Hospira Plum XL Service manual

Page 1
For use with the following list numbers:
Plum XL 11555-04, 12570-04
LifeCare XL 11555-09, 11555-13, 11555-27, 11555-29, 11555-36,
11555-46, 11555-54, 11555-88
Plum XLM 11846-04
LifeCare XLM 11846-09, 11846-27, 11846-29, 11846-36, 11846-42,
11846-46, 11846-54, 11846-88
Plum XLM
Plum XLM
Veterinary
LifeCare XLM
11859-04
12570-04
11859-09, 11859-27, 11859-29, 11859-36, 11859-42, 11859-54, 11859-63, 11859-69, 11859-71, 11859-88
Technical Service Manual
430-00587-008 (Rev. 2/05)
Page 2
© 2005 Hospira, Inc. This document and the subject matter disclosed herein are proprietary information. Hospira
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.
430-00587-008 (Rev. 2/05) Plum XL Series
Page 3
Change History
Insert
Description of
Part Number
430-00587-001 (Rev. 11/93) Original issue
430-00587-002 (Rev. 7/94) Second issue
430-00587-A02 (Rev. 11/94) Updated cover Cover Cover
Change
Remove and Destroy Pages
Change Pages
Updated Change History
Added error code 59-1 to Table 6-2
430-00587-003 (Rev. 2/96) Third issue
430-00587-004 (Rev. 12/97) Fourth issue
430-00587-005 (Rev. 2/99) Fifth issue
Updated Table 5-1
Included international DataPort content
430-00587-006 (Rev. 10/99) Sixth issue
Included nurse call adapter information
430-00587-007 (Rev. 08/01) Seventh issue
Updated PVT in Section 5
Updated replacement procedures in Section 7
i, ii i, ii
6-7 to 6-10 6-7 to 6-10
Updated IPB graphics in Section 9
430-00587-008 (Rev. 2/05) Eighth issue
Incorporated Hospira name change
Included IEC 60601-1-2 specifications in Appendix and throughout manual
Updated replacement procedures in Section 7
Updated IPB graphics in Section 9
Technical Service Manual i 430-00587-008 (Rev. 2/05)
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CHANGE HISTORY
This page intentionally left blank.
430-00587-008 (Rev. 2/05) ii Plum XL Series
Page 5
Contents
Section 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 GLOBAL PRODUCT CONFIGURATIONS . . . . . . . . . . . . . . 1-2
1.3 CONVENTIONS . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4 COMPONENT DESIGNATORS . . . . . . . . . . . . . . . . . . 1-6
1.5 ACRONYMS AND ABBREVIATIONS . . . . . . . . . . . . . . . . 1-6
1.6 USER QUALIFICATION . . . . . . . . . . . . . . . . . . . . . 1-7
1.7 ARTIFACTS . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.8 INSTRUMENT INSTALLATION PROCEDURE . . . . . . . . . . . . 1-8
1.8.1 UNPACKING . . . . . . . . . . . . . . . . . . . . . . 1-8
1.8.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 1-9
1.8.3 SELF TEST. . . . . . . . . . . . . . . . . . . . . . . . 1-9
Section 2
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Section 3
SYSTEM OPERATING MANUAL . . . . . . . . . . . . . . . . . . . . 3-1
Section 4
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . 4-1
4.2 ELECTRONICS OVERVIEW . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 POWER SUPPLY PWA . . . . . . . . . . . . . . . . . . . 4-2
4.2.1.1 SWITCHER CIRCUITRY . . . . . . . . . . . . . . . 4-2
4.2.1.2 VOLTAGE REGULATOR CIRCUITRY . . . . . . . . . . 4-3
4.2.1.3 BATTERY CHARGER CIRCUITRY . . . . . . . . . . . 4-4
4.2.2 POWER SUPPLY PWA . . . . . . . . . . . . . . . . . . . 4-5
4.2.2.1 SWITCHER CIRCUITRY . . . . . . . . . . . . . . . 4-5
4.2.2.2 VOLTAGE REGULATOR CIRCUITRY . . . . . . . . . . 4-6
4.2.2.3 BATTERY CHARGER CIRCUITRY . . . . . . . . . . . 4-6
4.2.3 MCU PWA. . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.3.1 WATCHDOG CIRCUITRY . . . . . . . . . . . . . . 4-7
4.2.3.2 SERIAL COMMUNICATION CIRCUITRY . . . . . . . . . 4-7
4.2.3.3 ALARM CIRCUITRY (XL) . . . . . . . . . . . . . . . 4-8
4.2.3.4 ALARM CIRCUITRY (XLM) . . . . . . . . . . . . . . 4-8
4.2.3.5 ALARM POWER BACKUP CIRCUITRY . . . . . . . . . . 4-8
4.2.3.6 MOTOR DRIVER CIRCUITRY . . . . . . . . . . . . . 4-9
4.2.3.7 PIN DETECTOR CIRCUITRY . . . . . . . . . . . . . 4-9
4.2.3.8 UART (XLM WITH DATAPORT) . . . . . . . . . . . . 4-9
4.2.3.9 NURSE CALL ALARM
(XLM WITH DATAPORT - NURSE CALL) . . . . . . . . . 4-10
4.2.4 BUZZER PWA (XLM) . . . . . . . . . . . . . . . . . . . . 4-10
4.2.4.1 HIGH VOLUME AUDIBLE ALARM . . . . . . . . . . . 4-10
4.2.4.2 LOCKOUT SWITCH . . . . . . . . . . . . . . . . . 4-11
4.2.5 DISPLAY PWA . . . . . . . . . . . . . . . . . . . . . . 4-11
4.2.5.1 DISPLAY CIRCUITRY (XL) . . . . . . . . . . . . . . 4-11
4.2.5.2 DISPLAY CIRCUITRY
(XLM DISPLAY PWA -003 AND LOWER) . . . . . . . . . 4-11
Technical Service Manual iii 430-00587-008 (Rev. 2/05)
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CONTENTS
4.2.5.3 DISPLAY CIRCUITRY
(XLM DISPLAY PWA -004 AND HIGHER) . . . . . . . . . 4-11
4.2.5.4 EL PANEL DRIVER CIRCUITRY (XL) . . . . . . . . . . 4-12
4.2.5.5 LED BACKLIGHT PANEL AND DRIVER (XLM) . . . . . . 4-12
4.2.5.6 RUN INDICATOR CIRCUITRY. . . . . . . . . . . . . 4-12
4.2.5.7 LINE POWER INDICATOR CIRCUITRY . . . . . . . . . 4-12
4.2.5.8 CONTROL KNOB CIRCUITRY (XL) . . . . . . . . . . . 4-13
4.2.5.9 CONTROL KNOB CIRCUITRY (XLM) . . . . . . . . . . 4-13
4.2.6 SENSOR PWA . . . . . . . . . . . . . . . . . . . . . . 4-13
4.2.6.1 PRESSURE AMPLIFIER/FILTER CIRCUITRY. . . . . . . . 4-13
4.2.6.2 AC AMPLIFIER CIRCUITRY . . . . . . . . . . . . . . 4-14
4.2.6.3 VOLTAGE REFERENCE CIRCUITRY . . . . . . . . . . 4-14
4.2.6.4 OPTO INTERRUPTER CIRCUITRY . . . . . . . . . . . 4-14
4.2.6.5 EEPROM CIRCUITRY . . . . . . . . . . . . . . . . 4-14
4.2.7 BUBBLE SENSOR PWA . . . . . . . . . . . . . . . . . . . 4-14
4.2.7.1 TRANSMITTER CIRCUITRY . . . . . . . . . . . . . 4-15
4.2.7.2 RECEIVER CIRCUITRY . . . . . . . . . . . . . . . 4-15
4.2.7.3 PIN DETECTOR FLEX CIRCUITRY . . . . . . . . . . . 4-15
4.3 MECHANICAL OVERVIEW . . . . . . . . . . . . . . . . . . . 4-16
4.3.1 CASSETTE . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.3.2 MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . 4-18
4.3.2.1 MOTOR AND VALVE ASSEMBLIES. . . . . . . . . . . 4-19
4.3.2.2 PRIMARY/SECONDARY VALVE SUBSYSTEM . . . . . . . 4-19
4.3.2.3 INLET/OUTLET VALVE SUBSYSTEM . . . . . . . . . . 4-20
4.3.2.4 PLUNGER DRIVE SUBSYSTEM . . . . . . . . . . . . 4-20
Section 5
MAINTENANCE AND SERVICE TESTS . . . . . . . . . . . . . . . . . . 5-1
5.1 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 INSPECTING THE INFUSION SYSTEM. . . . . . . . . . . . . 5-1
5.1.2 CLEANING THE INFUSION SYSTEM . . . . . . . . . . . . . 5-1
5.1.3 SANITIZING THE INFUSION SYSTEM . . . . . . . . . . . . . 5-2
5.1.4 CLEANING THE BUZZER . . . . . . . . . . . . . . . . . . 5-3
5.2 PERFORMANCE VERIFICATION TEST . . . . . . . . . . . . . . . 5-4
5.2.1 EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . 5-4
5.2.2 ICONS AND ENGLISH LANGUAGE EQUIVALENTS . . . . . . . 5-5
5.2.3 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 5-6
5.2.4 TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.2.5 SELF TEST . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.2.6 KEYPAD AND CONTROL KNOB TEST . . . . . . . . . . . . . 5-8
5.2.7 OPEN DOOR ALARM TEST . . . . . . . . . . . . . . . . . 5-9
5.2.8 ALARM LOUDNESS TEST (XL) . . . . . . . . . . . . . . . . 5-9
5.2.9 ALARM LOUDNESS AND LOCK FUNCTION TESTS (XLM) . . . . . 5-9
5.2.10 BATTERY LEGEND TEST . . . . . . . . . . . . . . . . . . 5-10
5.2.11 FREE FLOW TEST . . . . . . . . . . . . . . . . . . . . . 5-10
5.2.12 PROXIMAL OCCLUSION TEST. . . . . . . . . . . . . . . . 5-10
5.2.13 DISTAL OCCLUSION TEST . . . . . . . . . . . . . . . . . 5-11
5.2.14 DELIVERY ACCURACY TEST . . . . . . . . . . . . . . . . 5-12
5.2.15 EMPTY CONTAINER/AIR-IN-LINE ALARM TEST . . . . . . . . . 5-12
5.2.16 ELECTRICAL SAFETY TEST . . . . . . . . . . . . . . . . . 5-13
5.2.17 END OF PERFORMANCE VERIFICATION TEST . . . . . . . . . 5-14
5.3 PERIODIC MAINTENANCE INSPECTION . . . . . . . . . . . . . . 5-14
5.4 BATTERY OPERATION OVERVIEW . . . . . . . . . . . . . . . . 5-14
5.4.1 BATTERY CHARGER CURRENT TEST (OPTIONAL) . . . . . . . . 5-15
5.5 DATAPORT CONNECTION AND GROUND CONTINUITY TEST
(OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.6 NURSE CALL FUNCTION TEST (OPTIONAL). . . . . . . . . . . . . 5-18
430-00587-008 (Rev. 2/05) iv Plum XL Series
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CONTENTS
Section 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 TECHNICAL ASSISTANCE. . . . . . . . . . . . . . . . . . . . 6-1
6.2 ALARM MESSAGES AND ERROR CODES . . . . . . . . . . . . . . 6-1
6.2.1 OPERATIONAL ALARM MESSAGES . . . . . . . . . . . . . 6-2
6.2.2 ERROR CODES REQUIRING TECHNICAL SERVICE . . . . . . . . 6-6
6.2.3 SERVICE MODE . . . . . . . . . . . . . . . . . . . . . 6-11
6.2.3.1 ALARM HISTORY . . . . . . . . . . . . . . . . . 6-11
6.2.3.2 SOFTWARE REVISION NUMBER . . . . . . . . . . . . 6-12
6.2.3.3 RUN TIME AND BATTERY RUN TIME . . . . . . . . . . 6-12
6.2.3.4 PARAMETER PROGRAMMING
(XLM WITH DATAPORT) . . . . . . . . . . . . . . . 6-12
6.3 TROUBLESHOOTING PROCEDURES. . . . . . . . . . . . . . . . 6-14
Section 7
REPLACEABLE PARTS AND REPAIRS . . . . . . . . . . . . . . . . . . 7-1
7.1 REPLACEABLE PARTS . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . 7-3
7.2.1 SAFETY AND EQUIPMENT PRECAUTIONS . . . . . . . . . . . 7-3
7.2.2 REQUIRED TOOLS AND MATERIALS . . . . . . . . . . . . . 7-3
7.2.3 RUBBER FOOT PAD REPLACEMENT . . . . . . . . . . . . . 7-4
7.2.4 BATTERY WITH WIRE HARNESS ASSEMBLY, BATTERY DOOR, AND
BATTERY DOOR PAD REPLACEMENT . . . . . . . . . . . . . 7-6
7.2.5 SEPARATING THE FRONT ENCLOSURE ASSEMBLY, REAR ENCLOSURE
ASSEMBLY, AND MAIN CHASSIS ASSEMBLY . . . . . . . . . . 7-7
7.2.6 FRONT ENCLOSURE ASSEMBLY, REAR ENCLOSURE ASSEMBLY, OR
MAIN CHASSIS ASSEMBLY REPLACEMENT . . . . . . . . . . 7-9
7.2.7 FRONT ENCLOSURE ASSEMBLY COMPONENT REPLACEMENT . . . 7-10
7.2.7.1 DISPLAY PWA AND MCU/DISPLAY CABLE
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-11
7.2.7.2 FRONT PANEL KEY REPLACEMENT . . . . . . . . . . 7-12
7.2.7.3 CONTROL KNOB, KNOB DETENT, WASHER, GASKET, SNAP
RETAINER, AND DETENT RING REPLACEMENT . . . . . 7-13
7.2.7.4 FRONT PANEL LABEL REPLACEMENT . . . . . . . . . 7-14
7.2.8 REAR ENCLOSURE ASSEMBLY COMPONENT REPLACEMENT . . . 7-14
7.2.8.1 FUSE REPLACEMENT . . . . . . . . . . . . . . . . 7-15
7.2.8.2 POWER SUPPLY PWA REPLACEMENT . . . . . . . . . . 7-17
7.2.8.3 VELCRO RETAINER STRAP REPLACEMENT . . . . . . . 7-19
7.2.8.4 AC (MAINS) POWER CORD AND STRAIN RELIEF BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-19
7.2.8.5 AC (MAINS) POWER CORD REPLACEMENT
(INTERNATIONAL) . . . . . . . . . . . . . . . . . 7-21
7.2.8.6 AC RECEPTACLE, EMI SHIELD, AND EQUIPOTENTIAL POST
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-22
7.2.8.7 LIFECARE AC RECEPTACLE, BRACKET, GASKET, SEAL, AND
EQUIPOTENTIAL POST REPLACEMENT . . . . . . . . . 7-23
7.2.8.8 DATAPORT/MCU CABLE ASSEMBLY REPLACEMENT
(XLM WITH DATAPORT) . . . . . . . . . . . . . . . 7-25
7.2.8.9 LIFECARE DATAPORT/MCU CABLE ASSEMBLY REPLACEMENT
(XLM WITH DATAPORT) . . . . . . . . . . . . . . . 7-27
7.2.8.10 POLE CLAMP EXTRUSION, POLE CLAMP BACKING PLATE,
AND ADHESIVE-BACKED INSULATOR REPLACEMENT. . . 7-28
7.2.8.11 POLE CLAMP SHAFT/KNOB ASSEMBLY AND POLE CLAMP
SHAFT TIP REPLACEMENT . . . . . . . . . . . . . . 7-30
7.2.8.12 BUZZER PWA AND MCU/BUZZER CABLE
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-31
Technical Service Manual v 430-00587-008 (Rev. 2/05)
Page 8
CONTENTS
7.2.9 MAIN CHASSIS ASSEMBLY COMPONENT REPLACEMENT . . . . 7-32
7.2.9.1 MCU PWA AND SENSOR/MCU CABLE ASSEMBLY
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-33
7.2.9.2 MECHANISM ASSEMBLY REPLACEMENT . . . . . . . . 7-35
7.2.9.3 CASSETTE DOOR AND MECHANISM SHIELD
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-36
7.2.9.4 OPENER HANDLE ASSEMBLY REPLACEMENT . . . . . . 7-41
Section 8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 PLUM XL AND XLM . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 LIFECARE XL AND XLM . . . . . . . . . . . . . . . . . . . . 8-2
Section 9
DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
430-00587-008 (Rev. 2/05) vi Plum XL Series
Page 9
FIGURES
Figures
Figure 1-1. Plum XL Icon Based and English Language Front Panels . . . . . . . . 1-4
Figure 1-2. Plum XLM Icon Based and English Language Front Panels . . . . . . . 1-4
Figure 1-3. Plum XL LCD Test Screens . . . . . . . . . . . . . . . . . . 1-10
Figure 1-4. Plum XLM LCD Test Screens. . . . . . . . . . . . . . . . . . 1-10
Figure 4-1. Major Elements of the Dual-Channel Cassette. . . . . . . . . . . . 4-17
Figure 4-2. Fluid Path in the Cassette . . . . . . . . . . . . . . . . . . . 4-18
Figure 4-3. Mechanism Valve Pins and Sensor Locations . . . . . . . . . . . . 4-20
Figure 5-1. Cleaning the Buzzer . . . . . . . . . . . . . . . . . . . . . 5-3
Figure 5-2. Icons and English Language Equivalents . . . . . . . . . . . . . 5-5
Figure 5-3. Plum XL LCD Test Screens . . . . . . . . . . . . . . . . . . 5-7
Figure 5-4. Plum XLM LCD Test Screens. . . . . . . . . . . . . . . . . . 5-8
Figure 5-5. Distal Occlusion Test Setup . . . . . . . . . . . . . . . . . . 5-11
Figure 5-6. Special Cassettes with Bubble Sensor Tips Removed . . . . . . . . . 5-13
Figure 5-7. Battery Charger Current Test Configuration . . . . . . . . . . . . 5-16
Figure 5-8. DataPort Connector . . . . . . . . . . . . . . . . . . . . . 5-17
Figure 7-1. Bottom View of the Infusion System . . . . . . . . . . . . . . . 7-5
Figure 7-2. Front Enclosure, Main Chassis Assembly, and Rear Enclosure . . . . . . 7-8
Figure 7-3. Display PWA and MCU/Display Cable . . . . . . . . . . . . . . 7-10
Figure 7-4. Front Enclosure Assembly Components . . . . . . . . . . . . . . 7-11
Figure 7-5. Fuse Replacement (115 VAC) . . . . . . . . . . . . . . . . . . 7-16
Figure 7-6. Fuse Replacement (220 VAC) . . . . . . . . . . . . . . . . . . 7-16
Figure 7-7. Power Supply PWA . . . . . . . . . . . . . . . . . . . . . 7-18
Figure 7-8. AC Power Cord (115 VAC - Plum XL) . . . . . . . . . . . . . . . 7-20
Figure 7-9. AC Power Cord (115 VAC - Plum XLM) . . . . . . . . . . . . . . 7-21
Figure 7-10. AC Power Cord (220 VAC - Plum XLM) . . . . . . . . . . . . . . 7-23
Figure 7-11. AC Power Cord (220 VAC - Plum XLM) . . . . . . . . . . . . . . 7-24
Figure 7-12. DataPort Assembly (Domestic) . . . . . . . . . . . . . . . . . 7-26
Figure 7-13. DataPort Assembly (International) . . . . . . . . . . . . . . . . 7-28
Figure 7-14. XL Series Pole Clamp . . . . . . . . . . . . . . . . . . . . 7-30
Figure 7-15. Buzzer PWA . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Figure 7-16. Exploded View of the Main Chassis Assembly . . . . . . . . . . . 7-34
Figure 7-17. Top View of the Main Chassis Assembly . . . . . . . . . . . . . 7-35
Figure 7-18. Mechanism Shield Replacement . . . . . . . . . . . . . . . . 7-38
Figure 7-19. Cassette Door Replacement (1 of 3). . . . . . . . . . . . . . . . 7-39
Figure 7-20. Cassette Door Replacement (2 of 3). . . . . . . . . . . . . . . . 7-39
Figure 7-21. Cassette Door Replacement (3 of 3) . . . . . . . . . . . . . . . 7-40
Figure 7-22. Cassette Door Replacement, Bottom View . . . . . . . . . . . . . 7-40
Figure 7-23. Opener Handle Assembly Replacement (1 of 3) . . . . . . . . . . . 7-42
Figure 7-24. Opener Handle Assembly Replacement (2 of 3) . . . . . . . . . . . 7-43
Figure 7-25. Opener Handle Assembly Replacement (3 of 3) . . . . . . . . . . . 7-43
Figure 9-1. Illustrated Parts Breakdown . . .
Figure 9-2. Front Enclosure, Rear Enclosure, and Main Chassis Assemblies . . . . . 9-11
Figure 9-3. Front Enclosure Assembly . . . . . . . . . . . . . . . . . . . 9-13
Figure 9-4. Rear Enclosure Assembly (XL Domestic). . . . . . . . . . . . . . 9-15
Figure 9-5. Rear Enclosure Assembly (XL International) . . . . . . . . . . . . 9-17
Figure 9-6. Rear Enclosure Assembly (XLM Domestic) . . . . . . . . . . . . . 9-19
Figure 9-7. Rear Enclosure Assembly (XLM International) . . . . . . . . . . . 9-21
Figure 9-8. Rear Enclosure Assembly (XLM with DataPort - Domestic) . . . . . . . 9-23
Figure 9-9. Rear Enclosure Assembly (XLM with DataPort - International ) . . . . . 9-25
Figure 9-10. Rear Enclosure Assembly (Lifecare XLM with DataPort) . . . . . . . . 9-27
Figure 9-11. Main Chassis Assembly. . . . . . . . . . . . . . . . . . . . 9-29
Figure 9-12. Battery Replacement . . . . . . . . . . . . . . . . . . . . . 9-31
Figure 9-13. Mechanical Assembly . . . . . . . . . . . . . . . . . . . . 9-33
. . . . . . . . . . . . . . . 9-7
Technical Service Manual vii 430-00587-008 (Rev. 2/05)
Page 10
FIGURES
Figure 9-14. Plum XL Block Diagram . . . . . . . . . . . . . . . . . . . 9-37
Figure 9-15. MCU PWA Schematic (XL) . . . . . . . . . . . . . . . . . . 9-39
Figure 9-16. MCU PWA Schematic (XLM) . . . . . . . . . . . . . . . . . . 9-43
Figure 9-17. MCU PWA Schematic (XLM with DataPort) . . . . . . . . . . . . 9-47
Figure 9-18. Display PWA Schematic (XL). . . . . . . . . . . . . . . . . . 9-83
Figure 9-19. Display PWA Schematic (XLM) . . . . . . . . . . . . . . . . . 9-85
Figure 9-20. Bubble Sensor PWA Schematic . . . . . . . . . . . . . . . . . 9-99
Figure 9-21. Sensor PWA Schematic . . . . . . . . . . . . . . . . . . . . 9-105
Figure 9-22. Pin Detector Flex Circuit Schematic . . . . . . . . . . . . . . . 9-107
Figure 9-23. Power Supply PWA Schematic (XL Domestic). . . . . . . . . . . . 9-109
Figure 9-24. Power Supply PWA Schematic (XL International) . . . . . . . . . . 9-113
Figure 9-25. Power Supply PWA Schematic (XLM Domestic) . . . . . . . . . . . 9-117
Figure 9-26. Power Supply PWA Schematic (XLM International) . . . . . . . . . 9-121
Figure 9-27. Power Supply PWA Schematic (XLM with DataPort) . . . . . . . . . 9-129
Figure 9-28. Buzzer PWA Schematic . . . . . . . . . . . . . . . . . . . . 9-137
Tables
Table 1-1. Global Product Configurations . . . . . . . . . . . . . . . . . 1-2
Table 1-2. Conventions . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Table 4-1. Battery Charge Current States . . . . . . . . . . . . . . . . . 4-4
Table 5-1. Cleaning Solutions . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-2. Battery Charger Current Test Parameters . . . . . . . . . . . . . 5-16
Table 6-1. Operational Alarm Messages and Corrective Actions . . . . . . . . . 6-2
Table 6-2. Error Codes Requiring Technical Service . . . . . . . . . . . . . 6-6
Table 6-3. Service Mode Control Knob Settings . . . . . . . . . . . . . . . 6-11
Table 6-4. Sub-Modes of Parameter Programming . . . . . . . . . . . . . . 6-12
Table 6-5. Communication Circuitry Selections . . . . . . . . . . . . . . . 6-13
Table 6-6. PVT Troubleshooting . . . . . . . . . . . . . . . . . . . . 6-14
Table 7-1. Wire Color Coding . . . . . . . . . . . . . . . . . . . . . 7-18
Table 9-1. Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
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) viii Plum 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 1 Introduction
Section 2 Warranty
Section 3 System Operating Manual
Section 4 Theory of Operation
Section 5 Maintenance and Service Tests
Section 6 Troubleshooting
Section 7 Replaceable Parts and 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 Manual 1 - 1 430-00587-008 (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 Number Country
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*
USA 100-130
Canadian Spanish
Australia 210-260
UK
Spanish (Latin America)
Power
Supply
VAC
100-130 VAC
VAC
210-260 VAC
Rear Case LCD
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 - 2 Plum XL Series
Page 13
Group
Icon
Table 1-1. Global Product Configurations
List Number Country
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 Case LCD
* Complies with IEC/EN 60601-1-2: 2001
EN-2
Technical Service Manual 1 - 3 430-00587-008 (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 - 4 Plum 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
Convention Application Example
Italic Reference 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 Bold Emphasis CAUTION: Use proper ESD
Screen displays DOOR/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 Manual 1 - 5 430-00587-008 (Rev. 2/05)
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SECTION 1 INTRODUCTION
1.4
COMPONENT DESIGNATORS
Components are indicated by alpha-numeric designators, as follows:
Battery BT Diode D Resistor R
Capacitor C Fuse F Switch SW
Crystal Y Integrated Circuit U Transistor Q
The number following the letter is a unique value for each type of component (e.g., R1, R2).
Note: Alpha-numeric designators may be followed with a dash (-) number that
indicates a pin number for that component. For example, U15-13 is pin 13 of the encoder chip [U15] on the interface PWA.
1.5
ACRONYMS AND ABBREVIATIONS
Acronyms and abbreviations used in this manual are as follows:
A Ampere
AC Alternating current
ACE Asynchronous communication element
AC RMS Alternating current root mean square
A/D Analog-to-digital
CMOS Complementary metal-oxide semiconductor
CPU Central processing unit
DC Direct current
DMM Digital multimeter
DPM Digital pressure meter
ECG Electrocardiograph
EEG Electroencephalogram
EEPROM Electrically erasable programmable read-only memory
EL Electroluminescent
EMG Electromyogram
EMI Electromagnetic interference
ETO Ethylene oxide
FET Field-effect transistor
HKDC Housekeeping DC
hr Hour
Hz Hertz
IC Integrated circuit
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Page 17
1.6 USER QUALIFICATION
IEC International Electrotechnical Commission
IPB Illustrated parts breakdown
IV Intravenous
kHz Kilohertz
KVO Keep vein open
LCD Liquid crystal display
LED Light-emitting diode
mA Milliampere
MCU Micro controller unit
MHz Megahertz
mL Milliliter
mV Millivolt
PLL Phase-lock loop
PVT Performance verification test
PSI Pounds per square inch
PWA Printed wiring assembly
SPSTIN Single-pole, single-throw in
UART Universal asynchronous receiver/transmitter
VAC Volts AC
VCO Voltage-controlled oscillator
VCC Collector supply voltage
VDC Volts DC
VDIG Digital voltage
VMOT Motor voltage
Vpp Volts peak-to-peak
VTBI Volume to be infused
µA Microampere
µL microliter
µS microsecond
1.6
USER QUALIFICATION
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.
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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 - 8 Plum 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 Manual 1 - 9 430-00587-008 (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 LINE EMPTY LOW BATTERY KVO TURN TO RUN CHECK SETTINGS OCCLUSION
SECONDARY PRIMARY BACKPRIMING
AIR IN LINE EMPTY LOW BATTERY
SET
KVO
RATE
TURN TO RUN CHECK SETTINGS OCCLUSION
VTBI
SECONDARY PRIMARY BACKPRIMING
PIGGYBACK ML/HR SET
RATE VTBI PIGGYBACK ML/HR
AIR IN LINE LOCKED LOW BATTERY
KVO VTBI COMPLETE DOOR CASSETTE
TURN TO RUN CHECK SETTINGS OCCLUSION
SECONDARY PRIMARY BACKPRIMING SET
RATE VTBI PIGGYBACK ML/HR MICRO
VTBI COMPLETE
VTBI COMPLETE
ENGLISH LANGUAGE
ENGLISH LANGUAGE
DOOR/CASSETTE
DOOR/CASSETTE
TOTAL VOLUME DELIVERED
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/hr m
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 - 10 Plum 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 Manual 2 - 1 430-00587-008 (Rev. 2/05)
Page 22
SECTION 2 WARRANTY
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430-00587-008 (Rev. 2/05) 2 - 2 Plum 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).
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SECTION 3 SYSTEM OPERATING MANUAL
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430-00587-008 (Rev. 2/05) 3 - 2 Plum 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 Manual 4 - 1 430-00587-008 (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 - 2 Plum 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 Manual 4 - 3 430-00587-008 (Rev. 2/05)
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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 Signal CHRG_OFF Signal J26-3 to J26-4 Approximate Current
Low Low Short 0.8 A
Low Low Open 1.2 A High Low Short 0.16 A High Low Open 0.25 A
Don't care High Don't care Trickle = (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 - 4 Plum XL Series
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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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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
Figure 9-18, Display PWA Schematic (XL), or Figure 9-19, Display PWA Schematic (XLM)).
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.
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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 Manual 4 - 17 430-00587-008 (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.
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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.
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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.
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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.
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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 Solution Manufacturer Preparation
Coverage™ HB Steris Corporation Per manufacturer's
recommendation
Dispatch
Formula C™ JohnsonDiversey Per manufacturer's
Manu-Klenz
Precise
Sporicidin
Household bleach Various Per hospital procedures; do
®
®
Steris Corporation Per manufacturer's
®
®
Caltech Industries Per manufacturer's
recommendation
recommendation
recommendation
Caltech Industries Per manufacturer's
recommendation
Sporicidin International Per 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.
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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 Manual 5 - 3 430-00587-008 (Rev. 2/05)
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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
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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 RUN OCCLUSION
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 Manual 5 - 5 430-00587-008 (Rev. 2/05)
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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).
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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 LINE EMPTY LOW BATTERY
KVO
TURN TO RUN CHECK SETTINGS OCCLUSION
SECONDARY PRIMARY 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 Manual 5 - 7 430-00587-008 (Rev. 2/05)
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SECTION 5 MAINTENANCE AND SERVICE TESTS
ENGLISH LANGUAGE
AIR IN LINE LOCKED LOW BATTERY
KVO VTBI COMPLETE DOOR CASSETTE
TURN TO RUN CHECK SETTINGS OCCLUSION
SECONDARY PRIMARY 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/hr m
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.
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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.
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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.
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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 Manual 5 - 11 430-00587-008 (Rev. 2/05)
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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.
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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 Manual 5 - 13 430-00587-008 (Rev. 2/05)
Page 58
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 - 14 Plum 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 Manual 5 - 15 430-00587-008 (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 Value Maximum Value
1 No 1.0 Amps 1.4 Amps 2 Yes 0.64 Amps 0.92 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 - 16 Plum 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:
FXX;YYYY;RZZZZ (where “XX = Hard ID”, “YYYY = Soft ID”, “ZZZZ = CRC”)
12. Turn the control knob to the OFF position.
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 Manual 5 - 17 430-00587-008 (Rev. 2/05)
Page 62
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 - 18 Plum 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 Manual 6 - 1 430-00587-008 (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
01-1 OCCLUSION Distal
01-2 Distal
01-3 Distal
01-4 Distal
03-1 Proximal
03-2 Proximal
06-1 AIR IN LINE
Alarm Message Description Possible 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
07-1 AIR IN LINE Distal air-in-line 100 µL bolus
of air detected at distal sensor
07-2 Distal air-in-line 260 µL of air
detected in the last 2.6 mL of fluid delivered
430-00587-008 (Rev. 2/05) 6 - 2 Plum XL Series
Remove and reprime cassette
Remove and reprime cassette
Page 65
Table 6-1. Operational Alarm Messages and Corrective Actions
Error Code
08-1 AIR IN LINE
Alarm Message Description Possible 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
10-1 CHECK SETTINGS
mL/H=mL?
11-1 TURN TO RUN Turn to run alarm Rotary control
12-1 VTBI COMPLETE
Check settings alarm
Primary VTBI complete alarm
mL=mL
12-2 Secondary VTBI
complete alarm
13-1 CASSETTE
DOOR/CASSETTE
13-2 Primary/
13-3 Valve 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 Manual 6 - 3 430-00587-008 (Rev. 2/05)
Page 66
SECTION 6 TROUBLESHOOTING
Table 6-1. Operational Alarm Messages and Corrective Actions
Error Code
Alarm Message Description Possible Cause
14-1 LOCKED Lock
violation alarm
Control knob position changed while in LOCKED mode
Corrective
Action
Press LOCK button and reset settings
15-1 None
UART test failure The UART
The device does
not communicate
to the host computer
15-2 None
The device does
not communicate
Excessively frequent UART interrupts
to the host computer
15-3 None
The device does
not communicate
The UART receiver buffer has overflowed
to the host computer
16-1 TURN TO RUN Control knob in
between valid states for five minutes
17-1 LOW BATTERY Low
battery alarm
17-2 Low battery
re-alarms after 15 minutes
18-1 LOW BATTERY Discharged
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 battery Connect to AC
power or turn
control knob to
HOLD/RESET,
then to RUN Low battery Connect 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 - 4 Plum XL Series
Page 67
Table 6-1. Operational Alarm Messages and Corrective Actions
Error Code
Alarm Message Description Possible Cause
18-2 Display blank Infusion system
shutdown one minute after discharged battery alarm
19-1 DOOR
Door open Cassette
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 Manual 6 - 5 430-00587-008 (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.
Table 6-2. Error Codes Requiring Technical Service
Error Code
20-1 Stack overflow MCU RAM error Replace MCU PWA
21-1 Critical data checksum
21-2 Critical data checksum
21-3 Checksum of operational
21-4 Checksum of operational
29-1 ROM checksum failure
29-2 ROM checksum failure
29-3 ROM checksum test
34-1 EEPROM read/write
35-1 Critical RAM values
41-1 LCD driver chip
44-1 44-2
Malfunction
Description
failure at start up
failure during operation
parameters failure at startup
parameters failure during operation
at startup
during operation
not being performed
test failure
found incorrect
test failure
Audio BUZZER signal out of range
Possible Cause Corrective Action
(Section 7.2.9.1)
MCU RAM error Replace MCU PWA Nonvolatile memory error
MCU RAM error Replace MCU PWA
MCU RAM error
MCU RAM error
MCU ROM error
MCU ROM error
MCU execution error
Decode circuit failure Replace MC U PWA EEPROM chip failure MCU RAM error
Decode circuit failure Replace MC U PWA Driver chip failure
Audio buzzer or circuit failure
ADC on MCU chip not functioning properly or ADC reference voltage not correct
(Section 7.2.9.1)
If condition recurs,
contact Hospira
(Section 7.2.9.1)
(Section 7.2.9.1)
(Section 7.2.9.1)
Replace display PWA
(Section 7.2.7.1)
Replace MCU PWA
(Section 7.2.9.1)
Check fuse F3 on power supply PWA; replace fuse, if defective
(Section 7.2.8.1)
If condition recurs,
contact Hospira
430-00587-008 (Rev. 2/05) 6 - 6 Plum XL Series
Page 69
Table 6-2. Error Codes Requiring Technical Service
Error Code
Malfunction
Description
45-1 [PRI/SEC] key stuck
in ON position
45-2 [UP ARROW] key stuck
in ON position
45-3 [DOWN ARROW] key
stuck in ON position
45-4 [TITRATE] key stuck
in ON position
45-5 [BACKPRIME] key stuck
in ON position
45-6 [SILENCE] key stuck
in ON position
59-1 Valve motor moving
at the wrong time
6.2 ALARM MESSAGES AND ERROR CODES
Possible Cause Corrective Action
Switch S1 on display PWA shorted or stuck
Replace display PWA
(Section 7.2.7.1)
Front panel key stuck Replace key
(Section 7.2.7.2)
Replace front enclosure assembly
(Section 7.2.6)
Switch S3 on display PWA shorted or stuck
Replace display PWA
(Section 7.2.7.1)
Front panel key stuck Replace key
(Section 7.2.7.2)
Replace front enclosure assembly
(Section 7.2.6)
Switch S2 on display PWA shorted or stuck
Replace display PWA
(Section 7.2.7.1)
Front panel key stuck Replace key
(Section 7.2.7.2)
Replace front enclosure assembly
(Section 7.2.6)
Switch S4 on display PWA shorted or stuck
Replace display PWA
(Section 7.2.7.1)
Front panel key stuck Replace key
(Section 7.2.7.2)
Replace front enclosure assembly
(Section 7.2.6)
Switch S5 on display PWA shorted or stuck
Replace display PWA
(Section 7.2.7.1)
Front panel key stuck Replace key
(Section 7.2.7.2)
Replace front enclosure assembly
(Section 7.2.6)
Switch S6 on display PWA shorted or stuck
Replace display PWA
(Section 7.2.7.1)
Front panel key stuck Replace key
(Section 7.2.7.2)
Replace front enclosure assembly
(Section 7.2.6)
Position sensor failure Replace mechanism
assembly
(Section 7.2.9.2)
Motor drive circuit failure Replace MCU PWA
(Section 7.2.9.1)
Technical Service Manual 6 - 7 430-00587-008 (Rev. 2/05)
Page 70
SECTION 6 TROUBLESHOOTING
Table 6-2. Error Codes Requiring Technical Service
Error Code
60-1 Plunger motor position
Malfunction
Description
Possible Cause Corrective Action
Position sensor failure Replace mechanism flag stuck high during re-synchronization
Plunger motor not moving Check connection
60-2 Plunger motor position
Position sensor failure Replace mechanism signal is continuous low during re-synchronization
Enable circuit failed Check connection
Plunger motor not moving
61-1 Input/output motor
Position sensor failure Replace mechanism position flag is continuous high during re-synchronization
Input/output motor
not moving
61-2 Input/output motor
Position sensor failure Replace mechanism position signal is continuous low during re-synchronization
Enable circuit failure Check connection
Input/output motor
not moving
62-1 Primary/secondary
Position sensor failure Replace mechanism motor position flag is continuous high during re-synchronization
Primary/secondary
motor not moving
62-2 Primary/secondary
Position sensor failure Replace mechanism motor position signal is continuous low during re-synchronization
Enable circuit failure Check connection
Primary/secondary
motor not moving
63-1 Plunger motor phase loss Plunger motor does not
have enough torque
Mechanical assembly
failure
assembly
(Section 7.2.9.2)
at J7 on MCU PWA If condition recurs,
contact Hospira
assembly
(Section 7.2.9.2)
at J7 on MCU PWA If condition recurs,
contact Hospira
assembly
(Section 7.2.9.2)
Check connection at J8 on MCU PWA
If condition recurs,
contact Hospira
assembly
(Section 7.2.9.2)
at J8 on MCU PWA If condition recurs,
contact Hospira
assembly
(Section 7.2.9.2)
Check connection at J9 on MCU PWA
If condition recurs,
contact Hospira
assembly
(Section 7.2.9.2)
at J9 on MCU PWA If condition recurs,
contact Hospira
Replace mechanism assembly
(Section 7.2.9.2)
430-00587-008 (Rev. 2/05) 6 - 8 Plum XL Series
Page 71
Table 6-2. Error Codes Requiring Technical Service
Error Code
Malfunction
Description
64-1 Input/output motor
phase loss
65-1 Primary/secondary
motor phase loss
71-1 Internal timers
out of tolerance
73-1 +2.5-VDC ADC
reference voltage out of tolerance
73-2 +5-VDC ADC reference
voltage out of tolerance
74-1 Air sensor self test
failure; signal seen when sensors disabled
74-4 Proximal air sensor
signal too high
74-5 Distal air sensor signal
too high
6.2 ALARM MESSAGES AND ERROR CODES
Possible Cause Corrective Action
Input/output motor does not have enough torque
Mechanical breakage
Replace mechanism assembly
(Section 7.2.9.2)
in mechanism Primary/secondary motor
does not have enough torque
Replace mechanism assembly
(Section 7.2.9.2)
Mechanical breakage in mechanism
Internal MCU PWA malfunction
+2.5-VDC reference to ADC missing or bad
Replace MCU PWA
(Section 7.2.9.1)
Check fuse F3 on power supply PWA; replace fuse, if defective
(Section 7.2.8.1)
If condition recurs,
contact Hospira
+3.75-VDC reference to ADC missing or bad
Check fuse F3 on power supply PWA; replace fuse, if defective
(Section 7.2.8.1)
If condition recurs,
contact Hospira
ADC failure Replace MCU PWA
(Section 7.2.9.1)
+2.5-VDC reference to ADC missing or bad
Check fuse F3 on power supply PWA; replace fuse, if defective
(Section 7.2.8.1)
If condition recurs,
contact Hospira
+3.75-VDC reference to ADC missing or bad
Check fuse F3 on power supply PWA; replace fuse, if defective
(Section 7.2.8.1)
If condition recurs,
contact Hospira
ADC converter failure Replace MCU PWA
(Section 7.2.9.1)
Air sensor or circuitry failure Replace mechanism
assembly
(Section 7.2.9.2)
Air sensor or circuitry failure Replace mechanism
assembly
(Section 7.2.9.2)
Air sensor or circuitry failure Replace mechanism
assembly
(Section 7.2.9.2)
Technical Service Manual 6 - 9 430-00587-008 (Rev. 2/05)
Page 72
SECTION 6 TROUBLESHOOTING
Table 6-2. Error Codes Requiring Technical Service
Error Code
Malfunction
Description
81-1 Power supply PWA
signals HKDC and DHKDC do not match
81-2 Power supply PWA
signal HKDC out of tolerance
81-3 Power supply PWA
signal VMOT out of tolerance when AC power is applied
81-4 Motor voltage drops
too much when motor is energized
90-1 Calibration data in
EEPROM checksum failure
94-1 Control knob signal
seen when disabled
94-2 Illegal control knob
signal seen
94-4 Reed switch does not
match control knob signal
95-1 Primary valve pin
not moving
95-2 Secondary valve pin
not moving
96-1 UART test failure
during operation
99-1
through
99-6
Failure of one of the internal software self-tests
Possible Cause Corrective Action
Power supply PWA failure Replace power supply
PWA
(Section 7.2.8.2)
Failure in conditioning
circuit on MCU PWA
Replace MCU PWA
(Section 7.2.9.1)
Power supply PWA failure Replace power supply
PWA
(Section 7.2.8.2)
Failure of conditioning
circuit on MCU PWA
Replace MCU PWA
(Section 7.2.9.1)
Power supply PWA failure Replace power supply
PWA
(Section 7.2.8.2)
Power supply PWA failure Replace power supply
Motor drawing excessive
current
PWA
(Section 7.2.8.2)
If condition recurs,
contact Hospira
EEPROM internal failure Contact Hospira EEPROM decode circuitry
failure Control knob circuitry
failure Control knob circuitry
failure Control knob circuitry
failure
Replace display PWA
(Section 7.2.7.1)
Replace display PWA
(Section 7.2.7.1)
Replace display PWA
(Section 7.2.7.1)
Reed switch failure Pin detect circuitry failure Replace mechanism Valve pin not present
assembly
(Section 7.2.9.2)
Valve pin not moving Pin detect circuitry failure Replace mechanism Valve pin not present
assembly
(Section 7.2.9.2)
Valve pin not moving UART failure Replace MCU PWA
(Section 7.2.9.1)
MCU internal failure Replace MCU PWA
Section 7.2.9.1)
(
430-00587-008 (Rev. 2/05) 6 - 10 Plum 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 Setting Service Mode Information
SET RATE Alarm history SET VTBI Software revision number RUN Run 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 Manual 6 - 11 430-00587-008 (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 Name Purpose
Communication Selection Soft ID To enter the soft ID of the infusion system 2
Channel Label To enter the channel label of the infusion system 3
To select the communication with the host computer
Index
1
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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
Selection AC Operation Battery Operation
0 Power up communication circuitry Power down communication circuitry 1 Power up communication circuitry Power 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 Manual 6 - 13 430-00587-008 (Rev. 2/05)
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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 Failures Possible Causes Corrective 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 installed Reprime and re-insert cassette Defective MCU PWA Replace MCU PWA Defective display PWA
or ribbon cable Defective control knob Replace control knob Cassette door open Close cassette door Cassette not properly seated Reseat cassette Defective sensor PWA Replace mechanism assembly Defective mechanism assembly Replace 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 PWA Replace MCU PWA Defective power supply PWA Replace power supply PWA Defective fuse Replace fuse Defective AC (mains) cordset Replace AC (mains) cordset Defective display PWA
or ribbon cable Defective power supply PWA Replace power supply PWA Cassette not properly seated Reseat cassette Defective cassette Replace cassette Defective or dirty valve pins Clean valve pins
Closed proximal clamp Open clamp Cassette not properly primed Reprime cassette Defective cassette Replace cassette Dirty sensor pin Clean sensor pin Defective sensor PWA Replace mechanism assembly Cassette not properly primed Reprime cassette Defective cassette Replace cassette Dirty sensor pin Clean sensor pin Defective sensor PWA Replace mechanism assembly
Replace display PWA or ribbon cable
Replace MCU PWA or ribbon cable
Replace display PWA or ribbon cable
Clean buzzer
(see Section 5.1.4)
Replace display PWA or ribbon cable
Replace mechanism assembly
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6.3 TROUBLESHOOTING PROCEDURES
Table 6-6. PVT Troubleshooting
Test Failures Possible Causes Corrective Actions
Delivery accuracy test
Section 5.2.14
Empty container/ air-in-line alarm test
Section 5.2.15
Set not properly primed Reprime set Damaged or faulty set Prime using new set Defective mechanism assembly Replace mechanism assembly Defective special cassette Replace special cassette Dirty bubble sensors Clean bubble sensors Defective bubble sensor PWA Replace mechanism assembly Defective sensor PWA Replace mechanism assembly
Electrical safety test
Section 5.2.16
Insufficient ground connection Attach lead to T point screw
on rear of infusion system Defective AC (mains) cordset Replace AC (mains) cordset Defective power supply PWA Replace power supply PWA
Battery charger current test (optional)
Section 5.4.1
DataPort connection/ ground continuity test (optional)
Section 5.5
Blown fuse Replace fuse Defective AC (mains) cordset Replace AC (mains) cordset Defective power supply PWA Replace 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
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SECTION 6 TROUBLESHOOTING
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430-00587-008 (Rev. 2/05) 6 - 16 Plum XL Series
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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.
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SECTION 7 REPLACEABLE PARTS AND REPAIRS
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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
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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.
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Technical Service Manual 7 - 5 430-00587-008 (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.
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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.
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430-00587-008 (Rev. 2/05) 7 - 8 Plum 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.
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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
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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.
The replacement parts for this procedure are:
PWA, Display Assembly, Cable, MCU/Display Bumper, XL MCU Screw, 4-24 x 3/8, B/Point, Phillips
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.
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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.
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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.
The replacement parts for this procedure are:
Retainer, Snap, Knob Knob, Control Detent, Knob Washer, Knob Gasket, Knob Ring, Detent Shim Magnet
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.
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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
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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.
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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)
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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 Manual 7 - 17 430-00587-008 (Rev. 2/05)
Page 96
SECTION 7 REPLACEABLE PARTS AND REPAIRS
REAR ENCLOSURE
ASSEMBLY
6-32 x 5/16 HEX HEAD SCREW (2)
J18
J17
J16
POWER
SUPPLY
PWA
VELCRO
STRAP
AC POWER
CORDSET
04K01036
Figure 7-7. Power Supply PWA
Table 7-1. Wire Color Coding
Voltage Wire Color Signal Connects To
Black Hot (line) J16 White Neutral J17 Green Ground Rear panel Brown Hot (line) J16 Blue Neutral J17 Yellow/green Earth J18
430-00587-008 (Rev. 2/05) 7 - 18 Plum XL Series
Page 97
7.2 REPLACEMENT PROCEDURES
7.2.8.3
VELCRO RETAINER STRAP REPLACEMENT
No tools are required for this procedure.
The replacement part for this procedure is:
Strap, Velcro, 1.75 in x 10 in, Black
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 Manual 7 - 19 430-00587-008 (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 - 20 Plum 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 Manual 7 - 21 430-00587-008 (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 - 22 Plum XL Series
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