Connect to AC
power, turn
control knob to
OFF/CHARGE,
or replace
the battery
430-00587-008 (Rev. 2/05)6 - 4Plum XL Series
Page 67
Table 6-1. Operational Alarm Messages and Corrective Actions
Error
Code
Alarm MessageDescriptionPossible Cause
18-2Display blankInfusion system
shutdown one
minute after
discharged
battery alarm
19-1DOOR
Door openCassette
DOOR/CASSETTE
(XL only
or
6.2 ALARM MESSAGES AND ERROR CODES
Corrective
Action
Fully
discharged
battery
Connect to AC
power, turn
control knob to
OFF/CHARGE,
or replace
the battery
Turn control
door open
knob to
OFF/CHARGE,
or close
cassette door
Cassette not
Reseat cassette
seated properly
Technical Service Manual6 - 5430-00587-008 (Rev. 2/05)
Page 68
SECTION 6 TROUBLESHOOTING
6.2.2
ERROR CODES REQUIRING TECHNICAL SERVICE
Table 6-2 lists infusion system error codes that require technical service. Also listed
in Table 6-2 are the malfunction descriptions, possible causes, and corrective actions.
Note: The error code is displayed on the LCD screen. Associated malfunction
descriptions are not displayed. If reference to alarm history is required,
see Section 6.2.3.1.
Valve pin not moving
Pin detect circuitry failureReplace mechanism
Valve pin not present
assembly
(Section 7.2.9.2)
Valve pin not moving
UART failureReplace MCU PWA
(Section 7.2.9.1)
MCU internal failureReplace MCU PWA
Section 7.2.9.1)
(
430-00587-008 (Rev. 2/05)6 - 10Plum XL Series
Page 73
6.2 ALARM MESSAGES AND ERROR CODES
6.2.3
SERVICE MODE
The service mode provides diagnostic and repair service information. On the Plum XL,
the service mode is accessed by simultaneously pressing and holding the [TITRATE]
and [SILENCE] keys while turning the control knob from the OFF/CHARGE position.
On the Plum XLM, the service mode is accessed by simultaneously pressing and holding
the [TITRATE/QUICKSET] and [SILENCE] keys while turning the control knob from the
OFF/CHARGE position. These keys must be pressed until the end of the self-test sequence,
at which time normal infusion system operation is disabled and the service mode
is accessed.
The following sections briefly describe the service mode-particular alarm history, software
revision number, run-time, battery run-time, and parameter programming functions.
Table 6-3, Service Mode Control Knob Settings, lists the infusion system control knob
settings used during the service mode and provides functional differences for each control
knob setting.
Table 6-3.Service Mode Control Knob Settings
Control Knob SettingService Mode Information
SET RATEAlarm history
SET VTBISoftware revision number
RUNRun time and battery run time
HOLD/RESET (XLM with DataPort)Parameter programming
6.2.3.1
ALARM HISTORY
When the infusion system is in service mode and the control knob is turned to the
SET RATE position, the alarm history can be viewed. In viewing the alarm history list,
large digits indicate an alarm error number (Er01, Er02, Er03) and small digits indicate
a four-digit alarm code. If there are no entries in the alarm history, the large digits indicate
Er, and the small digits indicate ----.
The infusion system [S] and [T] keys are used to scroll through the alarm history. The first
entry displayed is the most recent alarm. To view a previous alarm, press the [S] key.
The large numerals increment to indicate the order of alarms. Pressing the [S] key has no
effect when the end of the alarm history is reached. To review the entries, press the [T] key.
When preventive maintenance is performed on the infusion system, it may be desirable to
clear the alarm history. Clear the alarm history by simultaneously pressing and holding
the [PRI/SEC] key and the [BACKPRIME] key for four seconds. The small digits flash and
an audible tone sounds four times at a once-per-second rate. After four seconds, the alarm
history list is cleared.
Technical Service Manual6 - 11430-00587-008 (Rev. 2/05)
Page 74
SECTION 6 TROUBLESHOOTING
6.2.3.2
SOFTWARE REVISION NUMBER
When the infusion system is in service mode and the control knob is set to the SET VTBI
position, the software revision number can be viewed. The decimal point does not appear
in the software revision number display, but is implied after the first digit. For example,
if the display shows 105, the software revision number is 1.05. The software revision
number may be necessary when contacting Hospira.
6.2.3.3
RUN TIME AND BATTERY RUN TIME
When the infusion system is in service mode and the control knob is set to the RUN
position, the run time and battery run time can be viewed. In the run time and battery
run time display, large digits indicate the total infusion system run time in tens of hours
and the small digits indicate the battery run time in tens of hours. For example: if the
large digits indicate 245 and the small digits indicate 79, the infusion system has been
operated for a total of 2,450 hours and has also been operated on battery for 790 of those
2,450 hours.
When replacing the battery, it may be desirable to clear the battery run time. To clear the
battery run time, simultaneously press and hold the [PRI/SEC] key and the [BACKPRIME]
key for four seconds. The small digits flash and an audible tone sounds four times at
a once-per-second rate. After four seconds, the battery run time is cleared. The total
infusion system time cannot be cleared.
6.2.3.4
PARAMETER PROGRAMMING (XLM WITH DATAPORT)
When the infusion system is in service mode and the control knob is set to HOLD/RESET,
three sub-modes can be viewed and changed. Each of these three sub-modes are used
to change the value of an operational parameter of the infusion system as shown in
Table 6-4, Sub-Modes of Parameter Programming.
The first sub-mode (communication selection) is the default sub-mode of parameter
programming. Subsequently pressing the [BACKPRIME] key will change it to the second
sub-mode (soft ID), the third sub-mode (channel label), then to the first sub-mode. Within
a sub-mode, the small digits indicate its index while the large digits indicate the current
value of the parameter to be viewed and programmed.
Table 6-4. Su b-Modes of Parameter Programming
Sub-Mode
Sub-Mode NamePurpose
Communication Selection
Soft IDTo enter the soft ID of the infusion system2
Channel LabelTo enter the channel label of the infusion system3
To select the communication with
the host computer
Index
1
430-00587-008 (Rev. 2/05)6 - 12Plum XL Series
Page 75
6.2 ALARM MESSAGES AND ERROR CODES
6.2.3.4.1
Communication Selection
The value of the communication selection can be either 0 or 1. Value 0 means that the
communication circuitry of the infusion system will be powered up when the device
is operating on AC (mains) power, and will be powered down when the infusion system
is operating on battery. Value 1 means the communication circuitry will be powered up
regardless of the power supply type. Table 6-5, Communication Circuitry Selections, shows
how the communication selection and the power supply determine the power of the
communication circuitry. Use the [S] and [T] keys to toggle the value between 0 and 1.
Table 6-5. Communication Circuitry Selections
SelectionAC OperationBattery Operation
0Power up communication circuitryPower down communication circuitry
1Power up communication circuitryPower up communication circuitry
6.2.3.4.2
Soft ID
The large digits indicate the current value of the soft ID. The range is between 0 and 9999.
Use the [S] and [T] keys to change the value. The [S] key increases the value up to,
but does not exceed, 9999. The [T] key decreases the value down to, but does not pass, 0.
6.2.3.4.3
Channel Label
The first two of the large digits indicate the current hard ID if the setting of the junction
box has no parity error. If there is no entry, two dashes will be displayed. The third digit
displays a dash. The fourth digit indicates the current value of the channel label.
The fourth digit should be 0 for the single channel version of the infusion system
(i.e., XLM with DataPort).
Simultaneously press and hold the [TITRATE/QUICKSET] and [SILENCE] keys for two
seconds to change the value. Use the [S] key to increase the value and [T] key to decrease
the value.
Technical Service Manual6 - 13430-00587-008 (Rev. 2/05)
Page 76
SECTION 6 TROUBLESHOOTING
6.3
TROUBLESHOOTING PROCEDURES
Table 6-6, PVT Troubleshooting, describes failures that may be detected during the
Performance Verification Test (PVT). If an error code displays, see Section 6.2.
Table 6-6.PVT Troubleshooting
Test FailuresPossible CausesCorrective Actions
Self test
Section 5.2.5
Keypad and
control knob test
Section 5.2.6
Open door alarm test
Section 5.2.7
Alarm loudness test
Section 5.2.8
Section 5.2.9
Battery legend test
Section 5.2.10
Free flow test
Section 5.2.11
Proximal occlusion
test
Section 5.2.12
Distal occlusion
test
Section 5.2.13
Cassette not properly installedReprime and re-insert cassette
Defective MCU PWAReplace MCU PWA
Defective display PWA
or ribbon cable
Defective control knobReplace control knob
Cassette door openClose cassette door
Cassette not properly seatedReseat cassette
Defective sensor PWAReplace mechanism assembly
Defective mechanism assemblyReplace mechanism assembly
Defective MCU PWA
or ribbon cable
Defective display PWA
or ribbon cable
Corrosive buildup on bottom
surface of the buzzer located on
the MCU board
Defective MCU PWAReplace MCU PWA
Defective power supply PWAReplace power supply PWA
Defective fuseReplace fuse
Defective AC (mains) cordsetReplace AC (mains) cordset
Defective display PWA
or ribbon cable
Defective power supply PWAReplace power supply PWA
Cassette not properly seatedReseat cassette
Defective cassetteReplace cassette
Defective or dirty valve pinsClean valve pins
Set not properly primedReprime set
Damaged or faulty setPrime using new set
Defective mechanism assemblyReplace mechanism assembly
Defective special cassetteReplace special cassette
Dirty bubble sensorsClean bubble sensors
Defective bubble sensor PWAReplace mechanism assembly
Defective sensor PWAReplace mechanism assembly
Electrical safety test
Section 5.2.16
Insufficient ground connectionAttach lead to T point screw
on rear of infusion system
Defective AC (mains) cordsetReplace AC (mains) cordset
Defective power supply PWAReplace power supply PWA
Battery charger
current test
(optional)
Section 5.4.1
DataPort connection/
ground continuity test
(optional)
Section 5.5
Blown fuseReplace fuse
Defective AC (mains) cordsetReplace AC (mains) cordset
Defective power supply PWAReplace power supply PWA
Insufficient ground connection
from DataPort connector to
Attach ground wire from DataPort
connector to ground screw
ground screw
Defective DataPort/MCU cable
assembly
DataPort/MCU cable not properly
seated on MCU PWA
Replace DataPort/MCU cable
assembly
Reseat DataPort/MCU cable
assembly to MCU PWA
Technical Service Manual6 - 15430-00587-008 (Rev. 2/05)
Page 78
SECTION 6 TROUBLESHOOTING
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430-00587-008 (Rev. 2/05)6 - 16Plum XL Series
Page 79
Section 7
REPLACEABLE PARTS AND
REPAIRS
This section itemizes all parts and subassemblies of the XL and XLM infusion systems
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, Illustrated Parts Breakdown. Table 9-2, IPB for the Infusion System,
identifies each infusion system part by an index number that correlates to Figure 9-1.
To request a copy of the current spare parts price list, contact Hospira(see
Section 6.1, Technical Assistance), 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 Manual7 - 1430-00587-008 (Rev. 2/05)
Page 80
SECTION 7 REPLACEABLE PARTS AND REPAIRS
This page intentionally left blank.
430-00587-008 (Rev. 2/05)7 - 2Plum XL Series
Page 81
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 infusion system. 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 infusion system, take all necessary precautions
for working on high-voltage equipment.
WARNING:POSSIBLE EXPLOSION HAZARD EXISTS IF THE INFUSION
SYSTEM IS SERVICED OR REPAIRED IN THE PRESENCE OF
FLAMMABLE ANESTHETICS.
WARNING:UNLESS OTHERWISE INDICATED, DISCONNECT THE
INFUSION SYSTEM FROM AC POWER BEFORE PERFORMING
ANY REPLACEMENT PROCEDURE.
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.
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 nutdrivers (1/4, 3/16, and 5/16 inch)
❏ Medium size flat blade screwdriver
®
❏ No. 2 Phillips
❏ Fuse puller
❏ Wide-head pliers
❏ Long needle nose pliers
❏ Diagonal cutters
❏ X-acto
❏ Wood chisel, 3/8 inch
❏ Mild solvent (such as isopropyl alcohol)
®
knife (with square, round, and pointed blades)
screwdriver
Technical Service Manual7 - 3430-00587-008 (Rev. 2/05)
Page 82
SECTION 7 REPLACEABLE PARTS AND REPAIRS
7.2.3
RUBBER FOOT PAD REPLACEMENT
Recommended tools and materials for this procedure are a 3/8 inch wood chisel or an
X-acto knife and mild solvent.
The replacement part for this procedure is:
Foot Pad, Rubber
To replace the rubber foot pads, refer to Figure 7-1, Bottom View of the Infusion System,
then proceed as follows:
1. Turn the control knob to OFF/CHARGE.
2. Disconnect the infusion system from AC (mains) power.
3. Set the infusion system on its back to access the foot pads.
4. Using a 3/8 inch wood chisel or an X-acto knife, remove the rubber foot pad and
scrape the enclosure recess to remove adhesive residue.
Note: Each adhesive-backed rubber foot pad is bonded in its recess. Do not
damage the recess.
5. Using a mild solvent, clean the enclosure recess.
6. Remove the protective backing from the self-adhesive surface on the replacement
rubber foot pad and bond the foot pad in place.
7. After approximately five minutes, verify the foot pad is secure.
8. Connect the infusion system to AC (mains) power.
Replacement of a rubber foot pad is a routine maintenance procedure and no verification
procedure is normally required. However, if the infusion system may have been damaged
during this procedure, perform the PVT in Section 5.2.
430-00587-008 (Rev. 2/05)7 - 4Plum XL Series
Page 83
Technical Service Manual7 - 5430-00587-008 (Rev. 2/05)
BATTERY
DOOR
BATTERY WITH WIRE
HARNESS ASSEMBLY
CHARGER
CIRCUIT
CABLE
7.2 REPLACEMENT PROCEDURES
RUBBER FOOT
PAD (4)
6-32 x 1/2
HEX HEAD
SCREW
BATTERY
DOOR PAD
BATTERY
CABLE
Figure 7-1. Bottom View of the Infusion System
04K01006
Page 84
SECTION 7 REPLACEABLE PARTS AND REPAIRS
7.2.4
BATTERY WITH WIRE HARNESS ASSEMBLY, BATTERY
DOOR, AND BATTERY DOOR PAD REPLACEMENT
Recommended tools and materials for this procedure are a medium size flat blade
screwdriver, an X-acto knife, and mild solvent.
The replacement parts for this procedure are:
Screw, 6-32 x 1/2, Hex Head, Slotted
Assembly, Battery, with Wire Harness
Pad, Door, Battery
Door, Battery
To replace the battery, battery door, and battery door pad, refer to Figure 7-1, then proceed
as follows:
1. Turn the control knob to OFF/CHARGE.
2. Disconnect the infusion system from AC (mains) power.
3. Set the infusion system on its back to access the bottom.
4. Using a medium size flat blade screwdriver, remove the hex head screw securing
the battery door to the infusion system. Remove the battery door and replace it if
necessary.
5. Inspect the battery door pad for damage. If the pad is damaged, remove it using an
X-acto knife and mild solvent. Dry the battery door thoroughly, and install a new
battery door pad on the battery door.
6. Disconnect the battery cable from the charger circuit cable. Pull the battery cable
wires and connector outside the enclosure. Remove the battery.
7. Connect the replacement battery cable to the charger circuit cable.
Note: The cable connectors are keyed so that cables cannot be connected
incorrectly.
8. Insert the replacement battery into the enclosure, confirming that the battery cable
is not pinched between the battery and the enclosure.
9. Using a medium size flat blade screwdriver, replace and tighten the hex head screw
to secure the battery door to the infusion system.
10. Connect the infusion system to AC (mains) power.
To verify successful battery, battery door, and battery door pad replacement, perform the
PVT in Section 5.2.
430-00587-008 (Rev. 2/05)7 - 6Plum XL Series
Page 85
7.2 REPLACEMENT PROCEDURES
7.2.5
SEPARATING THE FRONT ENCLOSURE ASSEMBLY,
REAR ENCLOSURE ASSEMBLY, AND MAIN CHASSIS
ASSEMBLY
The recommended tool for this procedure is a medium size flat blade screwdriver.
CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store the PWA
in an antistatic bag before placing it on any surface.
To separate the front enclosure assembly, rear enclosure assembly, and main chassis
assembly, refer to Figure 7-2, Front Enclosure, Main Chassis Assembly, and Rear Enclosure,
then proceed as follows:
1. Turn the control knob to OFF/CHARGE.
2. Disconnect the infusion system from AC (mains) power.
3. Remove the battery door and battery as described in Section 7.2.4.
4. Using the medium size flat blade screwdriver, remove the two remaining hex head
screws located on the enclosure bottom. Remove the two hex head screws from the
carrying handle.
Note: Do not remove the ground test-point screw.
5. Separate the front and rear enclosures by carefully pulling the carrying handles
apart.
6. Disconnect the MCU/Display PWA cable from J3 on the MCU PWA (see Figure 7-2).
7. (XLM only) Slowly back off the rear enclosure assembly two to three inches and
disconnect the MCU/Buzzer cable from J10 on the MCU PWA.
8. (For devices equipped with DataPort only) Disconnect the DataPort/MCU cable from
J11 on the MCU PWA.
9. Separate the main chassis assembly from the rear enclosure assembly, being
careful not to remove the power supply PWA from the rear enclosure.
Technical Service Manual7 - 7430-00587-008 (Rev. 2/05)
Page 86
430-00587-008 (Rev. 2/05)7 - 8Plum XL Series
GASKET (2)
MCU PWA
REAR
ENCLOSURE
6-32 x 1/2
HEX HEAD
SCREW (4)
SECTION 7 REPLACEABLE PARTS AND REPAIRS
FRONT
ENCLOSURE
MCU/DISPLAY
CABLE
MCU/BUZZER
CABLE
MAIN
CHASSIS
DATAPORT/MCU
CABLE
ASSEMBLY
Figure 7-2. Front Enclosure, Main Chassis Assembly, and Rear Enclosure
AC POWER
CORD
04K01005
Page 87
7.2 REPLACEMENT PROCEDURES
7.2.6
FRONT ENCLOSURE ASSEMBLY, REAR ENCLOSURE
ASSEMBLY, OR MAIN CHASSIS ASSEMBLY
REPLACEMENT
The recommended tool for this procedure is a medium size flat blade screwdriver.
The replacement parts for this procedure are:
Assembly, Enclosure, Front
Assembly, Enclosure, Rear
Chassis, Main
Gasket, Front/Rear Enclosure
CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store the PWA
in an antistatic bag before placing it on any surface.
To replace the front enclosure assembly, rear enclosure assembly, or main chassis
assembly, refer to Figure 7-2, then proceed as follows:
1. Separate the front enclosure assembly, rear enclosure assembly, and main chassis
assembly as described in Section 7.2.5.
2. To replace the front enclosure assembly, remove the specific components described
in Section 7.2.7, Front Enclosure Assembly Component Replacement.
3. To replace the rear enclosure assembly, remove the specific components described
in Section 7.2.8, Rear Enclosure Assembly Component Replacement.
4. To replace the main chassis assembly, remove the specific components described
in Section 7.2.9, Main Chassis Assembly Component Replacement.
5. Inspect the front enclosure assembly gaskets and replace if necessary (see
Figure 7-2).
6. Reassemble the replacement front enclosure assembly, rear enclosure assembly,
or main chassis assembly components. Refer to the specific procedure in
Section 7.2.7, Section 7.2.8, or Section 7.2.9.
7. Reassemble the device in the exact reverse order of separation.
Note: (XLM with DataPort) When joining the front and rear enclosures, do not
pinch the DataPort/MCU cable between the two enclosures (see Figure 7-12,
DataPort Assembly (Domestic) or Figure 7-13, DataPort Assembly
(International)).
8. Connect the infusion system to AC (mains) power.
To verify successful front enclosure, rear enclosure, or main chassis replacement, perform
the PVT in Section 5.2.
Technical Service Manual7 - 9430-00587-008 (Rev. 2/05)
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SECTION 7 REPLACEABLE PARTS AND REPAIRS
7.2.7
FRONT ENCLOSURE ASSEMBLY COMPONENT
REPLACEMENT
Front enclosure assembly component replacement includes the replacement of the
following:
❏ Display PWA and MCU/display cable
❏ Switch-activated front panel keys
❏ Control knob, knob detent, washer, and snap retainer
❏ Front panel label
To replace the front enclosure assembly components, refer to either Figure 7-3, Display
PWA and MCU/Display Cable, or Figure 7-4, Front Enclosure Assembly Components, then
proceed as detailed in the following sections.
4-24 x 3/8
B/POINT
SCREW
FRONT
ENCLOSURE
ASSEMBLY
DISPLAY PWA
TAB RETAINER (4)
MCU/DISPLAY
CABLE
04K01007
Figure 7-3. Display PWA and MCU/Display Cable
430-00587-008 (Rev. 2/05)7 - 10Plum XL Series
Page 89
7.2 REPLACEMENT PROCEDURES
CONTROL KNOB
SHIM
FRONT
LABEL
FRONT
ENCLOSURE
ASSEMBLY
XL MCU BUMPERS (2)
WASHER
GASKET
DETENT RING
MAGNET
DISPLAY PWA
4-24 x 3/8
B/POINT
PHILLIPS
SCREW
FRONT PANEL
KEY (6)
KNOB DETENT
SNAP RETAINER
MCU/DISPLAY CABLE
04K01008
Figure 7-4. Front Enclosure Assembly Components
7.2.7.1
DISPLAY PWA AND MCU/DISPLAY CABLE REPLACEMENT
Recommended tools for this procedure are a medium size flat blade screwdriver and a No.
2 Phillips screwdriver.
CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store the PWA
in an antistatic bag before placing it on any surface.
To replace the display PWA and the MCU/display cable, refer to Figure 7-3 and Figure 7-4,
then proceed as follows:
1. Separate the front enclosure assembly and rear enclosure assembly as described
in Section 7.2.5.
Technical Service Manual7 - 11430-00587-008 (Rev. 2/05)
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SECTION 7 REPLACEABLE PARTS AND REPAIRS
2. Place the front enclosure assembly face down.
3. Remove and replace the two XL MCU Bumpers.
4. Using a No. 2 Phillips screwdriver, remove the Phillips screw securing the display
PWA to the control knob assembly.
5. Disengage the four tab retainers securing the display PWA to the front enclosure
assembly. Remove the display PWA from the front enclosure assembly.
6. Disconnect the MCU/display cable from the display PWA. Replace the MCU/display
cable if it is defective or damaged.
7. Install the replacement display PWA in the exact reverse order of removal.
8. Reassemble the device in the exact reverse order of disassembly.
Note: (XLM with DataPort) When joining the front and rear enclosures, do not
pinch the DataPort/MCU cable between the two enclosures.
9. Connect the infusion system to AC (mains) power.
To verify successful display PWA and MCU/display cable replacement, perform the PVT
in Section 5.2.
7.2.7.2
FRONT PANEL KEY REPLACEMENT
Recommended tools for this procedure are a medium size flat blade screwdriver and No.
2 Phillips screwdriver.
The replacement part for this procedure is:
Key, Front Panel, Switch Activated
CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store the PWA
in an antistatic bag before placing it on any surface.
To replace the front panel keys, refer to Figure 7-4, then proceed as follows:
1. Separate the front enclosure assembly and rear enclosure assembly as described
in Section 7.2.5.
2. Remove the display PWA as described in Section 7.2.7.1.
3. Remove the front panel keys from the key recesses and install replacements (see
Figure 7-4).
4. Reassemble the device in the exact reverse order of disassembly.
Note: (XLM with DataPort) When joining the front and rear enclosures, do not
pinch the DataPort/MCU cable between the two enclosures.
5. Connect the infusion system to AC (mains) power.
To verify successful front panel key replacement, perform the PVT in Section 5.2.
430-00587-008 (Rev. 2/05)7 - 12Plum XL Series
Page 91
7.2 REPLACEMENT PROCEDURES
7.2.7.3
CONTROL KNOB, KNOB DETENT, WASHER, GASKET, SNAP
RETAINER, AND DETENT RING REPLACEMENT
Recommended tools for this procedure are a small flat blade screwdriver, a medium size
flat blade screwdriver, a No. 2 Phillips screwdriver, and long needle nose pliers.
CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store the PWA
in an antistatic bag before placing it on any surface.
To replace the control knob, knob detent, washer, gasket, detent ring, and snap retainer,
refer to Figure 7-4, then proceed as follows:
1. Separate the front enclosure assembly and rear enclosure assembly as described
in Section 7.2.5.
2. Remove the display PWA as described in Section 7.2.7.1.
3. Remove the front panel keys as described in Section 7.2.7.2.
4. Using long needle nose pliers, carefully remove the snap retainer.
5. Remove the control knob, knob detent, shim, washer, gasket, and detent ring.
6. Inspect the magnet on the knob detent. If the magnet appears damaged, carefully
remove it using the small flat blade screwdriver. Install the replacement, assuring
that the dot on the magnet is facing up.
7. Install the replacement control knob, washer, and gasket.
- Fit the gasket into the circular recess on the front side of the front enclosure.
- Install the washer on the control knob.
- Install the shim on the control knob.
- Place the control knob through the hole in the front enclosure.
- Turn the control knob to OFF/CHARGE.
8. Place the front enclosure assembly face down. Place the detent ring on the four
pins, centered on the control knob. Assure that the raised bumps on the detent
ring are facing up.
9. Using the snap retainer, secure the knob detent on the control knob retainer clips
and splines. Press the snap retainer firmly until it is secure.
Note: When the control knob is at OFF/CHARGE, the knob detent is
positioned on the detent ring as shown in Figure 7-4.
10. Verify that the control knob rotates fully.
11. Reassemble the device in the exact reverse order of disassembly.
Technical Service Manual7 - 13430-00587-008 (Rev. 2/05)
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SECTION 7 REPLACEABLE PARTS AND REPAIRS
Note: (XLM with DataPort) When joining the front and rear enclosures, do not
pinch the DataPort/MCU cable between the two enclosures.
12. Connect the infusion system to AC (mains) power.
To verify successful control knob, knob detent, washer, and snap retainer replacement,
perform the PVT in Section 5.2.
7.2.7.4
FRONT PANEL LABEL REPLACEMENT
Recommended tools and materials for this procedure are an X-acto knife, long needle nose
pliers, and mild solvent.
The replacement part for this procedure is:
Label, Front Panel
To replace the front panel label, refer to Figure 7-4, then proceed as follows:
1. Turn the control knob to OFF/CHARGE.
2. Disconnect the infusion system from AC (mains) power.
3. Using an X-acto knife, remove the front panel label from the front panel enclosure.
4. Using a mild solvent, remove adhesive residue from the front panel assembly recess.
5. Remove the adhesive backing from the replacement front panel label and press the
label into place on the front enclosure assembly.
Replacement of the front panel label is a routine maintenance procedure and no
verification procedure is normally required. However, if the infusion system may have been
damaged during this procedure, perform the PVT in Section 5.2.
7.2.8
REAR ENCLOSURE ASSEMBLY COMPONENT
REPLACEMENT
Rear enclosure assembly component replacement includes the replacement of the
following:
❏ Fuses
❏ Power supply PWA
❏ Velcro retainer strap
❏ AC (mains) power cord, and strain relief bushing
❏ AC (mains) power cord (International)
❏ AC receptacle, EMI shield, and equipotential post
❏ LifeCare AC receptacle, bracket, gasket, seal, and equipotential post
❏ DataPort/MCU cable assembly
❏ LifeCare DataPort/MCU cable assembly
❏ Pole clamp extrusion, knob, backing plate, and adhesive-backed insulator
❏ Pole clamp shaft/knob assembly and the pole clamp shaft tip
❏ Buzzer PWA and MCU/buzzer cable
430-00587-008 (Rev. 2/05)7 - 14Plum XL Series
Page 93
7.2 REPLACEMENT PROCEDURES
To replace the rear enclosure assembly components, proceed as detailed in the following
sections.
7.2.8.1
FUSE REPLACEMENT
Recommended tools for this procedure are a medium size flat blade screwdriver and a fuse
puller.
The replacement part for this procedure is:
Fuse, 0.5A, 250V, Slo-Blo, 5 x 20 mm
Cover, Fuse 5 x 20 mm
To replace the fuse, refer to Figure 7-5, Fuse Replacement (115 VAC) or Figure 7-6, Fuse
Replacement (220 VAC), then proceed as follows:
1. Separate the front enclosure assembly and rear enclosure assembly as described
in Section 7.2.5.
2. Remove the two plastic fuse covers. Using the fuse puller, remove the two fuses on
the power supply PWA and install replacements.
CAUTION: Confirm replacement fuse rating is identical to fuse rating
indicated on the power supply PWA or equipment damage may occur.
3. Reassemble the device in the exact reverse order of disassembly.
Note: (XLM with DataPort) When joining the front and rear enclosures, do not
pinch the DataPort/MCU cable between the two enclosures.
4. Connect the infusion system to AC (mains) power.
To verify successful fuse replacement, perform the PVT in Section 5.2.
Technical Service Manual7 - 15430-00587-008 (Rev. 2/05)
Page 94
SECTION 7 REPLACEABLE PARTS AND REPAIRS
REAR ENCLOSURE
ASSEMBLY
FUSE COVER (2)
AC POWER CORD
FUSE (2)
REAR ENCLOSURE
ASSEMBLY
FUSE COVER (2)
04K01034
Figure 7-5. Fuse Replacement (115 VAC)
AC POWER CORD
FUSE (2)
04K01035
Figure 7-6. Fuse Replacement (220 VAC)
430-00587-008 (Rev. 2/05)7 - 16Plum XL Series
Page 95
7.2 REPLACEMENT PROCEDURES
7.2.8.2
POWER SUPPLY PWA REPLACEMENT
Recommended tools for this procedure are a medium size flat blade screwdriver and a
1/4 inch nutdriver.
The replacement parts for this procedure are:
PWA, Power Supply
Screw, 6-32 x 5/16, Hex Head, Slotted
CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store the PWA
in an antistatic bag before placing it on any surface.
To replace the power supply PWA, refer to Figure 7-7, Power Supply PWA, then proceed as
follows:
1. Separate the front enclosure assembly and rear enclosure assembly as described
in Section 7.2.5.
2. Disconnect the AC (mains) power cord wire from J16 (see Table 7-1, Wire Color
Coding).
3. Disconnect the AC (mains) power cord wire from J17 (see Table 7-1).
4. For all infusion systems except Plum XL domestic: disconnect the AC (mains) power
cord wire from J18 (see Table 7-1).
5. Using a 1/4 inch nutdriver, remove the two hex head screws securing the power
supply PWA to the rear enclosure assembly. Remove the power supply PWA from
the rear enclosure assembly.
6. Install the replacement power supply PWA.
7. Connect the AC (mains) power cord wire to J17 (see Table 7-1).
8. Connect the AC (mains) power cord wire to J16 (see Table 7-1).
9. For all infusion systems except Plum XL domestic: connect the AC (mains) power
cord wire to J18 (see Table 7-1).
10. Reassemble the device in the exact reverse order of disassembly.
Note: (XLM with DataPort) When joining the front and rear enclosures, do not
pinch the DataPort/MCU cable between the two enclosures.
11. Connect the infusion system to AC (mains) power.
To verify successful power supply PWA replacement, perform the PVT in Section 5.2.
Technical Service Manual7 - 17430-00587-008 (Rev. 2/05)
To replace the Velcro retainer strap, remove the strap from the power cord and install the
replacement (see Figure 7-7).
Replacement of the Velcro retainer strap is a routine maintenance procedure and no
verification procedure is normally required. However, if the infusion system may have been
damaged during the Velcro retainer strap replacement, perform the PVT in Section 5.2.
7.2.8.4
AC (MAINS) POWER CORD AND STRAIN RELIEF BUSHING
REPLACEMENT
Recommended tools for this procedure are a medium size flat blade screwdriver,
a 1/4 inch nutdriver, and pliers.
The replacement parts for this procedure are:
Cordset, AC Power, Hospital Grade
Strain Relief, Nylon, Black
Nut, 6-32, KEP, with Washer
Washer, Flat, # 6
Screw, 6-32 x 3/4, Hex Head, Slotted, w/Washer (XL)
Screw, 6-32 x 1, Hex Head, Slotted, w/Washer (XLM)
CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store the PWA
in an antistatic bag before placing it on any surface.
To replace the AC (mains) power cord, and strain relief bushing, refer to Figure 7-8, AC
Power Cord (115 VAC - Plum XL) or Figure 7-9, AC Power Cord (115 VAC - Plum XLM), then
proceed as follows:
1. Separate the front enclosure assembly and rear enclosure assembly as described
in Section 7.2.5.
2. Using a 1/4 inch nutdriver, remove the two hex head nuts from the hex head ground
screw.
3. Disconnect the green ground wire from the ground screw.
4. Disconnect the AC (mains) power cord wire from J16 (see Table 7-1, Wire Color
Coding).
5. Disconnect the AC (mains) power cord wire from J17 (see Table 7-1).
6. Use the pliers to remove the strain relief bushing.
7. Pull the AC (mains) power cord through the mounting hole in the rear enclosure
assembly.
8. Install the replacement AC (mains) power cord in the exact reverse order of removal.
Technical Service Manual7 - 19430-00587-008 (Rev. 2/05)
Page 98
SECTION 7 REPLACEABLE PARTS AND REPAIRS
9. Connect the AC (mains) power cord wire to J17 (see Table 7-1).
10. Connect the AC (mains) power cord wire to J16 (see Table 7-1).
11. Connect the ground wire with the grounding lug to the ground screw. Using a 1/4
inch nutdriver, replace and tighten the two hex head nuts to the ground screw.
12. Reassemble the device in the exact reverse order of disassembly.
Note: (XLM with DataPort) When joining the front and rear enclosures, do not
pinch the DataPort/MCU cable between the two enclosures.
13. Connect the infusion system to AC (mains) power.
To verify successful AC (mains) power cord, strain relief bushing, and Velcro strap
replacement, perform the PVT in Section 5.2.
REAR ENCLOSURE
POWER
SUPPLY PWA
EMI SHIELD
6-32 KEP NUT (3)
FLAT WASHER (3)
GROUND WIRE (2)
STRAIN RELIEF
BUSHING
6-32 x 3/4 HEX
HEAD SCREW
Figure 7-8. AC Power Cord (115 VAC - Plum XL)
AC POWER
CORD
04K01044
430-00587-008 (Rev. 2/05)7 - 20Plum XL Series
Page 99
REAR ENCLOSURE
7.2 REPLACEMENT PROCEDURES
SHIELD
POWER
SUPPLY
PWA
EMI
DATAPORT/GROUND
CABLE ASSEMBLY
6-32 x 1 HEX
HEAD SCREW
6-32 KEP NUT (4)
FLAT WASHER (2)
GROUND WIRE (2)
Figure 7-9. AC Power Cord (115 VAC - Plum XLM)
STRAIN
RELIEF
BUSHING
AC POWER
CORD
04K01045
7.2.8.5
AC (MAINS) POWER CORD REPLACEMENT (INTERNATIONAL)
No tools are required for this procedure.
The replacement part for this procedure is:
Cordset, AC Power, Hospital, International
To replace the AC (mains) power cord, refer to Figure 7-10, AC Power Cord (220 VAC - Plum
XLM) or Figure 7-11, AC Power Cord (220 VAC - Plum XLM), then disconnect the power cord
from the rear of the infusion system and connect the replacement power cord.
Replacement of the AC (mains) power cord is a routine maintenance procedure and no
verification procedure is normally required. However, if the infusion system may have been
damaged during this procedure, perform the PVT in Section 5.2.
Technical Service Manual7 - 21430-00587-008 (Rev. 2/05)
Page 100
SECTION 7 REPLACEABLE PARTS AND REPAIRS
7.2.8.6
AC RECEPTACLE, EMI SHIELD, AND EQUIPOTENTIAL POST
REPLACEMENT
Recommended tool for this procedure is a 6 mm nutdriver.
The replacement parts for this procedure are:
Receptacle, AC Connection
Post, Equipotential
Shield, EMI
Nut, Hex, 6mm
Washer, Lock
Washer, Flat
Washer, Flat, 1/4 inch
CAUTION: Use proper ESD grounding techniques when handling components.
Wear an antistatic wrist strap and use an ESD-protected workstation. Store the PWA
in an antistatic bag before placing it on any surface.
To replace the AC connection receptacle and equipotential post, refer to Figure 7-10, then
proceed as follows:
1. Separate the front enclosure assembly and rear enclosure assembly as described
in Section 7.2.5.
2. Remove the power supply PWA as described in Section 7.2.8.2.
3. Remove the hex nut and two washers holding the EMI shield to the equipotential
post. Replace the EMI shield if necessary.
4. Remove the hex nut, three washers and three ground wires, then the remaining
hex nut and washers from the equipotential post (see Figure 7-10).
5. Remove the equipotential post and replace if necessary.
6. Remove the AC receptacle by pulling it through the rear enclosure. Install a
replacement if necessary.
7. Reassemble the device in the exact reverse order of disassembly.
Note: (XLM with DataPort) When joining the front and rear enclosures, do not
pinch the DataPort/MCU cable between the two enclosures.
8. Connect the infusion system to AC (mains) power.
To verify sucessful AC receptacle, EMI shield, and equipotential post replacement, perform
the PVT in Section 5.2.
430-00587-008 (Rev. 2/05)7 - 22Plum XL Series
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