Welch Allyn Propaq Encore User manual

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Propaq® Encore Vital Signs Monitor

Service Manual

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ii Welch Allyn Propaq Encore Vital Signs Monitor

Welch Allyn assumes no responsibility for any injury to anyone, or for any illegal or improper use of the product, that may result from failure to use this product in accordance with the instructions, cautions, warnings, or statement of intended use published in this manual.

Welch Allyn of Welch Allyn. ParamSet

SET a Masimo SpO

, Propaq®, Acuity®, FlexNet®, Smartcuf®, and Flexible Monitoring® are registered trademarks

™

is a trademark of Welch Allyn.

, LNOP®, and Masimo® are registered trademarks of Masimo Corporation. Possession or purchase of

-equipped monitor does not convey any express or implied license to use the device with

unauthorized sensors or cables which would, alone or in combination with this device, fall within the scope of one or more of the patents relating to this device.

Nellcor

and Oximax® are registered trademarks of Nellcor Puritan Bennett.

Software in this product is Copyright 2006 Welch Allyn or its vendors. All rights are reserved. The software is protected by United States of America copyright laws and international treaty provisions applicable worldwide. Under such laws, the licensee is entitled to use the copy of the software incorporated with this instrument as intended in the operation of the product in which it is embedded. The software may not be copied, decompiled, reverse-engineered, disassembled or otherwise reduced to human-perceivable form. This is not a sale of the software or any copy of the software; all right, title and ownership of the software remain with Welch Allyn or its vendors.

For information about any Welch Allyn product, call the nearest Welch Allyn representative:

USA 1800 535 6663

1315 685 4560

Canada 1800 561 8797 China 86 216 327 9631

European Call Center 353 46 906 7790 France 3315 569 5849

Germany 49 747 792 7186 Japan 8133 219 0071

Latin America 1305 669 9003 Netherlands 3115 750 5000

Singapore 656 419 8100 South Africa 2711 777 7555

United Kingdom 44 133 236 3812

Australia 6129 638 3000

800 074 793

Reorder Part Number 810-1084-XX (CD) Reorder Part Number 810-1316-XX (Printed)

Manual Part Number 810-0696-03 Rev A, 04/2006

Welch Allyn 8500 SW Creekside Place Beaverton, Oregon 97008-7107

www.monitoring.welchallyn.com

Printed in USA

0123

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1 - Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

iii

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Purpose and Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Other Applicable Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unpacking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Technical Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Recommended Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Identifying Propaq Encore Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Self Test and Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 - Functional Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Functional Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Equipment Needed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Recharger Supply Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Display Voltage Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Main Power Supply Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Calibrating Realtime ECG Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Non-Invasive Blood Pressure Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

EMI Null Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Invasive Blood Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

MSP Board (MCO2) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Screen Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Non-Recoverable Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Battery Capacity Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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iv Contents Welch Allyn Propaq CS Vital Signs Monitor

6 - Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Propaq Encore Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Propaq Encore Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Field Replaceable Units in the Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Replacing the Power Input Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Replacing the Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Opening the Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Closing the Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Replacing the Analog Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Replacing the Digital Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Replacing the EL Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Removing the Front Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Replacing the Recharger Board Fuse (F2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Replacing Air Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Replacing Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Replacing PROMs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Cuff Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Replacing the Recharger Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Replacing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Replacing the Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Replacing the Expansion Module Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Replacing the Expansion Module Button Board and Buttons . . . . . . . . . . . . . . . 82

Replacing the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Opening the SpO2 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Replacing the SpO2 Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Replacing the MSP/SpO2 Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Replacing the Sidestream CO2 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Replacing Expansion Module Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7 - Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Cabling Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Expansion Module and Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Pulse Oximetry (SpO2) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Capnography (CO2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

8 - Field Replaceable Units (FRUs) . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

A - Manufacturable Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 123

B - Dynatech/Nevada Patient Simulator Modification . . . . . . . . . . . . 125

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Warnings

Safety Summary

This Safety Summary should be read by all Propaq CS monitor users. Specific warnings and cautions are placed throughout the documentation where they apply.

Caution: Federal (U.S.A.) law restricts this device to sale, distribution, or use by or on the order of a licensed medical practitioner.

WARNING Place the Propaq monitor and accessories in locations where they cannot harm the patient if they fall from their shelf or mount. Lift the monitor only by its handle; do not lift it by any attached cables.

WARNING Do not connect more than one patient to a monitor. Do not connect more than one monitor to a patient.

WARNING Do not use the Propaq Encore in an MRI suite or a hyperbaric chamber.

WARNING Do not autoclave the Propaq Encore. Autoclave accessories only if the manufacturer's instructions clearly approve it. Many accessories can be severely damaged by autoclaving.

WARNING Inspect the power adapter cord periodically for fraying or other damage, and replace the adapter as needed. Do not operate the apparatus from mains power with a damaged power adapter cord or plug.

WARNING Make frequent electrical and visual checks on cables and electrode wires.

WARNING Safe interconnection between the Propaq monitor and other devices must comply with applicable medical systems safety standards such as IEC 60601-1-1. Within certain governmental jurisdictions, all interconnected accessory equipment must be labeled by an approved testing laboratory. After interconnection with accessory equipment, risk (leakage) current and grounding requirements must be maintained.

WARNING As with all medical equipment, carefully route the patient cabling to reduce the possibility of patient entanglement or strangulation.

WARNING Avoid electrosurgery burns at monitoring sites by ensuring proper connection of the electrosurgery return circuit so that the return paths cannot be made through monitoring electrodes and probes.

WARNING During defibrillation, keep the discharge paddles away from ECG and other electrodes, as well as other conductive parts in contact with the patient. Avoid contact with any accessories connected to the Propaq’s left side panel.

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2 Safety Summary Welch Allyn Propaq Encore Vital Signs Monitor

WARNING To ensure patient safety, the conductive parts of the ECG electrodes (including associated connectors) and other patient-applied parts should not contact other conductive parts, including earth ground, at any time.

WARNING Do not operate this product in the presence of flammable anesthetics or other flammable substance in combination with air, oxygenenriched environments, or nitrous oxide; explosion can result.

WARNING The pulse oximetry channel should NOT be used as an apnea monitor.

WARNING This monitor is to be operated by qualified personnel only. The operator of this monitor should read this entire manual, the monitor Reference Guide or Directions For Use, and all accessory Directions For Use before operating the monitor.

WARNING This monitor should only be repaired by qualified service personnel. The operator should not attempt to open the monitor case or perform any maintenance on the monitor except for procedures explicitly described in this manual that can be performed by operators such as inspection and cleaning.

WARNING When using a power adapter with this monitor, be sure to connect the power adapter to a three-wire, grounded, hospital-grade receptacle. Do not under any circumstances attempt to remove the grounding conductor from the power plug of the power adapter. Do not plug the power adapter into an extension cord. If there is any doubt about the integrity of the protective earth ground of the receptacle for the power adapter, do not plug in the power adapter; operate the monitor only on battery power. Contact your biomedical engineering department for assistance in identifying the proper power receptacle and making appropriate power connections.

Note

WARNING To ensure conformance to risk (leakage) current requirements when

operating from an ac mains power source, use only a Welch Allyn’ 503-0054 series power adapter.

WARNING To ensure patient safety, use only accessories recommended or supplied by Welch Allyn. For a list of those accessories, see the Welch Allyn Products and Accessories book that accompanied this manual (PN 810-0409-XX). Accessories must be used according to your hospital’s standards and the manufacturer’s recommendations. Always refer to the manufacturer’s directions for use.

WARNING A product that has been dropped or severely abused should be checked by qualified service personnel to verify proper operation and acceptable risk (leakage) current values.

WARNING If the monitor detects an unrecoverable problem, an error message window appears containing an error number and a short message. Report such errors to Welch Allyn.

WARNING The Propaq Encore should be serviced only by a Welch Allyn service technician while under warranty.

Within certain governmental jurisdictions, all interconnected accessory equipment must be labeled by an approved testing laboratory. After interconnection with accessory equipment, risk (leakage) current and grounding requirements must be maintained.

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Service Manual Safety Summary 3

Definitions

Note Identifies information that may be important to the reader.

Caution Identifies conditions or practices that could result in damage to

equipment or other property.

WARNING Identifies conditions or practices that could result in personal injury.

Symbols

The following symbols appear in the monitor documentation and on monitor labels. These internationally recognized symbols are defined by the International Electrotechnical Commission, IEC 878 and IEC 417A.

Off (Standby) Two-way communication port

On Input port to monitor

For continued fire protection, use only the specified fuse.

Direct current Alternating current

Caution: Refer to Reference Guide and accompanying documentation.

Battery charging when green indicator illuminated.

All patient connections are Type CF, isolated for direct cardiac application, and protected against defibrillation.

All patient connections are Type BF, and protected against defibrillation.

Protected during defibrillation Stacking limit by number

This way up Temperature limits

Fragile Humidity limit

IPX1

Signal output port from monitor

Enclosure Protection Drip proof: Classification IPX1 per IEC Publication 529.

Temperature sensor input

Transformer meets requirements of a shortcircuit-proof safety-isolating power transformer.

For indoor use only (on power adapter only).

Keep away from rain Altitude limit

All patient connections are Type B The CE mark signifies the device has met all

essential requirements of European Medical Device Directive 93/42/EEC for a Class 1

product.

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4 Safety Summary Welch Allyn Propaq Encore Vital Signs Monitor

The CE mark and notified body registration number signify Propaq CS Series monitors

0123

have met all essential requirements of European medical device directives 93/42/ EEC.

The Canadian Standards Association has

NRTL/C

Evaluated to CSA 601-1 and UL2601-1

evaluated this device according to CSA 6011 and Underwriters Laboratory Standard UL

2601-1.

NIBP cuff sizes: Thigh Large adult Adult Small adult Child Infant

a. This symbol is on the Universal Power Adapter.

Single-use only (not reusable).

This device has been tested and certified by the Canadian Standards Association International to comply with applicable U.S. and Canadian medical safety standards.

Apply the NIBP cuff as shown.

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Overview

Purpose and Scope

The Propaq Encore Service Manual is intended as a reference for monitor maintenance and repair to the field replaceable unit (FRU) level (“Field Replaceable Units (FRUs)” on page 117). This manual provides the technically qualified service person with troubleshooting information, repair procedures, and calibration and performance verification instructions. A technical overview of the monitor subsystems is provided as an introduction to the device’s circuitry and pneumatics.

Note

This manual is intended for the technically qualified service person. Service training classes on Welch Allyn’ products are available. Contact Welch Allyn Technical Service for information.

Configurations vary nationally. Some early versions of the Propaq Encore do not include impedance pneumagraphy (RESP) in some countries.

Unpacking Procedure

Use the following guidelines when unpacking the Encore monitor from its shipping carton.

1. Before opening the Encore monitor shipping carton, check it for damage.

2. If damage is apparent, stop unpacking the carton and contact the shipping company for further instructions. If the carton is intact, unpack the Encore monitor.

3. With the Encore monitor out of its carton, check to see that all the items listed on the packing slip (provided with shipment) are in the shipping carton.

4. If an item is missing, first recheck the carton, then check with your receiving department. If necessary, contact Welch Allyn at the address and phone number shown below.

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6 Overview Welch Allyn Propaq Encore Vital Signs Monitor

Note

Save the shipping carton and packing material for repacking the Encore monitor in case it needs to be sent to a repair center or back to Welch Allyn for service.

Warranty Service

DO NOT ATTEMPT TO REPAIR the Encore monitor yourself during the warranty period. For service and repair, contact Welch Allyn as described below.

Technical Support Services

Welch Allyn offers a wide range of technical support services including:

• 24-hour telephone support

• loaner equipment

• service contracts

• field replaceable units (FRUs)

• factory repair

For any of these services, contact Welch Allyn Technical Support at the following numbers:

USA 1-800-535-6663 France (+33) 1-60-09-33-66 Australia (+61) 2-9638-3000

Latin America (+1) 305-669-9591 Germany (+49) 7477-927-173 Singapore (+65) 6291-0882

European Call Center (+353) 469-067-790 Canada 1-800-561-8797 Japan (+81) 3-5212-7391

United Kingdom 0-207-365-6780 South Africa (+27) 11-777-7509 China (+86) 21-6327-9631

Worldwide Internet Access

World Wide Web (WWW) URL: http://www.monitoring.welchallyn.com/service World Wide E-mail: solutions@monitoring.welchallyn.com

Recommended Service Intervals

At the intervals listed below, check the Encore monitor for normal operation.

Interval/Condition Perform Located in this manual

Every 6 months to 2 years (according to hospital protocols).

If battery does not retain a charge. Check battery pack capacity. “Troubleshooting”

Monitor is dropped or suspected of damage or rough handling.

Suspected malfunction with all or part of monitoring parameters.

Complete risk (leakage) current Safety Check followed by a Functional Verification.

Complete Safety Check followed by Functional Verification.

Functional Verification of suspected parameter(s). “Functional Verification”

“Functional Verification”

Monitor does not pass Functional Verification.

Calibration of monitoring parameter circuits, or repair, followed by Safety Check and Functional Verification.

“Functional Verification”

and “Calibration”

Page 11

Service Manual Overview 7

WARNING If the monitor is opened for repair or calibration, a dielectric strength test must be completed to ensure the integrity of the patient isolation barrier. The dielectric strength test procedure is provided in “Functional Verification” on page 11.

Identifying Propaq Encore Configurations

The following table identifies Propaq monitor configurations and how they are indicated. The model-option number and serial number are located on the back of the housing. The monitor indicators are located under the handle on the back.

Table 1. Monitor Configurations

Product Model Option Parameters

Propaq Encore Monitor 202-EL ECG, NIBP, Two Temps, Resp, EL Display

204-EL ECG, NIBP, Two Temps, IBP, Resp, EL Display

206-EL ECG, NIBP, Two Temps, 2 IBP, Resp, EL Display

SpO2-Only Module 210 SpO2 and one of the following:

Nellcor MP-405 (Top level assembly 007-0059-XX) Nellcor MP-203 (Top level assembly 007-0020-XX) Nellcor MP-507 (Top level assembly 007-0109-XX) Masimo MS3 (Top level assembly 007-0060-XX)

Expansion Module (See next table.)

a. The Acuity option is available with all models.)

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8 Overview Welch Allyn Propaq Encore Vital Signs Monitor

Table 2. Expansion Module Option Configurations

Option Number

Printer Mainstream CO2Sidestream CO2SpO

Top Level Assembly Number

221 Yes No No N/A 007-0046-XX

222 No No No Nellcor MP-203 007-0050-XX

223 Yes No No Nellcor MP-203 007-0047-XX

223 Yes No No Nellcor MP-203 007-0051-XX

223 Yes No No Masimo MS3 007-0069-XX

223 Yes No No Nellcor MP-405 007-0086-XX

223 Yes No No Nellcor MP-507 007-0116-XX

224 No Yes No Nellcor MP-203 007-0049-XX

224 No Yes No Masimo MS3 007-0070-XX

224 No Yes No Nellcor MP-405 007-0085-XX

224 No Yes No Nellcor MP-507 007-0115-XX

225 Yes Yes No Nellcor MP-203 007-0048-XX

225 Yes Yes No Masimo MS3 007-0071-XX

225 Yes Yes No Nellcor MP-405 007-0084-XX

225 Yes Yes No Nellcor MP-507 007-0114-XX

226 No No Yes Nellcor MP-203 007-0045-XX

226 No No Yes Masimo MS3 007-0072-XX

226 No No Yes Nellcor MP-405 007-0083-XX

226 No No Yes Nellcor MP-507 007-0113-XX

227 Yes No Yes Nellcor MP-203 007-0043-XX

227 Yes No Yes Masimo MS3 007-0073-XX

227 Yes No Yes Nellcor MP-405 007-0082-XX

227 Yes No Yes Nellcor MP-507 007-0112-XX

228 No Yes Yes Nellcor MP-203 007-0052-XX

228 No Yes Yes Masimo MS3 007-0074-XX

228 No Yes Yes Nellcor MP-405 007-0081-XX

228 No Yes Yes Nellcor MP-507 007-0111-XX

229 Yes Yes Yes Nellcor MP-203 007-0044-XX

229 Yes Yes Yes Masimo MS3 007-0075-XX

229 Yes Yes Yes Nellcor MP-405 007-0080-XX

229 Yes Yes Yes Nellcor MP-507 007-0110-XX

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Service Manual Overview 9

Self Test and Service Menus

The Encore monitor includes built-in self-tests that verify the integrity of its hardware and software each time you turn it on. If the monitor turns on and displays the Main Menu, all self-tests were passed. If a self-test results in a failure, a message and error code are displayed indicating the failure mode. Refer to “Troubleshooting” on page 43 and contact Welch Allyn Technical Support for help.

The Encore monitor contains software routines that make the Functional Verification and Calibration procedures quicker and easier. You access these routines through the Service Menus as indicated in each of the procedures.

The figure below shows the hierarchy of the Service Menus once you enter the top level Service Menu.

The procedures in this manual indicate which buttons to push by separating each button menu name with the (>) character. For example, to access the Service Menu, the procedures would indicate for you to press SETUP > MORE > MORE > SERVICE > YES, which means you press the SETUP button, then the MORE button, then the MORE button, then the SERVICE button, and finally the YES button.

Note

service menus

The figure illustrates all Service Menu functions. Some of these functions are not available if you do not have the appropriate option.

NIBP TEST IBP TEST SpO2 TST CO2 TEST MORE

PUMP TEST AUTO PMP NIBP CAL ZERO PREV MENU

TEMP TEST PIXL TEST NET TST MORE

CYCLE CHECKER 1 CHECKER 2 BORDER PREV MENU

LOOP TEST OUT TEST PREV MENU

MAIN CAL MAIN TEST SIDE CAL SIDE TEST

PREV MENU

SETTINGS KEY TEST SYSTEM

(Software v. 2.5X only)

KEY 0 KEY 1 KEY 2 KEY 3

NEXT CHANGE ALL ALARM

PREV MENU

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10 Overview Welch Allyn Propaq Encore Vital Signs Monitor

Page 15

Functional Verification

Introduction

The functional verification procedures ensure proper operation of the Encore monitor and its options. These procedures should be performed following module-level repairs, calibration, or whenever there is a question about the accuracy or safety of the patient functions.

Use the calibration procedures (“Calibration” on page 33) to return the monitor to operation within its performance specifications. If the monitor does not pass the functional verification, or when it is time to do a routine calibration, see “Calibration” on page 33.

The Encore’s service menu facilitates the functional verification. It has several features for testing and verifying the NIBP (cuff) channel, display, invasive pressure channel, and printer. Refer to “Over v iew ” on page 5 for information about the Service Menu.

WARNING Whenever the monitor is opened for calibration or repair, a risk (leakage) current safety check as well as a dielectric strength integrity (hi-pot) test must be performed as described in this section.

Self Tests

Many functions, such as alarms, waveform and scale sizing, and printer control, are software operations. During the monitor’s power-up self-test, the integrity of all programming is checked first. If software testing is successful, hardware tests are initiated. If all testing is successful, the monitor is ready for use. (See “Troubleshooting” on page 43 for information on error messages.)

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12 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

Required Equipment

You will need the following equipment to verify that all functions of the Encore operate correctly. All test equipment must be calibrated to function within parameters specified by the manufacturer, and must be traceable to a national calibration standard.

Some equipment can be manufactured. See “Manufacturable Test Equipment” on page 123 for information on manufacturable test equipment.

Table 3. Required Equipment

Description

Luer connector, male, for use with 1/8" I.D. tubing (Value Plastics, MTLL230-1)

Luer connector, female, for use with 1/8" I.D. tubing (Value Plastics, FTLL230-1)

Test water trap, Welch Allyn, 008-0370-00

1/8" inside diameter tubing

Flow meter, Cole Parmer E 32000-06, 200ml/min. or equivalent

0 to 300 mmHg calibrated digital pressure meter, with inflation squeeze bulb (Netech, Digamano, or equivalent)

50 MHz triggered sweep oscilloscope

Variable dc power supply, 0-28 V, 3A with voltage and current metering

Dynatech/Nevada 213A, 214A, 215A, or 217A with IBP, Temperature, and EGG Cable/Leads

Adult cuff (provided with monitor); Neonatal cuff #3; 3 cm diameter solid cylinder; solid cylindrical object about the size of an adult’s arm

Welch Allyn cuff calibration kit, Welch Allyn PN 008-0012-XX

Power supply adapter cable, Welch Allyn PN 008-0290-00

Physio Control LifePak 5 or LifePak 6s with appropriate Welch Allyn Defib Sync adapter to use as Defib Sync Marker pulse source

Propaq ac power adapter (provided with the Encore)

Safety analyzer, Dynatech/Nevada, 431F-1D or equivalent

Rod-L Model M100AVS5 high-voltage potential (hi-pot) tester, or equivalent

Static-free work area

Simulator, Fluke (Biotek) Index 2 XL/XLFE

SpO

Test gas source: dry 4% to 10% CO concentration must be certified to ±0.01. (Convert percentage to partial pressure (mmHg) as instructed in “Partial

pressure of test gas source” on page 27.)

Two rubber test tube stoppers, with 1/8" to 1/4" holes drilled through (for CO2 tests)

a. Of the gas tolerance available, usually described as ±0.03% absolute, the container must contain at least 2,000 psi grams of gas, to

be within ±0.01% of the certified percentage of gas stated on the tag supplied by the vendor. The acutal percentage of gas in the container may vary from lot to lot.

, balance air (with flow meter). Gas may be between 4% and 10%, but exact CO2

Safety Tests

The following two safety tests, a risk (leakage) current safety check and a dielectric strength integrity (hi-pot) test, must be performed whenever the Encore has been opened for calibration or repair.

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Service Manual Functional Verification 13

Note

A hi-pot test is only required if the monitor has been opened.

Risk (Leakage) Current Test

A risk (leakage) current test must be performed to verify that the patient remains electrically isolated from the power circuits of the Encore.

Check leakage currents using a Dynatech/Nevada 431F-1D safety analyzer or its equivalent. The source current should not exceed 10μA rms. The sink current, measured between the isolated patient connections (ECG) and the dc power input connector of the monitor, should not exceed 20μA rms. See the analyzer's operator's manual for the proper safety check procedure.

Note

Table 4. Electrical Connections for Patient Risk (Leakage) Current Safety Tests

Safety Test Power Adapter Monitor

Source current Plugged into analyzer

Sink current Not used Connected to ground

Because of the all-insulated construction of the monitor, an Enclosure Leakage Current Test to ground is not necessary.

outlet

dc Input

Connected to power adapter

connector on analyzer

Monitor

Cable

RA LA

Safety

Analyzer

RA LA

Dielectric Strength (Hi-Pot) Test

Because of the close spacings of the monitor's internal components and the critical positioning of the insulation sheet within the monitor, Welch Allyn recommends that a dielectric strength test be performed following any procedure in which the monitor is opened.

WARNING The Hi-Pot test is extremely hazardous. Only qualified service personnel should perform this test. Conduct the test only on an insulated table top, away from other people and equipment.

Use a Rod-L Model M100AVS5 high-voltage potential tester, or equivalent. Refer to the Rod-L instruction manual for operating information and safety recommendations.

1. Set the high voltage potential of the tester as specified in the table below.

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14 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

Table 5. Summary of Connection Points and High-Voltage Test Potentials

Tester's high-voltage terminal connection

All ECG leads on patient cable connected together

2. Connect the high-voltage output lead of the tester to all ECG leads, using a dedicated patient cable reserved for use only in such tests.

3. Connect the tester's chassis-connected return lead to the monitor's dc input connector, using a suitable plug.

4. Apply the test voltage for one second. The tester must not indicate dielectric breakdown.

WARNING If any dielectric breakdown occurs, do not use the monitor. All internal sheet insulation barriers must be properly installed. Check the monitor to determine the cause of dielectric breakdown; then repair the monitor or return the monitor to Welch Allyn for repair.

Functional Verification

The functional verification must be done only when the monitor is fully assembled. If the monitor has been stored for longer than one month without the monitor connected to the ac adapter (for recharging), the battery voltage must be checked. The battery must be replaced if it cannot hold a charge. Refer to “Battery Capacity Check” on page 45.

Tester's grounded return connection

DC input connector; all pins connected together

High-voltage test parameters

Output: 4000 V ac rms Current Limit: 2.5mA Ramp-up: 8 seconds Dwell: 1 second

Note

Power System

The following steps check the integrity of the Encore’s power system.

1. Turn the ac power adapter’s power switch off.

2. Plug the ac power adapter into an ac mains receptacle and connect it to the Encore’s

3. Check that the green LED charging indicator on the monitor’s right side panel is off.

Some configurations of the Encore monitor do not include impedance pneumography (RESP) and other neonatal monitoring parameters. In these versions, RESP does not appear in menus or on the screen displays. You can ignore RESP and other terms relating to neonatal monitoring when indicated in the following instructions.

If you plan to use a Dynatech/Nevada model 213A, 215A, or 217A Patient Simulator to simultaneously simulate ECG and invasive blood pressure, see

“Dynatech/Nevada Patient Simulator Modification” on page 125 for important

information.

Before starting the verification procedures, charge the battery for at least 8 hours with the monitor turned off. (Charge for 12 hours if a Printer or SpO

module is

attached.)

right side panel dc power connector.

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Service Manual Functional Verification 15

4. Turn on the power adapter’s power switch.

5. Check that the green LED on the power adapter turns on and that the green LED charging indicator on the monitor’s right side panel turns on.

6. Disconnect the power adapter from the monitor. Check that the monitor’s green LED charging indicator on the right side panel turns off.

Caution In the next steps, carefully check for the proper polarity of the connection between the power supply and the monitor. If voltage is applied with the wrong polarity, it will open the right side panel fuse (F1). Refer to the figure below to verify proper polarity.

7. Set the dc power supply meter to Volts and turn the power switch on; set it for

15.0V ± 0.1V.

8. Turn off the dc power supply.

9. Using the Welch Allyn dc power supply adapter cable, refer to the figure below for polarity and connect the dc power supply to the monitor's dc input connector on the right side panel.

RIBBED (+) SMOOTH (-)

0696-02

10. Turn on the dc power supply.

11. Check that the green LED indicator lights up.

Note

Initial charge current for a low battery is higher than for a charged battery. As the battery charges, the current will decrease. The current draw may slowly drop the longer the dc supply is connected to the monitor.

12. Switch the dc power supply meter to current and check that the current draw from the supply is less than 1.8 A.

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16 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

13. Vary the power supply from 12 V to 28 V and verify that the charging LED stays on.

14. Turn off the power supply.

15. Disconnect the supply from the monitor.

System Tests

The following procedures check that the buttons operate properly, that the display works correctly, and that the date is correctly displayed.

1. Turn on the monitor.

2. Verify that no error messages appear and the monitor correctly powers up.

3. Press SETUP > MORE > MORE > SERVICE > YES > MORE > PIXL TST to test the display.

4. Press CYCLE three times, each time verifying that no pixels are missing.

5. Press MAIN MENU twice.

6. Press SETUP > WAVE SEL > INSERV to access the inservice features. This generates simulated waveforms.

7. If dual stream monitor, look for CO2 Sensor Change - Switching to Mainstream, YES or NO.

8. IBP screen indicates need to zero P1 or P2.

9. Press MAIN MENU.

10. Using the appropriate table below as a guide, press the indicated buttons in sequence and verify that the monitor responds as indicated and that the buttons do not stick.

Sequence for Software Versions 2.5

Press Result

FREEZE/UNFREEZE Freezes the waveforms

FREEZE/UNFREEZE Unfreezes the waveforms

SETUP Changes the menu

ALARMS Changes the display to ALARM STATUS

4 SUSPND (on menu) 4 SUSPND changes to RESUME

ALARM SILENCE/RESUME (button) Changes RESUME to 4 SUSPND

LIMITS Changes display to HR Limits

NEXT Moves cursor block: Next block within selected parameter limits, NEXT

MAIN MENU (button) Returns to the main menu

PAGE moves to next parameter

NIBP START/STOP (button) Starts the NIBP pump

NIBP START/STOP (button) Stops the NIBP pump

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Service Manual Functional Verification 17

Sequence for All Other Software Versions

Press Result

FREEZE/UNFREEZE Freezes the waveforms

FREEZE/UNFREEZE Unfreezes the waveforms

SETUP Changes the menu

ALARMS Changes the display to ALARM STATUS

SUSPEND (on menu) SUSPEND changes to RESUME

ALARM SUSPEND/RESUME (button) Changes RESUME to SUSPEND

ALL ALRM Changes display: Turn All Off, Are You Sure, Y or N

LIMITS Changes display to HR Limits

NEXT Moves cursor block: Next block within selected parameter limits, NEXT

PAGE to next parameter

MAIN MENU (button) Returns to the main menu

NIBP START/STOP (button) Starts the NIBP pump

NIBP START/STOP (button) Stops the NIBP pump

1. Press ECG/RESP > MORE. Then press CHANGE to select the four HR/PR TONE levels. Verify that the tone volume changes and goes off when turned OFF. Set the volume to LOW.

2. Press MAIN MENU.

3. Software versions 2.5X: Press SETUP > MORE > MORE > SERVICE > YES > MORE > MORE > SETTINGS > ALL ALRM. Verify alarm status displays "TURNING OFF ALL AUDIBLE VITAL SIGNS ALARMS", "ARE YOU SURE?", YES or NO. Then press MAIN MENU.

4. All software versions: Press SETUP > MORE > MORE (> TIME/DAY for monitor software less than version 2.0) and check that the displayed time and date are correct.

If incorrect, press NEXT and UP or DOWN to select and change the time and date, and then set by pressing the ENTER button.

5. Turn off the monitor.

ECG/RESP Channel and Alarm Indicators

The following procedures verify the ECG channel and the alarm indicator drivers. The setup procedure below is used for both the visual and the electrical checks that follow.

Setup

1. Turn on the monitor and verify that it powers up correctly.

2. Put the monitor into FACTORY ADULT MODE.

Software version 2.XX: SETUP > MORE > CHANGE > SETUP > USE NOW > YES Software version 1.XX: SETUP > MORE > CHANGE > ADULT > YES > MORE >

PROGRAM > DEFAULT > YES

3. Press MAIN MENU.

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18 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

4. Set the patient simulator as follows:

• ECG Waveform: normal sinus rhythm

• ECG Rate: 80 beats per minute (bpm)

• ECG Size: 1 mV amplitude

• Resp Lead: Lead I

• Resp Baseline Impedance: 1 KΩ

• Resp Rate: 40 breaths/minute (br/m)

• Resp Breath Amplitude: 1.0Ω

5. Set the monitor as follows:

• Respiration Lead: Lead I (ECG/RESP > MORE; select lead and change as

necessary)

• ECG Lead: Lead II (ECG/RESP > ECG LEAD)

• ECG Size: 1 mV (ECG/RESP > ECG SIZE)

• Resp Size: 8X (ECG/RESP > RESP SZE)

• Respiration ON (ECG/RESP > MORE; select and set RESP to ON)

• ECG Sweep: 25 mm/Sec (SETUP > MORE; select and change HR/PR sweep as

necessary)

•Alarms (software versions 2.5X): Set alarm limits to OFF for HR/PR and RR/BR

(SETUP > ALARMS > LIMITS > ON/OFF > NEXT > ON/OFF > NEXT PAGE > ON/ OFF > NEXT > ON/OFF. Press the MAIN MENU button. The ALARM(S) OFF light will turn on, indicating one or more alarm limits have been disabled.

•Alarms (all other software versions): All alarms OFF (SETUP > ALARMS > ALL

ALRM [software version 2.XX: press YES when prompted] until all alarms are off except for the Apnea alarm, which cannot be turned off. The ALARM(S) OFF light will turn on, indicating that one or more alarm limits have been disabled.

• Audible vital signs alarms (software versions 2.5X): OFF (SETUP > MORE >

MORE > SERVICE > YES > MORE > MORE > SETTINGS > ALL ALRM > YES. The ALARM light will turn on, indicating the patient alarms are suspended.

6. Connect the ECG channel to the patient simulator using all five ECG leads.

Part 1— Visual Check

1. Press MAIN MENU.

2. Press the FREEZE/UNFREEZE button to freeze the waveform.

3. Check that a normal sinus rhythm ECG waveform is displayed with a peak-to-peak amplitude of 10 ±1 mm. There should be a soft beep tone with each QRS event.

4. Check that the monitor’s displayed respiration peak-to-peak amplitude is 12.5 ±1 mm.

5. Press FREEZE/UNFREEZE to unfreeze the display.

6. Check that the monitor's heart rate display is 80 ± 4 bpm, and the respiration rate is 40 ± 2 bpm before proceeding to the next step.

7. Disconnect the LA ECG lead wire from the simulator.

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Service Manual Functional Verification 19

8. Check that an equipment alarm occurs. The EQUIPMENT ALERT / MULTIPLE message should accurately indicate the removed lead. The ALARM(S) OFF light will flash.

• Software version 2.5X: The ECG FAULT will flash in the upper left-hand corner of

the screen.

• All other software versions: The ECG FAULT and RESP FAULT will alternate in the

upper left-hand corner.

9. Press any button to acknowledge. Check that the ALARM(S) OFF light is on and no longer flashing.

10. Disconnect the LL ECG lead from the simulator.

11. Check that an equipment alert occurs. The ECG FAULT and RESP FAULT will alternate in the upper left-hand corner. The ALARM(S) OFF light will flash.

• Software version 2.5X: The EQUIPMENT ALERT - MULTIPLE message should be

displayed.

• All other software versions: The EQUIPMENT ALERT / ECG FAULT / MULTIPLE

LEAD FAIL message is displayed.

12. Press any button to acknowledge. Check that the ALARM(S) OFF light is on and no longer flashing.

13. Reconnect the LL ECG lead, and then LA ECG lead.

14. Check that the ALARM(S) OFF light is on. Software version 2.5X: Check that the ALARM light is on.

15. Check that the monitor's heart rate display is 80 ± 4 bpm, and the respiration rate is 40 ± 2 bpm before proceeding to the next step.

16. Software version 2.5X: Press RESUME to enable alert and alarm tones. All other software versions: Press SETUP > ALARMS > ALL ALRM to turn all alarms ON.

17. Press SETUP > ALARMS > STAT SET to automatically set heart and respiration rate alarm limits. Software version 2.XX: Select YES when prompted.

18. Check that the ALARM(S) OFF light is off.

19. Check that the ALARM light is off.

20. Set the patient simulator heart rate to 180 bpm or higher.

21. Check that an alarm violation occurs, causing the tone to sound and the ALARM light to flash.

22. Software version 2.5X: Press the 4 SUSPND button and verify that the tone turns off and the ALARM light is on and no longer flashing. Software version 2.XX: Press the ALARM SUSPEND/RESUME button and verify that the tone turns off and the ALARM light is on and no longer flashing.

23. Press MAIN MENU.

24. Set the patient simulator heart rate to 80 bpm.

25. Check that the ALARM light is ON.

26. Press SETUP > ALARMS > RESUME.

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20 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

27. Check that the ALARM light is OFF.

28. Press MAIN MENU.

Part 2— Electrical Check

Use the same setup for this check described in “Setup” on page 17.

1. Set the patient simulator to provide pacer signals.

2. If the pacer indicator is not on, press ECG/RESP > MORE and select and change the pacer setting.

3. Check that a dashed vertical line is displayed on the ECG waveform each time a pacer pulse occurs.

4. Set the oscilloscope to 0.2 second/division sweep and 0.5 Volt/division amplitude.

5. Insert a short piece of thin conductive wire into each of the ECG X1000 connector holes shown in the figure below or use real time ECG Out cable 008-0320-00.

ECG X1000

GND (scope gnd. clip)

ECG (scope probe)

0696-69

6. Connect the scope probe and the scope ground clip to the wires.

7. Check that the scope displays an ECG signal with an amplitude of 1 V ±100 mV baseline to peak of R-wave.

Note

Some amount of mains noise may also be present in the signal.

8. Move the wire and scope probe from the ECG pin of the ECG X1000 connector to the DEFIB SYNC connector pin shown in the figure below or use Defib Sunc Output cable, 008-0237-00. Leave the scope’s ground clip where it is.

DEFIB SYNC

SYNC OUT (scope probe)

0696-70

9. Change the vertical sensitivity of the scope to 1 Volt/division.

10. Check that the scope displays a 5 V p-p pulse with a 100 ±5 ms width.

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Service Manual Functional Verification 21

11. Disconnect the scope probe and ground clip and remove the wires from the connectors.

12. Using either a LifePak 5 or LifePak 6s and appropriate Welch Allyn adapter, set up the monitor and defibrillator according to instructions provided in the Defib Sync User’s Guide.

13. Check the monitor display for sync markers on the ECG waveform.

14. Disconnect the defibrillator from the monitor.

IBP

Note

15. Disconnect the ECG cable from the monitor. (Disconnecting an active channel

The following procedure verifies the operation of the invasive blood pressure channels. Some models of the Propaq Encore have no IBP channels; skip this procedure if your Encore does not support IBP. If your Encore has multiple IBP channels, repeat the verification procedure for each channel.

Note

If the patient simulator does not also provide an appropriate ECG signal, the heart rate value will be displayed as – – – and an alarm violation will occur.

initiates an equipment alarm; press any key to acknowledge the discontinuance of ECG monitoring.)

Caution Many blood pressure simulators are not intended to be used as calibration standards. Use only the blood pressure simulators specified in

“Required Equipment” on page 12.

If you are using the Dynatech/Nevada model 213A, 215A, or 217A patient simulator, do not simultaneously monitor ECG and invasive blood pressure (IBP) unless the modification to the simulator is performed as described in “Dynatech/

Nevada Patient Simulator Modification” on page 125. If you do not wish to modify

your simulator, use ECG and IBP independently.

1. Press SETUP > WAVESEL and check that the P1 and P2 waveforms are turned on.

2. Connect the IBP cable from the patient simulator to an IBP input jack on the left side panel of the Encore.

3. Set the simulator output pressure to 0 mmHg.

Note

4. Zero P1 by pressing ZERO P1.

5. Check that ZEROED is displayed.

6. Press RESCALE.

7. Check for a noise level of ≤3 mm on the IBP waveform.

8. After allowing a few seconds for settling, check that the mean pressure reading is 0

9. Set the pressure simulator to 200 mmHg.

If an alarm tone sounds, press the SUSPEND/RESUME button.

mmHg ±1 mmHg.

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22 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

10. After allowing a few seconds for settling, check that the mean pressure reading is 200 mmHg ±2 mmHg.

11. Remove the cable from the P1 input jack and verify that the message: P1 FAULT TRANSDUCER NOT DETECTED appears.

12. Press any button to acknowledge the discontinuance of IBP monitoring.

13. Press MAIN MENU.

NIBP

1. Connect the cuff, digital pressure meter, bulb, and the Encore together with the cuff calibration kit. Using T-connectors from the kit, connect the cuff, pressure meter, and bulb.

2. Connect this NIBP test setup to the pressure transducer at PT1 on the Analog board.

3. Wrap the adult cuff around the black tube volume or a cylindrical object about the size of an adult’s arm.

4. Press SETUP > MORE > MORE > SERVICE > YES > NIBP TEST > NIBP CAL.

Note

The NIBP CAL mode holds pressure for 10 minutes. If performing steps 4 through 9 takes longer than 10 minutes, press NIBP CAL again.

5. Close the valve on the bulb and inflate the cuff to 250 mmHg as shown on thepressure meter.

6. Check that the readings (PR1 and PR2) on the monitor's display are 250 ±3 mmHg (PR1) and 250 ±15 mmHg (PR2), as show in the figure below.

19:00:25

NIBP TEST BATTERY: 8.1 VOLTS

CNTS mmHg DAC VALVE

PR1: 578 249.4 130 0 PR2: 338 259 OSC: 1600 LEAK: 10 mmHg DIAG: 0 BLEED: mmHg/min PUMP: secs

PUMP TEST

AUTO PMP NIBP CAL ZERO PREV MENU

7. Manually reduce the pressure as indicated on the pressure meter to each of the levels shown in the following table, and check the displayed value of PR1 to be within the tolerance listed in the following table.

Pressure (mmHg) Tolerance

(mmHg)

270 ± 4

250

± 3

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Service Manual Functional Verification 23

Pressure (mmHg) Tolerance

(mmHg)

200 ± 2

100

8. Reduce the pressure to 0 mmHg and check that the displayed readings (PR1 and PR2) are 0 ± 2 mmHg.

9. Close the bulb valve.

10. Press CANCEL. (If there is no CANCEL button at this time, go to the next step.)

11. Disconnect the adult cuff from the test setup and connect the neonatal cuff #3 that is wrapped around a solid 3 cm diameter cylinder, the black PVC tube volume.

12. Press PUMP TEST.

13. Check that the pump inflates the cuff to approximately 280 mmHg.

14. After four minutes, check that the displayed leakage is less than 50 mmHg.

Note

15. Press MAIN MENU.

16. Disconnect the cuff and Cuff Calibration Kit.

If the leakage exceeds this specification, first check all exterior hoses and fittings before diagnosing an internal air leak problem.

± 2 ± 2 ± 2

Temperature

1. Plug a 37.0° C YSI 400 series (two conductor) calibrated temperature probe simulator into the T1 jack on the Encore’s left side panel.

2. Check that the T1 temperature is 37° ± 0.1° C.

3. Repeat Steps 1 and 2 for T2.

4. Plug a 37° C YSI 700 series (three conductor) temperature probe simulator into the T1 jack.

5. Check for 37° ± 0.1° C.

6. Repeat Steps 4 and 5 for T2.

7. Remove all connectors and turn the Encore off.

Functional Verification for Masimo SpO

This functional verification procedure helps to confirm the proper operation of the Masimo Pulse Oximetry option installed in the Propaq monitor. This procedure supports the requirements of routine preventive maintenance. No monitor disassembly is required to perform this procedure.

You will need the following equipment to perform this procedure.

• Masimo-compatible SpO

cable.

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24 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

• Compatible adult SpO2 sensor for finger.

• BIO-TEK Index 2 Series SpO

Simulator with optical finger for sensor connection

(or equivalent).

1. Turn on power to the SpO

2. Connect the SpO

3. Apply the SpO

cable to the monitor and the SpO2 sensor.

sensor to the SpO2 simulator optical finger.

simulator.

4. Set the simulator manufacturer type (“MAKE”) to Masimo.

5. Set the simulator output to SpO

saturation 94% and pulse rate 60 beats per minute

(with no motion artifact selected).

Confirm that the monitor displays SpO moving.

Confirm that the displayed saturation is 94% ±4 counts, and the displayed pulse rate is 60 ± 4 bpm.

6. Disconnect the sensor from the simulator and cable, and disconnect the SpO

Functional Verification for Nellcor SpO

This functional verification procedure helps to confirm the proper operation of the Nellcor Pulse Oximetry option installed in the Propaq monitor. This procedure supports the requirements of routine preventive maintenance. No monitor disassembly is required to perform this procedure.

You will need the following equipment to perform this procedure.

data and the pulse amplitude indicator is

cable.

• Nellcor-compatible adult SpO

• BIO-TEK Index 2 Series SpO

finger sensor

Simulator with optical finger for sensor connection

(or equivalent).

1. Turn on power to the SpO

2. Connect the SpO

sensor to the monitor and apply to the SpO2 simulator optical

simulator.

finger.

3. Set the simulator manufacturer type (“MAKE”) to Nellcor.

4. Set the simulator output to SpO

saturation 94% and pulse rate 60 beats per minute

(with no motion artifact selected).

Confirm that the monitor displays SpO

data and the pulse amplitude indicator is

moving.

Confirm that the displayed saturation is 94% ±4 counts, and the displayed pulse rate is 0 ± 4 bpm.

5. Disconnect the sensor from the simulator.

6. Check that an equipment alarm occurs.

7. Press any button to acknowledge the discontinuance of SpO

monitoring.

8. Press MAIN MENU.

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Service Manual Functional Verification 25

Sensor Compatibility

Some sensors are not compatible with the particular Nellcor processing board installed in the Propaq. To determine which pulse oximetry optional processing board is installed in the Propaq, find the option number on the back label of the Propaq, then refer to the table

“Expansion Module Option Configurations” on page 8. The following table shows how to

identify compatible sensors for each Nellcor option:

Table 6. Sensor Compatibility

Sensor Description Connector Compatible With

Pins Notches Color MP-203 MP-405 MP-507

Single-ended 7 0 Varies Yes No No

Differential 7 1 Varies Yes Yes No

OxiMax 9 2 Purple Yes Yes Yes

OxiMax-Exclusive 8 2 White No No Yes

Printer Tests

The following steps check the functionality of the printer.

Note

1. Disconnect all cables from the monitor.

2. Turn the monitor OFF then ON.

3. Press SETUP > WAVE SEL > INSERV.

4. Press MAIN MENU.

5. Wait at least 8 seconds and then press the printer's SNAPSHOT button.

6. Check that the printer prints an approximately eight-inch strip of the simulated patient

7. Press the printer's START/STOP button. The printer should begin continuous printing.

8. Press the START/STOP button to stop printing.

9. Lay the Propaq Encore on its back.

10. Press the START/STOP button to start printing.

Functional verification should be performed on the monitor before beginning the printer tests. The monitor must be functioning properly in order to perform printer tests.

data. The paper should stop only after the entire waveform has been fed out of the printer.

11. Completely open the paper door on the bottom of the Expansion Module.

12. Check that the printer stops printing, and that an equipment alarm and CHECK DOOR message appear on the monitor screen.

13. Cut or tear the printer paper in the printer mechanism from the roll, leaving the strip of paper in the printer mechanism.

14. Completely close the paper door.

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26 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

15. Press the START/STOP button.

16. After the printer runs out of paper, check that an equipment alarm and PAPER OUT message appear on the monitor screen.

17. Open the printer door and reload the paper into the printer.

18. Close the paper door and set the monitor upright.

19. Simultaneously press the PRINT TRENDS and START/STOP buttons.

20. Check that a test printout similar to one shown in the figure below is printed.

test print

VER. 1.00.01 5B 4F B7

CO2 Verification Preparation

The mainstream and sidestream CO2 functional verification procedures require calculating the local barometric pressure and partial pressure of the test gas (in mmHg) to compare to Propaq Encore displayed values.

Local barometric pressure

The first step is to determine the local barometric pressure:

1. Determine local altitude above sea level.

For worldwide locations, obtain altitude from local geological maps (U.S.G.S. maps in the United States) or other local references on the maps. Refer to the table titled: Uncorrected Barometric Pressure as as Function of Altitude; use this table to determine the local uncorrected pressure (LUP).

2. Determine ATIS reported pressure (inches or millimeters of Hg).

For U.S. locations, consult local telephone directories to obtain the Automated Terminal Information Service (ATIS) number, typically listed under United States Government Offices, Department of Transportation, Federal Aviation Administration, and Air Traffic Control Towers.

Among various statistics reported is the “altimeter,” which is given in four integers. The four digits represent the barometric pressure as referred to sea level, in units of inches of mercury, with an assumed decimal point occurring between the second and third numbers.

For worldwide locations, equivalent altimeter statistics, in millimeters of mercury, may be obtained from local agencies.

Note

The difference in altitude between the calibration site and the ATIS site should not be greater than 30 m or 100 ft.

3. Determine local barometric pressure using LUP and ATIS. Apply the ATIS and LUP values to the following formula to calculate the local barometric pressure (mmHg):

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Service Manual Functional Verification 27

Local Barometric Pressure =

0.033421 x LUP x ATIS (ATIS in inches of Hg)

0.00131579 x LUP x ATIS (ATIS in mm of Hg)

Example 1

a. The altitude is 5000 feet. The local uncorrected pressure (LUP) is determined

from the following table to be 632.35.

b. The reported ATIS is 30.09 inches Hg. (Altimeter: three zero zero niner.)

c. Multiply the LUP (632.35) times the ATIS (30.09) times 0.033421.

This gives the local barometric pressure of 635.92 mmHg.

Example 2

a. The altitude is 1000 meters. The local uncorrected pressure (LUP) is determined

from the following table to be 674.11.

b. The reported ATIS is 764.29 mmHg.

c. Multiply the LUP (674.11) times the ATIS (764.29) times 0.00131579.

This gives the local barometric pressure of 677.92 mmHg.

Partial pressure of test gas source

To determine the partial pressure of test gas source multiply the local barometric pressure (as determined in step 3 above) by the certified percentage (±0.01% accuracy) of the test gas.

Example

The local barometric pressure (as calculated in Example 1 above) is 635.92 mmHg.

The certified CO

Determine the CO

This gives the partial pressure of the CO

Table 7. Local Uncorrected Barometric Pressure (LUP) as a Function of Altitude (Feet)

Altitude

(Feet)

-2000 816.56 1000 732.93 4000 656.38 10000 522.65

-1900 813.66 1100 730.27 4200 651.52 10333 515.93

-1800 810.76 1200 727.62 4400 646.68 10667 509.26

-1700 807.87 1300 724.97 4600 641.88 11000 502.69

-1600 804.99 1400 722.33 4800 637.10 11333 496.18

-1500 802.11 1500 719.70 5000 632.35 11667 489.72

-1400 799.25 1600 717.07 5200 627.64 12000 483.34

-1300 796.39 1700 714.46 5400 622.95 12333 477.04

-1200 793.54 1800 711.85 5600 618.28 12667 470.78

-1100 790.70 1900 709.25 5800 613.65 13000 464.60

-1000 787.87 2000 706.65 6000 609.04 13333 458.50

-900 785.05 2100 704.07 6200 604.47 13667 452.44

-800 782.23 2200 701.49 6400 599.92 14000 446.46

-700 779.42 2300 698.92 6600 595.40 14333 440.55

gas percentage is 5.00%.

partial pressure by multiplying (635.92) x (0.0500).

Pressure

(mmHg)

Altitude

(Feet)

as 31.8 mmHg.

Pressure

(mmHg)

Altitude

(Feet)

Pressure

(mmHg)

Altitude

(Feet)

Pressure

(mmHg)

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28 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

Table 7. Local Uncorrected Barometric Pressure (LUP) as a Function of Altitude (Feet)

Altitude

(Feet)

-600 776.62 2400 696.36 6800 590.90 14667 434.68

-500 773.83 2500 693.80 7000 586.44 15000 428.89

-400 771.05 2600 691.26 7200 582.00 15333 423.17

-300 768.28 2700 688.72 7400 577.58 15667 417.49

-200 765.51 2800 686.18 7600 573.20 16000 411.89

-100 762.75 2900 683.66 7800 568.84 16333 406.35 0 760.00 3000 681.14 8000 564.51 16667 400.86 100 757.26 3100 678.63 8200 560.21 17000 395.44 200 754.52 3200 676.13 8400 555.93 17333 390.08 300 751.80 3300 673.64 8600 551.68 17667 384.76 400 749.08 3400 671.15 8800 547.45 18000 379.52 500 746.37 3500 668.67 9000 543.26 18333 374.34 600 743.67 3600 666.20 9200 539.08 18667 369.20 700 740.97 3700 663.73 9400 534.94 19000 364.13 800 738.28 3800 661.27 9600 530.82 19333 359.12 900 735.61 3900 658.82 9800 526.72 19667 354.15 1000 732.93 4000 656.38 10000 522.65 20000 349.24

Pressure

(mmHg)

Altitude

(Feet)

Pressure

(mmHg)

Altitude

(Feet)

Pressure

(mmHg)

Altitude

(Feet)

Pressure

(mmHg)

Table 8. Local Uncorrected Barometric Pressure (LUP) as a Function of Altitude (Meters)

Altitude

(Meters)

-700 825.23 1000 674.11 2700 546.23 4400 438.74

-650 820.43 1050 670.03 2750 542.79 4450 435.86

-600 815.65 1100 665.98 2800 539.37 4500 432.99

-550 810.89 1150 661.94 2850 535.96 4550 430.14

-500 806.15 1200 657.92 2900 532.58 4600 427.31

-450 801.43 1250 653.92 2950 529.21 4650 424.49

-400 796.74 1300 649.94 3000 525.85 4700 421.69

-350 792.07 1350 645.98 3050 522.52 4750 418.90

-300 787.43 1400 642.04 3100 519.20 4800 416.12

-250 782.80 1450 638.12 3150 515.90 4850 413.36

-200 778.20 1500 634.22 3200 512.62 4900 410.62

-150 773.61 1550 630.34 3250 509.35 4950 407.89

-100 769.05 1600 626.48 3300 506.10 5000 405.18

-50 764.52 1650 622.63 3350 502.87 5050 402.48 0 760.00 1700 618.81 3400 499.65 5100 399.79 50 755.51 1750 615.00 3450 496.45 5150 397.12 100 751.03 1800 611.22 3500 493.27 5200 394.46 150 746.58 1850 607.45 3550 490.10 5250 391.82 200 742.15 1900 603.70 3600 486.95 5300 389.19 250 737.74 1950 599.97 3650 483.82 5350 386.58 300 733.35 2000 596.26 3700 480.70 5400 383.98 350 728.99 2050 592.57 3750 477.60 5450 381.39 400 724.64 2100 588.89 3800 474.51 5500 378.82 450 720.32 2150 585.24 3850 471.44 5550 376.27 500 716.01 2200 581.60 3900 468.39 5600 373.72 550 711.73 2250 577.98 3950 465.36 5650 371.20 600 707.47 2300 574.38 4000 462.33 5700 368.68 650 703.23 2350 570.80 4050 459.33 5750 366.18 700 699.01 2400 567.24 4100 456.34 5800 363.69 750 694.81 2450 563.69 4150 453.37 5850 361.22 800 690.63 2500 560.16 4200 450.41 5900 358.76 850 686.47 2550 556.65 4250 447.47 5950 356.31 900 682.33 2600 553.16 4300 444.54 6000 353.88 950 678.21 2650 549.68 4350 441.63 6050 351.46

Pressure

(mmHg)

Altitude (Meters)

Pressure

(mmHg)

Altitude (Meters)

Pressure

(mmHg)

Altitude (Meters)

Pressure

(mmHg)

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Service Manual Functional Verification 29

Table 8. Local Uncorrected Barometric Pressure (LUP) as a Function of Altitude (Meters)

Altitude

(Meters)

1000 674.11 2700 546.23 4400 438.74 6100 349.05

Pressure

(mmHg)

Altitude (Meters)

Pressure

(mmHg)

Mainstream CO2 Verification Procedure

This procedure verifies the accuracy of the Encore’s mainstream CO2 (MCO system. If verification test results exceed specification limits, calibration (“MSP Board

(MCO2) Calibration” on page 42) MAY or MAY NOT be required—there are multiple

possible sources of errors in testing as listed in the table “Possible Sources of CO2

Verification Test Errors” on page 30.

1. Connect a MCO

2. Turn on the Encore. Press ALARM SUSPEND/RESUME to disable the alarms.

3. Press SETUP > MORE > MORE (>SERVICE > YES > MORE > MORE > SETTINGS, for software versions 2.0 and greater) and then set the CO millimeters of mercury (mmHg).

4. Allow the monitor and sensor to warm up for at least 15 minutes.

Note

Possible errors may be caused if the area has high background CO CO

has been forced outside of the airway adapter and into the sensor itself. To

reduce the background CO preferably, the technician should be the only person present. If CO forced into the sensor, allow 24 to 48 hours for the CO

sensor with airway adapter to the Encore MCO2 input connector.

level, the area should be well ventilated and,

Altitude (Meters)

Pressure

(mmHg)

Altitude (Meters)

measurement units to

to dissipate.

Pressure

(mmHg)

) measuring

levels or if

has been

5. After 15 minutes, check that the CO

reading (of ambient room air) on the Encore

display is 1 mmHg, ±1 mmHg.

6. Install a rubber stopper in each end of the sensor airway adapter. (See “Required

Equipment” on page 12.)

7. Connect the CO

gas source through the hole in the stopper on one end of the airway

adapter. Leave the other end open.

Note

Before performing the following steps, convert the percentage of the gas source to partial pressure (mmHg) according to the procedures in Mainstream “CO2

Verification Preparation” on page 26.

8. Introduce a flow of test CO

at a rate of 60 to 200 ml/min into the sensor airway

adapter.

9. For test gas calculated partial pressure values of 30 mmHg or less, check the CO

reading on the Encore display to be within 3 mmHg.

10. For test gas calculated partial pressure values greater than 30 mmHg, check the CO reading on the Encore display to be within ±10% of the partial pressure value.

test results are out of specification limits, check the table “Possible

Note

If CO

Sources of CO2 Verification Test Errors” on page 30 for possible error sources.

Always verify the test setup to minimize errors.

11. Disconnect the test gas source and other test equipment.

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30 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

12. Disconnect the CO2 sensor from the monitor.

13. Turn off the monitor.

14. Log the test date and results in your department log.

WARNING Eliminate all the possibilities causing errors shown in the following table before performing the calibration procedure (“MSP Board (MCO2)

Calibration” on page 42). Recalibrating the altimeter, as described in that

procedure, without adequately eliminating all other possible faults may result in inaccurate EtCO

readings.

Table 9. Possible Sources of CO

Error Specification Correction

Incorrect/unknown calibration gas concentration

Insufficient/excessive gas flow rate

Excessive back pressure in cuvette

Air mixed with standard gas Check integrity of test setup.

Gas temperature Gas temperature entering airway

Cuvette error Results should not vary more than

Thermal equilibrium error Sensor not warmed up Allow sensor/system to operate for a 15 minute

reading with sensor

High CO

subject to room air only

Verification Test Errors

4 to 10% certified to within ±0.01% Verify gas supply. Gas must be between 4% and

10%. Once known, convert percentage to partial pressure (mmHg) (“Partial pressure of test gas

source” on page 27).

Between 60 and 200 ml/min Verify with flow meter.

Back pressure should not exceed 1þmmHg

adapter should be at room temperature

0.5 mmHg due to cuvette tolerances

CO2 forced outside of airway adapter into sensor. This is possible during demonstration if exhaled gases are blown through hands cupped around cuvette and exhaled gases are forced into sensor.

Connect gases as instructed in verification test.

Store gas at room temperature.

Use another cuvette (airway adapter).

warm-up period.

Contain exhaled breath through the inside of cuvette only. Do not allow gases to be forced outside of cuvette and into sensor housing. If CO

has been forced into sensor allow 24 to 48

hours for the CO

to dissipate.

Sidestream CO2 Verification Procedure

The following procedures verify the operation of the sidestream CO2 (SCO2) option.

1. Allow the monitor to warm-up for 3 minutes before performing the SCO

2. If present, disconnect the mainstream sensor from the monitor.

3. If installed, remove the water tap from the receiver on the front left panel of the expansion module

4. Determine the local barometric pressure (“CO2 Verification Preparation” on page 26), steps 1-3.

5. Select the SIDE TST screen through SETUP > MORE > MORE > SERVICE > YES > CO

TEST

tests.

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Service Manual Functional Verification 31

6. Verify that BARO TRUE and INT are within 15mmHg (5mmHg, typical) of the barometric pressure determined in step 4.

7. Connect the test tubing setup shown in the figure below to both ends of a test water trap.

300 mmHg Manometer

mmHg

Pressure Meter

Calibration

Adapter Kit

Test Watertrap

Standard adult cuff wrapped around arm-sized cylinder.

Luer Connectors

1097-17

8. Use the pump bulb to manually inflate the pressure to 100mmHg as read on the pressure meter.

9. Wait 15 seconds for the pressure to stabilize. Note the pressure reading, then wait an additional 60 seconds and check that the pressure has not dropped more than 10mmHg. (Replace the water trap and retest if the leak rate is over 10mmHg.) Record the leak rate value for use in step 17 below.

10. Disconnect the water trap from the test setup and install it into the water trap receiver of the monitor under test. Wait for SRCH to appear in the SCO

numerics

window.

11. Plug the water trap inlet and verify that the monitor generates an OCCLUSIONCHECK WATER TRAP/TUBING equipment alert message. Acknowledge the equipment alert. Wait for SRCH to appear in the SCO

numerics window.

12. Plug the exhaust port and verify that the monitor generates an OCCLUSION-CHECK EXHAUST PORT/TUBING equipment alert message. Acknowledge the equipment alert.

Caution The occlusion test can stress any defective pneumatic tubing connections and may cause leakage. Always perform the following leak test after the occlusion test to reveal any tubing problems.

13. Through the CO

/SPO2 > CO2 >MORE menu, push SOURCE to turn off CO2/BR

monitoring. Confirm the message.

14. Connect the test tubing setup (step 7 on page 31) to the water trap inlet and to the exhaust port.

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32 Functional Verification Welch Allyn Propaq Encore Vital Signs Monitor

Caution Do not exceed 100mmHg during the following pressurization. Excessive pressure can open internal tubing connections and cause leakage.

15. Use the pump bulb to manually inflate the pressure to 100mmHg.

16. Wait 15 seconds for the pressure to stabilize. Note the pressure reading, then wait an additional 60 seconds and record the leak rate. This is the total leakage (including water trap leakage from step 9).

17. Subtract the water trap leakage (determined in step 9) from the total leakage (determined in step 16) to obtain the internal SCO

leak rate which should be less

than 10mmHg. The total leakage, including water trap leakage from step 9, cannot be more than 10mmHg.

18. Disconnect the tubing setup from the water trap and exhaust port.

19. With water trap installed in the water trap receiver, turn on SCO CO

/SPO2 > CO2 >MORE > SOURCE.

20. Through the CO

/SPO2 > CO2 > MORE > FLOW RATE menus, set the monitor flow

monitoring through

rate to 90mL/min.

21. Wait 5 minutes.

22. Connect the flow meter to the water trap.

23. Check that the measured flow rate is between 76 and 104 mL/min.

24. Disconnect the flow meter from the tubing connected to the water trap (leave the open length of tubing connected.)

25. Connect the flow meter in line with the CO

26. Adjust the CO

flow for a rate of 110-200mL/min.

gas delivery tubing.

27. Insert the gas delivery tubing and the open sampling line from step 24 into a small ziplock bag (sandwich sized) with the zip lock closed as far as possible without pinching the tubing. This will slightly pressurize the bag with the test gas.

28. Wait two minutes for the bag to fully equalize with the test gas.

29. Calculate the partial pressure of the test gas used (“CO2 Verification Preparation” on page 26).

30. Multiply the calculated partial pressure (in mmHg) from step 29 by 0.95316. Record this calculation for use in step 33.

31. Select the SIDE TST through the SERVICE > CO

32. Observe the instantaneous CO indicating that the CO

concentration in the ziplock bag has stabilized.

value on the service screen for a constant value

33. Check that the observed instantaneous CO

TEST > SIDE TST menus.

value is within 3mmHg or 10%,

whichever is greater, of the calculated value from step 30 (round up all half values on the service screen to the next higher mmHg).

34. Disconnect the test setup.

Page 37

Calibration

Introduction

This section provides calibration procedures for the Propaq Encore. These procedures allow you to calibrate the Encore to Welch Allyn factory specifications. Calibrations procedures should be performed only by qualified service personnel.

Calibration procedures must be performed whenever a question arises as to the performance of the Encore, and as indicated in “Over view” on page 5.

Functional verification procedures (“Functional Verification” on page 11) verify that the monitor is performing to its specifications. A functional verification must follow the calibration.

Note

Respiration, temperature, printer, and SpO Sidestream CO modules to support service of these options, perform a functional verification for those associated modules.

The mainstream CO verification procedure AND you have eliminated all possible faults as listed in the table .

has no user-performable calibration. After replacement of any

circuitry should be calibrated only if it fails the functional

options do not require calibration.

Equipment Needed

You will need the following equipment to calibrate the Propaq Encore monitor. Part numbers are given for equipment available from Welch Allyn.

Note

Table 10. Required Equipment

Description

Digital multimeter (DMM), 4 1/2 digit, Fluke 805A or equivalent

50MHz triggered sweep oscilloscope, Tektronix 2225 or equivalent

Variable dc power supply, 0-28V, 3A, VIZ WP-715A or equivalent

Patient simulator, Dynatech/Nevada 213A, 214A, 215A, or 217A with temperature and EGG cable/leads

0 to 300mmHg digital pressure meter with bulb (Netech, Digamano, or equivalent)

Invasive blood pressure (IBP) simulator, 5μ/V/mmHg, Fogg Systems BP48C, BP28, or MDE Datasim 6000, with IBP cables

All test equipment must be calibrated to function within parameters specified by the manufacturer, and be traceable to a national calibration standard.

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34 Calibration Welch Allyn Propaq Encore Vital Signs Monitor

Table 10. Required Equipment

Description

Adult cuff (provided with monitor); cylindrical object about the size of an adult’s arm

Welch Allyn cuff calibration kit, Welch Allyn part number 008-0012-XX

Propaq Encore ac power adapter (provided with monitor)

Resistor test loads (4.9¾ and 4.65¾). Refer to “Manufacturable Test Equipment” on page 123.

DC supply cable, Welch Allyn part number 008-0290-XX

Tools necessary to disassemble and reassemble the Encore monitor. (See “Repair

Procedures” on page 47 for a list of necessary tools and instructions on opening the

monitor.)

Procedures

This section contains procedures for calibrating the Propaq Encore monitor:

• Recharger board

• Analog board

• Digital board

Setup

Caution All calibration, service, and repair must be done at a static-protected work station. Failure to protect against damage due to static discharge can damage components in the Propaq Encore.

You must work at a static-protected work station. In order to calibrate the monitor you must open and then perform some disassembly to reach the necessary calibration points.

Caution Refer to “Repair Procedures” on page 47 for all disassembly and re- assembly procedures. Failure to follow disassembly procedures may result in damaged internal parts.

1. Before you begin disassembly, charge the battery pack for at least 8 hours to ensure it is fully charged.

2. Remove any options attached to the monitor. If either the SpO is attached to the monitor, remove it before starting the calibration. The calibration procedures in this section are for the three Encore monitor boards only.

3. Remove the battery pack.

4. Disconnect the ac power adapter from the monitor’s right side panel power input connector.

or expansion module

5. Open the monitor.

6. Disconnect P1 (expansion connector cable) from the Analog board and open the front chassis approximately 90 degrees.

Page 39

Service Manual Calibration 35

Note

To disable the alarms while performing the calibration procedures, press SETUP > ALL ALRM ( >YES - version 2.0 software)to remove the bell symbol from the display. In order to inhibit the Apnea alarm, turn off Respiration monitoring: press ECG/RESP > MORE and set RESP to OFF.

Recharger Supply Adjustments

WARNING High voltages (approximately ± 200V dc or 360V ac) are present on the recharger board when the Encore is turned on. These voltages present a shock hazard if contacted during calibration.

Use non-conductive adjustment tools and keep fingers and conductive objects away from the Recharger board components when calibrating.

1. Verify that the Encore power switch is off.

2. Disconnect the battery connector from P12 on the recharger board (see figure below).

3. Disconnect P8 from the Digital board (see figure below).

P12

4. Connect the 4.9¾ test load (see “Manufacturable Test Equipment” on page 123) to the battery connector (P12).

5. Set the power supply output to 15.0V dc.

Caution Adjustment of RP3 (step 12 on page 36) sets an overvoltage limit which, if misadjusted, can cause fuse F1 (on the right side panel) to open. If you suspect that RP3 has been misadjusted, turn it fully clockwise before connecting power to the dc input jack on the Propaq Encore.

6. Attach the dc power adapter cable to the variable dc power supply as shown figure below.

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36 Calibration Welch Allyn Propaq Encore Vital Signs Monitor

RIBBED (+) SMOOTH (-)

0696-02

7. Connect the adapter cable to the monitor’s dc input jack.

8. Verify that the input current from the variable dc power supply is less than 1.8A and that the green LED on the Encore’s right side panel is on.

Note

Refer to the figure below for adjustment and test point locations.

9. Connect the DMM positive lead to P12 pin 1 or 5.

10. Connect the DMM reference (negative) lead to non-isolated ground at TP2.

11. Adjust RP5 to 9.400V ± 0.010V dc.

12. Move the DMM positive lead to TP4.

13. Adjust RP3 to 2.393 V ± 0.015V dc.

14. Move the positive lead back to P12 pin 1 or 5.

15. Vary the input voltage from 12V to 28V and check that the output voltage remains constant. The battery load voltage must not vary more than 0.100V dc.

16. Decrease the power supply voltage from 12V to 7V while checking the right side panel green LED. The LED should turn off between 7 and 12V.

17. Disconnect the adapter cable from the Encore’s right side panel.

18. Remove the 4.9¾ test load and replace it with the 4.65¾ test load.

19. Reconnect the adapter cable.

20. Adjust RP1 to 9.350V ± 0.010V dc.

21. Remove the 4.65¾.

22. Reconnect the cable to P12.

Page 41

Service Manual Calibration 37

Display Voltage Adjustments

Procedure 1

Note

Do not adjust the display voltage unless the display has been changed and the lack of contrast between illuminated and non-illuminated pixels affects the display readability.

The following calibration adjusts the monitor display’s high voltage supply which is located on the recharger board. The factory-set voltage is specific to the display and is indicated on the display module label.

If you know the voltage specified on the display label (i.e., are calibrating following an installation) use Procedure 1, below. If you do not know the voltage, use Procedure 2.

1. Install the display according to the procedures described in “Repair Procedures” on page 47, reconnect the cables between the front and rear chassis, and turn on the Encore. Note that when you turn the power on and off you initiate an equipment alert. Press any one of the five bottom buttons to reset.

2. Connect the DMM positive lead to the D33 cathode.

VLV2

VLV1

GND

TP2

OVR SET

TP4

PT2

RP5

RP3

TP3

RP1

Procedure 2

RP7

CATHODE D33

P11

VLV3

P14

+BAT

NIBP PUMP

TP1

PIN 1

P12

P10

3. Connect the DMM reference lead to ground at TP2.

4. Adjust RP7 to the value indicated on the display module label.

1. Turn on the Encore and position the display for easy viewing.

2. Adjust RP7 clockwise until the background illuminates.

3. Find the brightest background area on the display and view this area through a paper tube approximately 2 inches in diameter (such as a paper towel or tissue paper tube) to shield the area from ambient light.

4. Adjust RP7 counter-clockwise until the viewed area fades to black.

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38 Calibration Welch Allyn Propaq Encore Vital Signs Monitor

5. Reposition the tube to view the brightest area (now dim) and simultaneously a lighted area (pixels on). Adjust RP7 clockwise until the background area just begins to illuminate.

Main Power Supply Adjustments

The following procedures assume you are continuing from the recharger board calibration. If not, refer to the setup procedures provided at the beginning of this section.

1. Turn off the monitor.

2. Remove the metal shield from the analog board. (Note the two different screw sizes; refer to “Repair Procedures” on page 47 for instructions, if necessary.)

TP9

TP21

TP43

TP7

TP15

TP17

RP4

U109 (DAP)

TP39

TP3

TP 19

RP6

TP11

RP7

J4 PIN 26

TP29

0696-09

PIN 1

TP35

TP41

TP45

P6 PIN 10

PT1

TP23

TP31

TP49TP47

RP2

TP1

U1 U3 U5

TP13

TP25

TP33

TP37

U55

PIN 1

TP51

TP5

TP27

RP5

3. Connect the DMM reference lead to TP39.

4. Connect the DMM positive lead to TP29.

5. Turn on the monitor.

Press any of the lower five buttons to reset the Encore following equipment alerts.

6. Adjust RP7 to 5.000 V ± 0.010 V dc.

7. Refer to the table below and check the dc supply voltages using the DMM.

Table 11. Main Power Supply Voltage Checks

Supply Voltages Ref. Lead Pos. Lead Voltage Limits

Non-isolated

+15 TP39 TP3 +14.7 to +15.3

–15 TP39 TP11 –14.8 to -15.5

Isolated

+VR TP43 or TP1 TP9 +4.91 to +5.09

+VS TP43 or TP1 TP5 +6.58 to +7.15

–VS TP43 or TP1 TP21 -6.65 to -7.15

Page 43

Service Manual Calibration 39

Table 11. Main Power Supply Voltage Checks

Supply Voltages Ref. Lead Pos. Lead Voltage Limits

+VB TP43 or TP1 TP13 +5.40 to +6.10

+5.6 TP43 or TP1 TP33 +5.55 to +5.70

IBP shield TP43 or TP1 P6, Pin 10 +2.47 to +2.53

C.L.P. detector

NIBP Pressure Offset TP43 or TP1 TP31 +2.40 to +2.60

OSC baseline TP43 or TP1 TP47 -0.95 to -1.25

+VA TP43 or TP1 TP7 (+VR + 0.1V) to (+VR + 0.2V)

-VA TP43 or TP1 TP15 (+VR + 0.2V) to -(VR + 0.35V)

+2.5 TP43 or TP1 TP17 +2.48 to+2.52V

a. Make sure the ECG input connector (P5) is disconnected from the analog board for this

measurement. Reconnect when done.

TP43 or TP1 U5, Pin 1 0.00 to +0.25

8. Disconnect the DMM leads.

Calibrating Realtime ECG Out

1. Connect the 5-lead ECG cable to the monitor and the simulator.

2. Set the simulator to 80 bpm, normal sinus rhythm.

3. Set the monitor to Lead II.

4. Connect the dc-coupled oscilloscope probe to the Digital board at P9 pin 6, and the reference probe to TP4 on the Digital board.

5. On the Analog board, carefully short together U55 pins 1 and 2.

6. Adjust RP6 on the Analog board to 0V dc ± 0.1V.

7. Remove the short and check for an ECG signal displayed on the oscilloscope of 1.0V±

0.1V baseline to peak of the R-wave.

8. Disconnect the ECG cable from the monitor.

PIN 6

GND

TP4

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40 Calibration Welch Allyn Propaq Encore Vital Signs Monitor

Non-Invasive Blood Pressure Calibration

1. Connect the cuff, digital pressure meter, bulb, and the Encore together with the cuff calibration kit. Using T-connectors from the kit, connect the cuff, pressure meter, and bulb.

2. Connect this NIBP test setup to the pressure transducer at PT1 on the Analog board.

3. Wrap the adult cuff around the black tube volume or a cylindrical object about the size of an adult’s arm.

4. Press SETUP > MORE > MORE > SERVICE > YES > NIBP TEST > NIBP CAL. Use the bulb to inflate the system pressure to 250mmHg, as read on the pressure meter.

Note

5. Watching the value of PR1 on the Encore monitor screen, adjust RP2 until the service

6. Manually change the system pressure to check linearity tolerances at the following

Pressure (mmHg) Tolerance

If testing takes more than 10 minutes, NIBP CAL will cancel. Press NIBP CAL again and resume testing.

screen reading matches the pressure meter.

19:00:25

NIBP TEST BATTERY: 8.1 VOLTS

CNTS mmHg DAC VALVE

PR1: 578 249.4 130 0 PR2: 54 0 OSC: 1600 LEAK: mmHg DIAG: 0 BLEED: mmHg/min PUMP: secs

PUMP TEST

levels:

AUTO PMP NIBP CAL ZERO PREV MENU

(mmHg)

270

250

200

100

7. Deflate the pressure to 0mmHg.

8. Disconnect the tube from the transducer.

9. Set the oscilloscope to ac-coupled, bandwidth limited.

10. Connect the oscilloscope probe to TP47 on the Analog board.

± 4 ± 3 ± 2 ± 2 ± 2 ± 2

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Service Manual Calibration 41

11. Connect the oscilloscope reference lead to TP43 or TP1 on the Analog board.

12. Check for ≤ 15mV peak-to-peak noise.

Note

13. Disconnect all patient inputs to the Encore’s left side panel.

Measure the low frequency noise (bounce) only. Make the peak-to-peak measurement from the center-to-center of the trace to disregard the “fuzzy” high frequency noise.

EMI Null Adjustment

1. Touch the oscilloscope probe to TP45 on the Analog board (square metal pad).

2. Disconnect the oscilloscope reference lead.

3. Set the oscilloscope vertical sensitivity and horizontal timing to observe the ac mains noise component.

4. Adjust RP4 to null the higher frequency (≈100kHz) noise over-riding the ac mains component.

5. Move the oscilloscope probe to TP19 (upside down “L” shaped pad above J4). See the figure on page 38.

6. Adjust RP1 on the Digital board (accessed through slot in Analog board) to null higher frequency (≈100kHz) noise, over-riding the ac mains component.

7. Disconnect the scope probe.

Invasive Blood Pressure

Skip this part of the calibration procedure if your Encore does not support IBP measurements.

Caution Many blood pressure simulators are not intended for use as calibration standards. Use only recommended simulators for calibrating the Encore.

1. Connect the IBP simulator to P1 on the Encore left side panel.

2. Set the patient simulator to 0mmHg.

3. Press ZERO P1 to zero the channel.

4. Set the patient simulator to 200mmHg.

5. Adjust RP5 for a numeric reading of 200mmHg on the Encore monitor screen.

Note

6. Move the IBP cable to the P2 connector.

7. Set the simulator to 0mmHg.

8. Press ZERO P2 to zero the channel.

If your Propaq Encore does not include a second pressure channel, skip Steps 6 - 10.

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42 Calibration Welch Allyn Propaq Encore Vital Signs Monitor

9. Set the simulator to 200mmHg.

10. Check that P2 displays 200mmHg ±2 mmHg.

11. Disconnect all patient cables from the left side panel.

12. Reinstall the Analog board shield and torque it according to the procedure in “Repair

Procedures” on page 47.

MSP Board (MCO2) Calibration

The Propaq MSP board has two calibration adjustments. One adjustment (RP2) is a null adjust for electromagnetic interference emissions—this adjustment has no effect on MCO

performance/accuracy. The other adjustment (RP1) is a barometric pressure/

altimeter setting. This adjustment is set at Welch Allyn during the production calibration process and does not require readjustment for use at other altitudes.

Note

1. From Propaq main menu, push SETUP > MORE > MORE > SERVICE > YES > CO

2. Adjust RP1 on MSP board if required to calibrate displayed pressure to specified

3. Using an oscilloscope with a 1X probe, connect probe tip to TP50 on the MSP board.

4. Adjust RP2 for minimum high frequency (100kHz) signal.

“Functional Verification” on page 11 provides a procedure to verify MCO

accuracy. if the verification test results are within specifications, board calibration is not required. If verification test results exceed specification limits, RP1 calibration MAY or MAY NOT be required. Before adjusting RP1, check test parameters as indicated in the Table “Local Uncorrected Barometric Pressure

(LUP) as a Function of Altitude (Feet)” on page 27 to minimize testing errors.

Determine local barometric pressure as described in “Local barometric pressure” on page 26 to verify Propaq barometer setting. Adjust RP1, if required, as instructed below.

TEST > MAIN TST and observe the displayed barometric pressure. Check that the displayed pressure is within 3mmHg of the local barometric pressure as calculated in Functional Verification.

limits.

Leave probe groundtip open.

WARNING You must perform a functional verification after calibrating the Propaq Encore to ensure all monitoring functions and safety features operate normally.

Note

Because the battery was disconnected in the calibration procedures, you will need to reset the time, date and all saved settings. See the Propaq Encore Reference Guide for information on resetting these parameters.

Page 47

Troubleshooting

Introduction

This section provides information that can be helpful in troubleshooting the Propaq Encore monitor.

Screen Messages

Messages may appear on the display to inform the operator of some condition requiring operator or service attention. Messages that indicate that the Propaq Encore may need servicing are listed below. For information about other messages, refer to the Propaq Encore Reference Guide.

PROGRAM FAULT: SETTINGS LOST, TIME/DAY RESET. If this message appears when the Propaq Encore is first turned on, it generally indicates a drained battery. The monitor can be used, but the time and date and all other settings will return to factory defaults each time the monitor is turned off. Replace the battery as soon as possible and reprogram the time, date, and other settings according to the Propaq Encore Reference Guide.

CUFF FAULT: NIBP DISABLED, SERVICE REQUIRED. A single fault was encountered in the NIBP system. Perform a functional check and calibration or repair as needed.

CALIBRATION ERROR, TEMP DISABLED. This message appears when the Propaq Encore has detected that temperature circuitry is out of calibration. The temperature channel is disabled until the Propaq Encore is repaired. There are no temperature channel adjustments; the temperature channel uses a regulated power supply as a reference. Check all power supply values (“Calibration” on page 33). The Analog board may need to be replaced.

SENSOR FAILURE - EEPROM - (MCO

(typically a checksum error). The CO disconnected. Replace the sensor.

SENSOR FAILURE, HEATER - (MCO

hardware is detected. This is typically a sensor error, but may be an MSP board fault. Replace the sensor or MSP board as required.

SENSOR FAILURE, MOTOR DRIVE - (MCO

hardware has failed. The channel is disabled until the sensor is disconnected. Replace the sensor.

DEGRADED WAVEFORM, CHECK ADAPTER - (MCO

may be contaminated or the light source in the sensor may be faulty. Clean or replace the cuvette as required or replace the CO

). A failure in the sensor EEPROM is detected

channel is disabled until the sensor cable is

). A failure in the sensor temperature control

). The mainstream sensor motor drive

). The airway adapter (cuvette)

sensor.

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44 Troubleshooting Welch Allyn Propaq Encore Vital Signs Monitor

LACK OF WAVEFORM, SENSOR DISABLED - (MCO2). The airway adapter (cuvette) may be contaminated or the light source in the sensor may be faulty. Clean or replace the cuvette as required or replace the CO

sensor.

SENSOR FAILURE, CALIBRATION ERROR - (MCO

). A Sensor failure has occurred.

Replace the sensor.

PUMP FAILURE, SERVICE REQUIRED - (SCO

). The sidestream pneumatic tubing is

kinked or a pump failure on the SSP board has occurred. Correct the tubing problem or replace the SSP board as required.

DEGRADED WAVEFORM-SERVICE REQUIRED - (SCO

contamination or light source failure in the CO

measurement chamber (bench) that is

). This error indicates possible

located on the Stick board or by a failure of the SSP Board. Replace the Stick or SSP board as required.

LACK OF WAVEFORM-SERVICE REQUIRED - (SCO

contamination or light source failure in the CO

measurement chamber (bench) that is

). This error indicates possible

located on the Stick board or by a failure of the SSP Board. Replace the Stick or SSP board as required.

MOTOR FAILURE-SERVICE REQUIRED - (SCO

). The motor drive in the CO2 bench has

failed. Replace the Stick board.

CALIBRATION ERROR-SERVICE REQUIRED - (SCO

). A CO2 bench failure has

occurred. Replace the Stick board.

OCCLUSION-CHECK EXHAUST PORT/TUBING - (SCO

). Repeated error messages

after removing any occlusion on the exhaust connector can indicate a defective pump located on the SSP board. Replace the SSP board.

Non-Recoverable Error Codes

Non-recoverable errors are detected by software and indicate the Propaq Encore is no longer able to function properly and must be returned to Welch Allyn for service. Contact Welch Allyn Technical Support.

When a non-recoverable error is found, the software attempts to put the error message and its number on the Propaq Encore display. All monitoring functions are locked out. Non-recoverable errors are therefore distinct from equipment alerts, which permit reduced monitoring capability.

Non-recoverable errors are indicated in the following format: x - yyy -zzzz

where:

x = 0 indicates a problem found by the Display Control Processor (DCP).

x = 1 indicates a problem found by the Data Acquisition Processor (DAP).

x = 2 indicates a problem found by the Printer Control Processor (PCP) on the

Printer Main board.

x = 3 indicates a problem found by the SpO

SCP board.

x = 5 indicates a problem found by the Main Stream Processor (MSP) on the

MSP (CO

) board.

Control Processor (SCP) on the

Page 49

Service Manual Troubleshooting 45

x = 7 indicates a problem found by the Side Stream Processor (SSP) on the

sidestream main board.

yyy-zzzz indicate specific types of problems. Contact Welch Allyn Technical

Support for more details.

Battery Capacity Check

Several variables affect monitor operating time on battery:

• active options

• frequency of NIBP measurements

• frequency and length of printouts

• ambient temperature,

• battery age and condition

• displayed information.

Refer to the Propaq Encore Reference Guide for battery care information and expected operating times. If the monitor fails to operate on battery for an extended period of time, follow the procedure below to check the capacity of the Encore’s lead acid battery. Lead acid batteries have a very limited shelf life; you must test the battery if the Encore has been stored for two or more months without the ac power adapter plugged in.

Caution A new battery should pass the following test. The run time of older batteries will decrease proportionally with age. Replacement is recommended when the run time becomes insufficient for the monitor's intended application.

1. Use the ac power adapter and charge the monitor for at least 8 hours with the monitor turned off (12 hours if a printer or pulse oximeter is attached).

2. Disconnect the cuff and all cables from the monitor.

3. Turn off all printing (if a printer is attached).

4. Disconnect the power adapter.

5. Turn on the monitor.

6. Run the monitor for 4 hours.

7. Check that the monitor did not automatically turn off.

8. Press MAIN MENU.

9. Use the ac power adapter and charge the monitor for at least 8 hours with the monitor turned off. (Charge at least 12 hours if a printer or pulse oximeter is attached.)

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46 Troubleshooting Welch Allyn Propaq Encore Vital Signs Monitor

Page 51

Repair Procedures

Introduction

This section provides instructions for removing and replacing serviceable modules in the:

Instructions on how to remove the battery pack are followed by instructions on how to disassemble the monitor, the expansion module, the printer, the SpO CO

Note

• Propaq Encore monitor

• expansion module (which may include any or all of the following: printer, SpO

mainstream CO

•SpO

module.

-only module

In general, reassembly procedures are the reverse of the disassembly procedures. If there are items to note during reassembly, they are described after the disassembly section.

WARNING Whenever the monitor is opened for calibration or repair, a risk (leakage) current safety check and a hi-pot test must be performed, followed by a complete functional verification. See “Functional Verification” on page 11.

,sidestream CO2)

module, and the

Propaq Encore Software

Propaq Encore system software is contained in PROMs (programmable read-only memory) on various system board. The following PROMs may require replacement during board exchange processes. See“Replacing PROMs” on page 70.

• DAP PROM on the analog board in the Encore monitor

• PCP PROM on the printer main board in the Expansion Module

• SCP PROM on the SCP board in the SpO

• MSP PROM on the CO

• SSP PROM on the sidestream main board (SSP) in the Expansion Module

When you remove one of these boards for replacement, you should remove the PROM from the board and store it in an anti-static plastic bag until you receive the replacement board. Keeping the PROM allows you to install it in the new board and ensures the replacement board will be compatible with the rest of your Encore system software.

Note

The DCP PROM and the digital board are not field replaceable due to external programming requirements. Do not remove the DCP PROM. For digital board service and/or a DCP software update, contact your Welch Allyn Service representative.

option

board (MSP) in the Expansion Module

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48 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

WARNING STATIC DISCHARGE

All calibration, service, and repair must be done at a static-protected work station. Failure to protect against damage due to static discharge may reduce monitor operation life and increase repairs. Place the monitor in an anti-static area before servicing the monitor.

Required Tools

The following tools are required to disassemble and reassemble the Propaq Encore components.

Description

Phillips screwdrivers, #1 and #2

Flat blade screwdriver

Adjustable torque screwdriver (2.5in-lb to 7.35in-lb.; .43N-m to .83N-m), with Phillips and 3/16" nut driver heads

Tweezers to help with screw removal and replacement

Static-free mat and wrist band equipment

Wire cutter to remove tie wraps

Tie wrap tool

De-ionized (neutralized), filtered, dry, non-combustible gas under pressure for removing any dust or debris from the monitor’s interior.

Pliers, standard needle-nosed

Pliers, looping - non-serrated, rounded edges for use on tubing

PROM Remove Tool: Amp Part Number 821903-1

Caution It is recommended you use de-ionized gas for removing dust and debris prior to reassembly of monitor components. Commercial devices are available to neutralize compressed gases.

Propaq Encore Options

Your Propaq Encore may contain an option module that attaches to the monitor. You must remove the option module before you can disassemble the monitor. For instructions on how to remove the expansion module, refer to “Replacing the Battery Pack” on page 52. For instructions on how to remove the SpO

in SpO2 Module” on page 55.

module, refer to “Removing the Dual Battery

Page 53

Service Manual Repair Procedures 49

Monitor Only Monitor with SpO2

Monitor with

Expansion Module

0696-10

Field Replaceable Units in the Monitor

The front chassis of the monitor contains the following components:

• insulator

• Analog board with metal shield and insulator

• Digital board with shields

• EL display unit

• front chassis with display filter and gasket

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50 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Plastic Insulator

Analog Board with Shield

Digital Board Top Shield

Digital Board

Brackets

The rear chassis contains the following components:

• Recharger board

• Side panels (right and left)

•NIBP pump

• NIBP tubing

•NIBP valves

EL Display Panel

Front Chassis

0696-11

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Service Manual Repair Procedures 51

Recharger

Board

Right Side Panel

Left

Side Panel

Rear Chassis

Replacing the Power Input Fuse

The F1 fuse protects the Recharger board circuitry against excessive current at the dc input connector. You do not need to disassemble the Propaq Encore to replace this fuse.

Check fuse F1 if the ac power adapter is functioning properly and the following two conditions exist:

• the green LED charging indicator on the monitor’s right side panel does not

illuminate

• the monitor battery does not charge

DEFIB SYNCHROMONITOR

2AG

EKG x 1000

0696-12

12-28V, 3A

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52 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

To remove the fuse, use a flat blade screwdriver to turn the fuse cover and release the fuse.

Caution Replace the fuse only with one of the same rating and size. See “Field

Replaceable Units (FRUs)” on page 117 for Welch Allyn part numbers.

Replacing the Battery Pack

WARNING Although the battery pack includes a fuse to prevent against personal and equipment damage, the sealed lead-acid battery pack is capable of quickly delivering dangerously high currents if improperly handled, misused, or abused. These current levels may burn skin or damage the Propaq Encore. Use extreme caution when handling the battery pack.

The battery fuse is not replaceable. If the battery is shorted, the entire pack must be replaced. Do not try to service the battery fuses.

Insert a new battery pack into the Propaq Encore when the current battery no longer holds an adequate charge. Verify the battery charges to capacity according to “Battery

Capacity Check” on page 45.

Dispose of used battery promptly. Keep away from children. Do not disassemble and do not incinerate or burn.

BATTERIES MUST BE SEPARATED FROM OTHER DISPOSABLES FOR RECYCLING

The battery maintains programmed defaults and time of day. Without the battery, the values for these items return to the factory settings. If the power up error message TIME/ DATE SETTINGS LOST is displayed, reprogram the time and day and monitoring default parameters according to the procedures described in the Propaq Encore Reference Guide.

WARNING Do not pinch the battery wires when inserting the battery pack into the Propaq Encore. Monitor failure or fire could occur if wires get pinched.

You must remove the battery pack before opening the monitor case and replacing components. A Propaq Encore without options contains a single battery pack. An Encore with an option package uses a dual battery package.

Removing the Single Battery Pack

The following steps describe how to remove the battery pack from the monitor:

1. Using a flat blade screwdriver, unscrew the four screws securing the battery pack cover as shown below.

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Service Manual Repair Procedures 53

single battery cover removal

Battery Pack

Battery

Pack Cable

2. Disconnect the battery pack cable from the battery pack.

3. Remove the battery pack from the monitor.

4. Store the battery in a safe place while disassembling the monitor.

Removing the Dual Battery in Expansion Module

The expansion module uses a dual battery pack. The following instructions describe how to remove the dual battery.

Battery Cover

0696-13

Note

Four screws secure the expansion module to the monitor. Four additional screws secure the rear panel to the expansion module chassis; do not remove these additional screws.

1. Using a Phillips screwdriver, remove the four screws securing the expansion module to the monitor (see figure below).

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54 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

2. Use the flat blade screwdriver to gently loosen the expansion module from the monitor (see inset above).

3. Slide the monitor forward until you can disconnect the battery pack cable from the monitor's power cable. The battery pack should remain in the expansion module chassis.

4. Continue to slide the monitor forward until it can be completely separated from the expansion module.

5. Slide the dual battery pack forward out of the expansion module until the battery connector can be reached.

6. Disconnect the battery connector from the expansion module (see figure below).

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Service Manual Repair Procedures 55

7. Remove the dual battery pack from the expansion module.

8. Store the battery in a safe place while disassembling the monitor and expansion module.

Removing the Dual Battery in SpO2 Module

The steps for removing the battery pack from the SpO2 module are identical to those in removing the battery from the expansion module, except you remove all screws on the rear panel. The monitor is secured to the SpO two washers.

1. Using a Phillips screwdriver, remove the four screws from the SpO panel.

2. Slide the monitor forward until you can disconnect the battery pack cable from the monitor's power cable.

3. Slide the monitor forward until it can be completely separated from the SpO

4. Remove the dual battery pack.

5. Store the battery in a safe place while disassembling the monitor and SpO

When attaching the SpO

module, verify that the continuous O-ring gasket is in place.

module with four screws; each screw has

module rear

module.

Opening the Monitor

Follow these steps to open the monitor casing and gain access to the three removable monitor boards.

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Using a Phillips screwdriver, remove the six screws securing the handle and monitor casing.

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56 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

0696-18

Caution Before opening the casing more than one inch in the next step, disconnect the tube from the pressure transducer at the joint. Failure to disconnect the tubing may cause damage to the transducer or tubing.

3. Slightly spread the casing open at the top until you can disconnect the pressure transducer tube indicated in the figure below.

1. Spread the casing open to an angle of 45 degrees.

2. Detach the expansion connector cable (to P1) from the front chassis of the monitor as indicated in the figure below.

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Service Manual Repair Procedures 57

3. Spread the casing open to an angle of about 80 degrees.

4. Detach the following cables from the front chassis (indicated in figure below):

• Cable to P5 on the Analog board, from the left side panel ECG connector on the

rear chassis.

• Cable to P6 on the Analog board, from the left side panel IPB connector on the

rear chassis.

• Cable to P7 on the Analog board, from the left side panel temperature jack on the

rear chassis.

• Cable to P8 on the lower (Digital) board, from the right side panel on the rear

chassis.

• Cable to P9 on the Digital board, from the right side panel on the rear chassis.

DISCONNECT 3 CABLES

DISCONNECT 2

CABLES FROM UNDERLYING DIGITAL BOARD

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58 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

1. Detach the two ribbon cables from the rear chassis:

• Ribbon cable to P10 on the Recharger board, from the Digital board.

• Ribbon cable to P11 on the Recharger board, from the Digital board.

Note

The two halves are sealed by rubber O-ring gaskets that are recessed around the perimeter of the rear chassis. If the gaskets become loose, replace them in the perimeter before re-assembling the monitor.

2. Separate the front chassis from the rear chassis (see figure below).

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Service Manual Repair Procedures 59

Closing the Monitor

1. Before closing the monitor casing, verify the following:

• Cable to P6 on the Analog board goes behind and below the cable to P5, and over the cable to P7.

• Cable to P5 on the Analog board goes over and in front of the cable to P6.

• Cable to P7 on the Analog board goes under the cable to P6.

• Cable to P1 (the expansion cable) must not lay over the transformer.

• Cable to P8 on the Digital board rests to the right of the transformer and over the ribbon cable and cable to P9.

• Cable to P9 lies under the cable to P8.

• All cables and hoses are not pinched.

• The front chassis pressure transducer tube has been securely reconnected.

• The rubber O-ring gasket is in place in the rear chassis.

• P10 and P11 locking clips are secure.

P10

2. Torque the six screws securing the front chassis to the rear chassis to 6.65in-lbs to

7.35in-lbs (.75N-m to .83N-m).

Replacing the Analog Board

P11

0696-37

If a problem occurs with the Analog board, return the entire monitor to Welch Allyn for service. See “Technical Support Services” on page 6.

Note

Do not remove the PROM from the Analog board.

This section provides instructions on removing the Analog board. The Analog board is secured in the front chassis by five screws: three on the right side of the board (side containing the transformer), and two passing through the metal shield on the left side of the board.

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60 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Note

You do not need to lift the plastic insulator nor remove the metal shield to remove the Analog board. However, you must lift the insulator to calibrate the board.

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Open the monitor (“Opening the Monitor” on page 55).

3. Remove the five screws fastening the Analog board to the front chassis.

Note that of the five screws, the two longer screws pass through the metal shield to secure the board.

Caution The Analog and Digital boards are connected together on the right side by connectors P4 and J4. It may be necessary to use two flat blade screwdrivers to gently pry the boards apart.

Place the screwdriver blades as close to the edge of the board as possible so you don’t contact or disturb components on the board. Components are located as close as 1/8" to the edge of the board. Use extreme caution. Try not to flex the board when prying.

4. Gently lift the Analog board up and out of the front chassis.

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Service Manual Repair Procedures 61

When installing the Analog board:

• Blow out any dust and particulates from the board using pressurized de-ionized gas before installing it.

• Align the board so that P4 correctly plugs into J4.

• Torque the screws holding the Analog board to 3.8in-lbs to 4.2in-lbs (.43N-m to .47N-m).

Replacing the Digital Board

If a problem occurs with the Digital board, return the entire monitor to Welch Allyn for service. See “Technical Support Services” on page 6.

Note

The Digital board is secured beneath the Analog board by four screws and one hex post. The four screws are located in the black brackets, the hex post is located in the lower right corner of the board.

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Open the monitor (“Opening the Monitor” on page 55).

3. Remove the Analog board (“Replacing the Analog Board” on page 59).

Do not remove the PROM from the Digital board.

4. Remove the four screws fastening the Digital board to the front chassis.

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62 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

5. Use the nut driver to loosen and remove the hex post.

6. Lift the Digital board up and out of the front chassis.

Note

The Digital board is connected to the EL display module by connector J1. This connector should detach easily.

7. Remove the 10-pin ribbon cable (cable from the Digital board to the Recharger board).

Caution Do not touch the button contact surfaces on the underside of the Digital board. These surfaces must remain clean and oil-free. If you touch them, clean them with a cotton swab moistened with isopropyl alcohol.

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Service Manual Repair Procedures 63

When installing the Digital board:

• Make sure the cable between the Digital board and the Recharger board is installed on the Digital board before placing the board in the front chassis.

• Remove the shield on the top of the Digital board in order to reconnect the display cable.

REMOVE ALL SEVEN SCREWS INDICATED ON SHIELD

INSTALL THIS CABLE BEFORE INSTALLING BOARD

• Blow out any dust and particulates from the board using pressurized de-ionized gas before installing it.

• Connect the display cable to the Display module.

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64 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

• Replace the shield, noting the correct screw lengths indicated on the shield. When replacing the insulating shield, make sure the left side of the shield is placed underneath the top surface of the bracket.

• Torque all screws and the hex post to 3.8in-lb to 4.0in-lb (0.43 N-m to 0.47 N-m).

Replacing the EL Display Module

Caution Removing the EL display module may damage the electricallyconductive inner surface of the display filter. Welch Allyn recommends leaving the display unit in the front chassis unless you replace the display unit and the front chassis together.

The conductive silicone gasket between the display module and display filter may remove the delicate coating from the perimeter of the filter if the gasket peels up as the display module is removed. If electrical contact with the filter is degraded sufficiently, the display's EMI may interfere with ECG and/or SpO patient cables pass near the display.

If you must remove the display module, use two people in the removal procedure to attempt to minimize damage to the display filter.

monitoring if

This section provides instructions on how to replace the display module. The display module is attached to the front chassis beneath the Analog and Digital boards by two brackets, each fastened at the top and bottom by a screw and two washers.

Note the voltage indicated on the label of the display module. This value is used for calibrating the display high voltage supply on the Recharger board.

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Open the monitor (“Opening the Monitor” on page 55).

3. Remove the Analog board (“Replacing the Analog Board” on page 59).

4. Remove the Digital board (“Replacing the Digital Board” on page 61).

5. Remove the screws and washers holding the brackets on the left and right sides of the board.

Caution Handle these brackets carefully. They are constructed of very thin metal. Their purpose is for conductivity, not to secure the display.

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Service Manual Repair Procedures 65

HOLD THE GASKET DOWN

REMOVE 4 SCREWS

AT CORNERS

AT THESE POINTS ON BOTH SIDES OF THE BOARD.

Caution In the next step, if the gasket lifts off the display filter at any point, you must inspect the display filter to verify that the conductive coating on the filter is still intact. See the steps below.

6. To carefully remove the display:

a. Using a flat blade screwdriver, each person should hold the silicone gasket down

where it is visible between the posts at the top and bottom of the chassis (see figure above).

b. With their free hand, each person should gently lift one side of the display

module, attempting to keep the silicone gasket in place on the display filter.

If the gasket lifts off the display filter at any time, inspect the filter beneath the section where the gasket lifted to ensure the conductive coating around the perimeter of the filter is still intact. Try not to disturb the rest of the gasket/filter interface as you do this. To inspect the filter, look for a slight color variation between the perimeter conductive coating and the rest of the filter (see the figure below). (Tilting the front assembly at different angles under a bright light can help you see the color variation of the conductive coating.) The slight color variation should be continuous around the perimeter under the gasket. If there is a break in this coating, you must replace the front assembly with the display filter.

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66 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

OTI Coating

Approx. 0.125"

0696-33

When installing the display module:

• Remove any dust from the display filter using pressurized de-ionized gas.

• Orient the display module so that the J1 connector is toward the buttons.

• Orient the brackets so that the holes on the bracket straps align with the holes in

the posts on the sides of the chassis.

• Verify two washers are present for each screw.

• Torque screws to 3.8in-lbs to 4.2in-lbs (.43N-m to .47N-m).

• After the display is in place, blow out any particulate with de-ionized gas.

Removing the Front Panel Buttons

This section describes how to remove the front panel buttons.

Note

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Open the monitor (“Opening the Monitor” on page 55).

You do not need to remove the display module to service the front panel buttons. Buttons can be replaced while the display module remains in the front chassis.

3. Remove the Analog board (“Replacing the Analog Board” on page 59).

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Service Manual Repair Procedures 67

4. Remove the Digital board (“Replacing the Digital Board” on page 61).

5. Grasp the Silastic™ gray dome and pull the dome off the button post.

6. Squeeze the plastic button latches together and then push the button out the front of the panel.

0696-34

Note

The button dome can be replaced on the post without regard to the orientation of the notch engraved in the dome.

Replacing the Recharger Board Fuse (F2)

The Recharger board fuse (F2) protects the monitor power supply input at the battery line to the monitor. If the monitor does not turn on but the BATTERY CHARGING indicator lights when the ac power adapter is connected, check fuse F2 (3 Amp).

Caution The fuse is heat sensitive and must be soldered with heat sinks in place between the fuse body and the solder joint.

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Open the monitor (“Opening the Monitor” on page 55).

3. Remove the Recharger board (“Replacing the Recharger Board” on page 72).

4. Replace the fuse (F2 below).

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68 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

D33

Replacing Air Tubing

Replace the NIBP tubing as a single assembly to ensure accurate tubing lengths. Refer to

“Field Replaceable Units (FRUs)” on page 117 for the tubing assembly part number.

Note

If you don’t need to replace the length of tubing between the cuff hose connector in the left side panel and the rest of the tubing assembly, don’t remove the left side panel to disconnect this tube. Leave that length of tubing connected to the side panel but disconnect it from the rest of tubing assembly as indicated by the arrow in the figure below, and replace the tubing assembly.

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Service Manual Repair Procedures 69

Replacing Cables

If you suspect a cable to be faulty, check its continuity on all pins. If you need to replace a cable, refer to “Field Replaceable Units (FRUs)” on page 117 for part numbers..

When removing a cable, be sure to note the routing. It is important that the new cable is routed in the same manner.

P11

P10

0696-37

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70 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Replacing PROMs

Read “Propaq Encore Software” on page 47.

The PROMs require a special removal tool to replace them. (“Required Tools” on page 48.) To prevent damage to the PROM sockets, do not use any other tools.

Caution The PROMs can be damaged by static discharge. Work only at a staticprotected work station.

Do not remove the PROMs from the Analog and Digital board. The following instructions describe how to replace all other PROMs:

• To remove the PROMs, insert the fingers of the PROM removal tool into the slots

at two corners of the PROM and pull out the PROM, while squeezing the legs against the PROM.

• To load the new PROM, align the beveled corner of the PROM with beveled

OUTSIDE corner of the socket. Carefully press the new PROM into place.

Fingers

PROM

Slot

Beveled Corner

Beveled Outside Corner

Slot

1097-02

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Service Manual Repair Procedures 71

Cuff Fittings

Air system integrity in the NIBP system is essential for accurate measurements. Routine wear of the O-ring gasket located in the threaded fitting of the cuff hose can result in air leaks. If you encounter air leaks that cannot be found from the tests in this manual, replace the O-ring first.

WARNING Use of NIBP channel with leaking cuff hose fittings may result in inaccurate noninvasive blood pressure measurements.

1. Disconnect the cuff hose from the monitor.

Knurled

Nut

O-ring

Cuff

Hose

C-Ring

0150-31

2. Using pliers, pull off the metal fitting from the cuff hose.

3. Cut approximately 1/2" off the cuff hose.

4. Using a small screwdriver, remove the C-clip from the fitting.

5. Remove the knurled nut from the fitting.

6. Remove the O-ring gasket and replace it with a new one, being careful not to nick or otherwise damage the new O-ring.

7. Reassemble the fitting with the knurled nut and C-clip.

8. Press the fitting back onto the cuff hose.

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72 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Replacing the Recharger Board

The Recharger board is secured to the rear chassis by four screws. When removing the Recharger board, note the location of cables, plumbing, and screws and screw lengths.

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Open the monitor (“Opening the Monitor” on page 55).

3. Disconnect the air tubing attached to the valves and pump at the junction indicated in this figure.

DISCONNECT PLUMBING AT THIS POINT

4. Disconnect cables P2, P3, P12, and P14 from the Recharger board. Note cable routing for reinstallation.

P15

P12

5. Remove the four screws securing the Recharger board to the rear chassis. Note the screw passing through the pressure transducer is longer than the three that pass through the board only.

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Service Manual Repair Procedures 73

Screws

6. Lift out the Recharger board.

Caution As you set the board in place during installation, keep the board clear of the power switch solder terminals to avoid binding against them. The terminals may become damaged if force is applied against them.

When installing the Recharger board:

• blow out any dust and particulates using pressurized de-ionized gas

• move all cables out of the way

• torque screws to 3.8in-lbs to 4.2in-lbs (.43N-m to .47N-m)

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74 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Replacing the Pump

New wires and a connector are provided with the replacement pump kit.

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Open the monitor (“Opening the Monitor” on page 55).

3. Remove the Recharger board (“Replacing the Recharger Board” on page 72).

4. Unplug the pump cable from the Recharger board.

5. Disconnect the tubing from the pump.

6. Cut the tie wraps securing the pump to the Recharger board.

7. Lift the pump from the board, and remove the old tie wraps from the support brackets.

When installing a pump:

• Slide new tie wraps into support brackets as shown here.

• Set the pump onto the Recharger board.

• Secure the pump to the Recharger board with tie wraps, aligning the fastener

ends as shown in the figure below and cutting off the excess.

• Plug in the pump cable to connector P7 on the Recharger board.

NIBP

Pump

Support

Bracket

Correct

Position of

Tie-wrap

0696-41

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Service Manual Repair Procedures 75

Replacing the Side Panels

The Propaq Encore side panels are complete assemblies.

The side panels are sealed to the rear chassis with an adhesive gasket. A new gasket is provided with the new side panel kit.

Removing the Right Side Panel

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Open the monitor (“Opening the Monitor” on page 55).

3. Remove the Recharger board (“Replacing the Recharger Board” on page 72).

4. Cut and remove the tie wrap securing the bead connected to the side panel.

INSERT SMALL SCREWDRIVER BETWEEN PLASTIC AND CLAMP TO RELIEVE TENSION AGAINST PLASTIC

5. Remove the two right panel clamps by inserting the end of the flat blade screwdriver under the clamp and gently rotating the blade to loosen the clamp. Then slide the clamp out.

6. Press the side panel out of the rear chassis. There is an adhesive gasket around the side panel which requires considerable force to separate. Do not pry against components.

Removing the Left Side Panel

1. Remove the battery pack (“Replacing the Battery Pack” on page 52).

2. Open the monitor (“Opening the Monitor” on page 55).

3. Remove the Recharger board (“Replacing the Recharger Board” on page 72).

4. Remove the U-shaped clamp that secures the left side panel assembly by inserting a small screwdriver between the clamp and plastic and the end of another flat blade screwdriver under the clamp and gently rotating the blade to loosen the clamp. Then slide the clamp out.

0696-42

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76 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

INSERT SMALL SCREWDRIVER BETWEEN PLASTIC AND CLAMP TO RELIEVE TENSION AGAINST PLASTIC

5. Press the side panel out of the rear chassis. There is an adhesive gasket around the side panel which requires considerable force to separate. Do not pry against components.

6. Remove the tubing attached to the cuff hose connector. You can reuse this tubing when installing the new side panel.

Installing the Side Panels

1. Clean all gasket material from the rear chassis where the side panel is to be installed. (The adhesive side of duct tape can be used to pull away old gasket residue.)

2. Attach the tubing to the NIBP cuff hose connector.

3. Route the bundle of cabling with the bead under the temperature connector housing so that when the side panel is installed the connectors will extend out of the rear chassis along the bottom of the chassis.

ROUTE CABLE BUNDLE ALONG BOTTOM OF REAR CHASSIS

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Service Manual Repair Procedures 77

Note

Uncovering the protective paper in the next step exposes the adhesive on the gasket. Do not touch or otherwise contaminate the adhesive, or the adhesive may not properly seal the side panel.

4. On the new side panel, remove the protective paper from the gasket attached to the side panel.

Note

When installing the left side panel in the next step, slightly bend up wires at the P1 and P2 pressure connector pins to allow proper fit.

5. Set the side panel in place.

Make sure the side panel completely sets in place (it should be flush with the exterior of the rear chassis). If not properly fitted, the clamp securing the side panel will not seat.

6. Apply slight pressure to seal the side panel in the rear chassis.

Caution Do not force the clamp in the next step. Forcing it may damage the side panel or rear chassis.

7. Slide the clamp(s) in place with the detent facing the chassis plastic so that it presses against the chassis.

If the clamp requires excessive pressure to slide in place, remove the clamp and check the side panel to be sure it is completely seated.

8. Connect all plumbing and cables.

9. When installing the right side panel, install a new tie wrap to secure the bead to the rear chassis (see figure below).

0696-45

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78 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Expansion Module

The expansion module housing contains one or all of the following:

• printer mechanism with printer main board

• MSP board (units with CO

•CO

•SCP/SpO

•SpO

connector side panel

board (units with printer and SpO2 options)

connector side panel

speaker side panel

• front panel assembly with pushbuttons

• SSP board (units with sidestream CO

• Stick board (units with sidestream CO

• Extender board

option)

)

Note

For specific option configurations, see “Technical Overview” on page 93.

Filler Panel

Front Panel, no SCO2

Front Panel, with SCO2

Printer

Main Housing

SSP Board

SpO2 Connector Panel

CO2 Connector Panel

Printer Door

Extender Board

Stick Board

SpO2 Board

Rear Panel

Speaker Panel

Filler Panel

SCP Board

Expansion Module

Assembly

Components

MSP Board

1097-03

Note

The expansion module does not need to be separated from the monitor to replace the expansion module front panel.

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Service Manual Repair Procedures 79

Opening the Expansion Module Rear Panel

1. Separate the monitor and expansion module (“Removing the Dual Battery in

Expansion Module” on page 53).

Note

For all sidestream CO

options (226, 227, 228, or 229) remove the front panel

(“Replacing the Expansion Module Front Panel” on page 81) and the extender board “Replacing the Extender Board” on page 88 before proceeding with the rear-panel removal.

2. Remove the four screws securing the rear panel to the expansion module chassis.

SCREWS MAY HAVE SPACERS. KEEP SPACERS FOR REASSEMBLY.

0696-68

Caution When disconnecting the expansion cable connector in the next step, note that it has two plastic securing clips that must be separated from the connector. These clips are fragile and should be handled carefully.

3. Separate the rear panel from the chassis a few inches (keep any side panels with the rear), then disconnect the expansion cable connector and the printer cable connector from the circuit board (SCP or MSP board) in the rear panel.

4. Remove the rear panel with the side panels in place.

Note

The rear panel is sealed to the chassis with rubber gaskets around the perimeter of the rear panel. These gaskets can be reused when reassembling the expansion module. Save these gaskets. Also, spacers might not be secured to the rear panel and can fall out. As the unit is disassembled set aside the spacers for reuse during reassembly.

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80 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Closing the Expansion Module

1. Make sure all cables are in place and the gaskets removed earlier are available.

2. Set the rubber gaskets in their proper places as shown in the figure below.

3. Connect the printer cable and expansion cable to the SCP or MSP board.

Gasket

Material

4. Set the chassis onto the rear panel, verifying that the gaskets don’t slip out of a channel and become pinched between the rear panel and the chassis.

Caution To prevent damage to the expansion module chassis, make sure that the spacers are in place. The chassis may crack if screws are tightened without the spacers in place. Note that the 5 upper spacers are not used when the SpO module is present.

5. Torque screws to 4.75 in-lb to 5.25 in-lb (.54 N-m to .59 N-m).

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Service Manual Repair Procedures 81

Replacing the Expansion Module Front Panel

The front panel contains the printer buttons. Like the rear panel, the front is sealed to the chassis with a rubber O-ring gasket. This gasket can be re-used when replacing the front panel.

The expansion module front panel is attached to the chassis with four screws. Use the following procedure to remove the front panel:

1. Remove the four screws (as shown below) holding the front panel.

2. For expansion module options with sidestream CO disconnect the cables from J1 and J3 on the SSP board.

Note

To replace the sidestream CO

Assemblies” on page 88.

assemblies, see “Replacing the Sidestream CO2

(226, 227, 228, or 229),

0696-48

3. Separate the front panel from the chassis, disconnecting the front panel cable from the expansion module button board.

A rubber O-ring gasket seals the front panel to the chassis. This gasket should be saved for re-installing on the front panel.

When installing the expansion module front panel:

• Verify the O-ring gasket is in place and not pinched.

• Torque screws to 6.65in-lbs to 7.35in-lbs (.75N-m to .83N-m)

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82 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Replacing the Expansion Module Button Board and Buttons

The expansion module contains a button board that has electrical contact areas to detect when an expansion module button is pressed. The front panel buttons are similar to the monitor buttons. A plastic button and flexible contact touches the contact area on the button board when a button is pressed.

Use the following procedure to remove the button board and buttons:

1. Remove the expansion module front panel (“Replacing the Expansion Module Front

Panel” on page 81).

2. Remove the two screws securing the button board to the front panel.

3. Remove the button board.

Note

4. To remove each button, gently lift out the rubber portion of the button contact

When installing the button board,

Do not touch the contact areas on the button board or the contact inside the flexible contacts. Touching these areas may deposit oil on them, reducing the ability of the parts to make electrical contact. If you touch these areas, clean them with a cotton swab moistened with isopropyl alcohol.

attached to the inside of the front panel, then squeeze together the stem ends of the button from the inside of the front panel while gently pushing it out of the button channel. See the illustration on page 67.

• make sure all buttons are completely installed

• make sure the rubber button contact is seated onto the channel

• torque screws to 4.75in-lbs to 5.2 in-lbs (.54N-m to .59N-m).

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Service Manual Repair Procedures 83

Replacing the Printer

This section provides instructions on removing and installing the printer mechanism and printer main board. These two components are provided as a replacement unit called the printer assembly.

Caution Do not attempt to separate the printer mechanism from the printer main board. Replace these as a unit.

Removing the Printer

Remove the printer assembly according to the following instructions.

1. Remove any printer paper.

2. Open the Expansion Module (“Opening the Expansion Module Rear Panel” on page 79).

3. Remove the Expansion Module front panel (“Replacing the Expansion Module Front

Panel” on page 81).

4. Disconnect the front panel button cable from the front of the Printer Main board.

Caution When removing the shield in the next step, be careful not to tear it. The shield is held in place by double-sided adhesive pads.

5. Carefully remove the plastic shield from the rear of the Expansion Module chassis. Set this shield aside.

6. Disconnect the battery cable and printer cable from the rear of the Printer Main board.

7. Lay the chassis on its back.

8. Completely open the paper door.

Caution As you remove the printer assembly from the chassis in the next step, rotate the printer door latch mechansim counter-clockwise to clear the chassis.

9. Carefully slide the printer assembly out the front of the chassis. The printer assembly fits snugly, requiring some force to slide it out, and the door latch mechanism must be rotated counter-clockwise after it disengages from the printer door pin.

Door Pin

Print Head Latch

0696-49

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84 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Installing the Printer

1. Lay the chassis on its back

2. Completely open the paper door.

Caution As you install the printer assembly, rotate the printer door latch mechansim out of the way so it clears the chassis. The assembly fits snugly, but should not require much force to slide it in place.

3. Slide the printer assembly into the guides as shown here, making sure that after the door latch mechanism clears the chassis you rotate it clockwise to engage the printer door pin. (See above.)

Guides

4. Carefully close and open the door a couple times to verify that the door pin and latch mechanism function without binding.

5. Connect the battery cable and printer cable to the Printer Main board. It is important to properly dress the cables as shown here.

Battery Cable

(Dress tight against plastic)

Printer

Cable

Battery

Cable

6. Connect the button cable to the front of the Printer Main board.

7. Install the Expansion Module front panel, close the Expansion Module, and reattach it to the monitor.

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Service Manual Repair Procedures 85

Opening the SpO2 Module

1. Separate the SpO2 module from the monitor (“Removing the Dual Battery in SpO2

Module” on page 55).

2. Two tabs secure the SpO small screwdriver or your finger, press on each of the tabs inside the SpO

module rear panel to the SpO2 module chassis. Using a

module

chassis while applying pressure to separate the rear panel from the chassis, as shown here. (When separating the rear panel from the chassis, make sure the side panels remain seated in the rear panel.)

SpO2 Module

Rear Panel

Release

Tabs

Continuous

O-Ring Gasket

3. Once the tabs allow the rear panel to be removed, separate the rear panel from the chassis.

The rear panel is sealed to the chassis with rubber O-ring gaskets. These gaskets can be reused when re-assembling the SpO

module.

SpO2

Connector

Panel

SCP Board

SpO2

Board

Rear

Panel

O-Ring

Cord

Release

Tab (2)

When closing the SpO

module, verify no O-ring gasket slips out of its channel and

becomes pinched between the rear panel and the chassis.

Chassis

Speaker

0696-53

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86 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Replacing the SpO2 Circuit Boards

This describes how to replace the two SpO2 circuit boards in the SpO2 module and in the expansion module without a CO with a CO

option, see “Replacing the MSP/SpO2 Circuit Boards” on page 87.

Caution When replacing the SpO2 circuit boards, remove both circuit boards with the patient connector side panel still connected. Attempting to disconnect the patient connector side panel from the SpO both circuit boards with the side panel can damage the flex-cable between the side panel and the SpO

option. To replace SpO2 boards in an expansion module

circuit board before removing

circuit board.

1. Open the SpO

module (“Opening the SpO2 Module” on page 85) or the expansion

module (“Opening the Expansion Module Rear Panel” on page 79).

Caution In the next step, the connector securing clips are fragile and will break if not handled carefully.

2. Disconnect the cable(s) from the SpO

SCP board by carefully releasing the securing

clips and unplugging the connectors.

3. Disconnect the speaker cable from the SCP board.

4. Remove the speaker side panel from the chassis.

5. Remove the one or two screws securing the SCP board and SpO

board to the rear

panel.

6. Lift out the two circuit boards and patient connector side panel as a unit. (The side panel easily slides out.)

7. Using equal pressure on both sides of the connector, disconnect the patient connector side panel connector from the SpO

circuit board.

8. Disconnect the two circuit boards by gently pulling them apart.

When installing the SpO

• Connect the patient connector side panel connector to the SpO

circuit boards first, plug the two circuit boards together. Then:

circuit board.

• Set the two circuit boards and side panels in place, making sure that the boards

are seated on the support tabs.

• Torque screws to 4.75in-lbs to 5.25in-lbs (.54N-m to .59N-m).

• Reconnect the printer and expansion cables to the SCP board.

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Service Manual Repair Procedures 87

Replacing the MSP/SpO2 Circuit Boards

This describes how to replace the MSP/SpO2 circuit boards in the expansion module with a CO

option. To replace SpO2 boards in the SpO2 module and the expansion module

without a CO

1. Open the expansion module (“Opening the Expansion Module Rear Panel” on page 79).

2. Unplug the flex-cable connector J5 from the MSP board, but do not attempt to remove the mainstream CO

option installed, see “Replacing the SpO2 Circuit Boards” on page 86.

Caution When replacing the MSP/SpO2 circuit boards, remove both circuit boards with the patient connector side panel still connected. Attempting to disconnect the patient connector side panel from the SpO

circuit board before

removing both circuit boards with the side panel can damage the flex-cable between the side panel and the SpO

circuit board.

Caution In the next step, the connector securing clips are fragile and will break if not handled carefully.

connector side panel.

Flexible

Connector J5

Speaker

Cable

3. Disconnect the speaker cable from the MSP board and remove the speaker side panel.

4. Remove the three screws securing the MSP board and SpO

board to the rear panel

(see the figure above).

5. Lift out the two circuit boards and SpO

patient connector side panel as a unit. (The

side panel easily slides out.)

6. Using equal pressure on both sides of the connector, disconnect the patient connector side panel connector from the SpO

circuit board.

7. Disconnect the two circuit boards by gently pulling them apart.

When installing the MSP/SpO

circuit boards:

• plug the two circuit boards together

• connect the patient connector side panel connector to the SpO

circuit board

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88 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

• set the two circuit boards and side panels in place, making sure that the boards

are seated on the support tabs

• torque screws to 4.75in-lbs to 5.25in-lbs (.54N-m to .59N-m)

• reconnect the mainstream CO

patient connector cable

Replacing the Sidestream CO2 Assemblies

The following instructions describe how to replace the sidestream CO2 option assemblies in the expansion module. These include the sidestream processor (SSP) board, the sidestream CO

1. Loosen the expansion module front chassis (“Replacing the Expansion Module Front

Panel” on page 81).

2. Disconnect J1 and J3 from the SSP board to completely separate the front chassis.

Replacing the Extender Board

Remove the extender board from the MSP board through the left card slot in the expansion module.

“Stick” board, and the extender board.

When reinstalling the extender board, observe P6 connector mating while installing through the left card slot to ensure proper connection with the MSP board.

Page 93

Service Manual Repair Procedures 89

Removing the SSP/Stick board assembly:

Caution When servicing the SSP and Stick board assemblies, be sure to note the tubing routing prior to disconnection. Always reassemble tubing exactly as removed.

Stick Board

Retainer

Pressure Transducer

No connection

Retainer

Pump

Water Trap Receiver

Exhaust Port Hole

SSP Board

1097-18

Screws

Pneumatic Reservoir

1097-19

1. Remove the two screws located on the right edge of the SSP board (as viewed from the front).

2. Tilt the loosened right edge of the SSP board assembly (with interconnected Stick board) up, away from the mounting screw posts far enough to allow access to the tubing connections under the board.

3. Disconnect the tubing from the water trap receiver and exhaust port using rounded, non-serrated pliers only. Disconnect the water trap switch connector from J4.

4. Lift the SSP/Stick assembly up and out of the front chassis plastic, clearing all board components from the retaining tabs on the insides of the front chassis plastic as the assembly is removed.

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90 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Removing the Stick board from the SSP board:

1. Disconnect the tubing from the pump and pressure transducer PT2 on the frontfacing side of the SSP board and the pneumatic reservoir on the rear-facing side.

2. Remove the two screws from the front-facing side of the SSP board that secure two slotted nylon Stick board retainers.

3. Pull the Stick board up to free it from connector J7 and remove it from the SSP board. For Stick board replacement purposes, leave all tubing as removed connected to the Stick board.

When reconnecting the Stick and SSP boards:

• reconnect the two boards (connector J7)

• install retainers onto Stick board

• install screws into retainers to secure the Stick board (torque to 2.5 in/lbs.)

• reconnect tubing to the pump, transducer PT2, and the pneumatic reservoir

(route tubing exactly as removed)

When reinstalling the SSP/Stick assembly into the front panel:

• reconnect water trap switch to J4 on the SSP board

• from a vertical position, insert left edge of SSP board into retaining tabs on the

inside of the front panel plastic

• align tubing as originally configured to allow access for connections and to

prevent pinching

• connect tubing to the water trap, using rounded, non-serrated pliers only

WARNING Failure to connect the exhaust post tubing may allow concentration of oxygen inside of the monitor and create a potential explosion risk.

• lower the right side of the SSP/Stick assembly and slide the left side into the

retaining tabs to properly seat the boards into the front panel assembly (check all tubing and cable routing to ensure that none are pinched.

• connect exhaust port tubing, using rounded, non-serrated pliers only

• secure screws through SSP board to front panel (torque to 5.0 in/lbs.)

When reinstalling the front panel on the expansion module:

• connect J1 and J3 to the SSP board

• route printer cable in front of printer motor

• fit front panel to the main expansion module chassis

• secure front panel with four screws (torque to 3.5 in/lbs.)

WARNING To ensure that all tubing is properly connected after servicing SCO2, perform the sidestream functional test (see “Functional Verification” on page 11) when complete.

Page 95

Service Manual Repair Procedures 91

Replacing Expansion Module Side Panels

The side panels easily slide out after the chassis and rear panel are separated. If the patient connector side panel is being replaced, this side panel and the two circuit boards must be removed together before disconnecting the side panel from the circuit board. See “Replacing the SpO2 Circuit Boards” on page 86 or “Replacing the MSP/SpO2

Circuit Boards” on page 87.

If the speaker side panel is being replaced, separate the chassis and rear panel as described earlier in this section, disconnect the speaker from the SCP or MSP board, and slide out the speaker side panel.

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92 Repair Procedures Welch Allyn Propaq Encore Vital Signs Monitor

Page 97

Technical Overview

This section describes the electronics of the Encore monitor and three of its options: Printer, Pulse Oximetry (SpO

This section is intended as an aid to servicing at the field-replaceable unit level and contains only system-level and functional-level circuit descriptions.

When replacing modules or components, refer to “Repair Procedures” on page 47. For part numbers, see “Field Replaceable Units (FRUs)” on page 117.

), and Capnography (CO2).

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94 Technical Overview Welch Allyn Propaq Encore Vital Signs Monitor

System Description

The Encore monitor can be configured as a standalone monitor or with one of two optional housings containing different monitoring and printer options.

Analog Board with Insulator

Shield

Digital

Board

Brackets and

Recharger

Board

Right Side

Panel

Display Module

Front Chassis

Left Side

Panel

Rear

Chassis

Monitor

Rear Chassis

Assembly

Monitor

Front Chassis

Assembly

1097-14

Rear

Panel

SpO

Connector

SCP Board

SpO

Board

SpO

Speaker

Front Panel

SpO2-Only

Module

Option 210

1097-15

The main functional modules (e.g. Analog Board, Recharger Board, Printer, SCP Board, etc.) reside in the housings. The figures on the following pages illustrate the location of the main functional modules in the Propaq Encore monitoring system housings.

The Encore monitor electronics reside on three circuit boards within the monitor housing (front and rear chassis). Additional circuitry for the printer and optional monitoring parameters reside on additional circuit boards housed in the expansion modules.

The Encore system block diagram is shown on page 99.

The Encore electronics consist of the power system, monitoring electronics, and the cuff pneumatics.

Page 99

Service Manual Technical Overview 95

Filler Panel

Rear Panel

Printer

Front Panel, no SCO

Main Housing

Printer Door

SpO2 Connector Panel

SpO2 Board

Filler Panel

Expansion Module

Option 221

printer

1097-04

Rear Panel

Speaker Panel

SCP Board

Front Panel, no SCO

Printer

Printer Door

Expansion Module

Option 223

printer

SpO

1097-05

Page 100

96 Technical Overview Welch Allyn Propaq Encore Vital Signs Monitor

SpO2 Connector Panel

Rear Panel

CO2 Connector Panel

SpO2 Board

Speaker Panel

Main Housing

MSP Board

Expansion Module

Option 224

SpO

MCO

Front Panel, no SCO

1097-06

Printer

Front Panel, no SCO

SpO2 Connector Panel

Main Housing

Printer Door

Connector Panel

SpO2 Board

Rear Panel

08 MSP Board

Expansion Module

Option 225

printer

SpO

MCO

Speaker Panel

1097-07

Welch Allyn Propaq Encore User manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Warnings

Safety Summary

Definitions

Symbols

Overview

Purpose and Scope

Other Applicable Documents

Unpacking Procedure

Warranty Service

Technical Support Services

Recommended Service Intervals

Identifying Propaq Encore Configurations

Self Test and Service Menus

Functional Verification

Introduction

Safety Tests

Functional Verification

Calibration

Introduction

Equipment Needed

Procedures

Setup

Recharger Supply Adjustments

Display Voltage Adjustments

Main Power Supply Adjustments

Calibrating Realtime ECG Out

Non-Invasive Blood Pressure Calibration

EMI Null Adjustment

Invasive Blood Pressure

MSP Board (MCO2) Calibration

Troubleshooting

Introduction

Screen Messages

Non-Recoverable Error Codes

Battery Capacity Check

Repair Procedures

Introduction

Propaq Encore Software

Required Tools

Propaq Encore Options

Field Replaceable Units in the Monitor

Replacing the Power Input Fuse

Replacing the Battery Pack

Opening the Monitor

Closing the Monitor

Replacing the Analog Board

Replacing the Digital Board

Replacing the EL Display Module

Removing the Front Panel Buttons

Replacing the Recharger Board Fuse (F2)

Replacing Air Tubing

Replacing Cables

Replacing PROMs

Cuff Fittings

Replacing the Recharger Board

Replacing the Pump

Replacing the Side Panels

Expansion Module

Replacing the Expansion Module Front Panel

Replacing the Expansion Module Button Board and Buttons

Replacing the Printer

Opening the SpO2 Module

Replacing the SpO2 Circuit Boards

Replacing the MSP/SpO2 Circuit Boards

Replacing the Sidestream CO2 Assemblies

Replacing Expansion Module Side Panels

Technical Overview

System Description