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PCA PLUS AND PLUS II SERIES INFUSERS

1. 7 53 7 3 41 FRONT CASE ASSEMBLY REPLACEMENT 7 53 7 3 42 RUBBER FOOT PAD REPLACEMENT 7 54 Technical Service Manual V LifeCare PCA Plus and Plus II Series Contents Section 8 SPECIFICATIONS 8 1 PCA 8 2 PCA Section 9 PLUS DRAWINGS Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 5 1 Figure 6 1 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Figure 7 9 Figure 7 10 Figure 7 11 Figure 7 12 Figure 7 13 Figure 7 14 Figure 7 15 Figure 7 16 Figure 7 17 Figure 7 18 Figure 7 19 Figure 7 20 Figure 7 21 Figure 7 22 Figure 7 23 Figure 7 24 Figure 7 25 Figure 7 26 Figure 7 27 Figure 9 1 Figure 9 2 LifeCare PCA PI Figures Infuser Slide Assembly 008 and Lower Infuser Slide Assembly 010 and Higher Syringe Low and Syringe Empty Alarm System 008 and Lower Syringe Empty Alarm System 010 and Higher Occlusion Pressure Alarm System 008 and Lower Occlusion Pressure Alarm System 010 and Higher Sample Printer Test ae us Sample Event Log and Malfunction Log Separating Front and Rear Case Assemblies Injector Sensor Switch 008 and Lower Injector Sensor Switch 010 and Higher Vial Sensor Switch and Syringe Low Switch 008 andi Lower Vial Sensor Switch and Syringe Low Switch 010 and ee Syringe
2. Latch Door Lock Door Bracket Spring Extension Latch Door Lock Actuator Door Lock Screw 6 32 x 5 16 Hex Head w Washer Lock Door Latch Pivot Pin Ring Retaining 125 x 015 Thk Insulator LCD Assembly LCD PWA CPU PWA Power Supply Assembly Cable 40 Conductor Technical Service Manual 9 3 LifeCare PCA Plus and Plus II Series Section 9 DRAWINGS Table 9 2 Illustrated Parts Breakdown Index Number Nomenclature Panel Sub Panel Front Case Front Assembly Flange Clamp Arm Lever Mechanism Clip Cradle Cradle Mechanism Cradle Vial Support Vial Knob Right Knob Left Door Front Clear Case Rear Gasket Assembly Battery w Wire Harness Housing Pole Clamp Plunger Pole Clamp Assembly Shaft Knob Retainer AC Power Cord Strap Velcro Hook and Loop Light Gray Assembly Switch Pendant Cordset Hospital Grade Detachable 10 Ft Retainer Power Cord Cover Battery Pad Foam 1 W x 3 in L x 375 Thk Foot Case Rubber LifeCare PCA Plus and Plus Il Series 9 4 Technical Service Manual Table 9 2 Illustrated Parts Breakdown Index Number Nomenclature Assembly Cable D Sub 15 Conductor Module Power 2 Pole w Ground Fuse 25 A 250 V Slo Blo Drawer Fuse 2 Pole Screw
3. HOSPIRA INC Figu igure 9 1 Illustrated Parts Breakdown DRAWING NO NOT APPLICABLE Rev N A Sheet 7 of 16 LifeCare PCA Plus and Plus II Series SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 20 Technical Service Manual R N ALD ine AV US V HOSPIRA INC o 3 o 2 28 o2 oc 55 on iro 2 S 5 eo 2 Rev N A Sheet 8 of 16 DRAWING NO NOT APPLICABLE LifeCare PCA Plus and Plus II Series 9 21 Technical Service Manual SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 22 Technical Service Manual HOSPIRA INC igure 9 1 Illustrated Parts Breakdown Sheet 9 of 16 DRAWING NO NOT APPLICABLE LifeCare PCA Plus and Plus II Series 9 23 Technical Service Manual SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Serie 9 24 Technical Service Manual Technical Service Manual Cas SS Lm HOSPIRA INC
4. 4 Press and hold the patient pendant switch Verify the DMM displays continuity 0 9 and the continuity beeper sounds Note A value of up to Q may be indicated due to patient pendant cable assembly internal resistance 5 Press and hold the patient pendant switch Grasp the patient pendant cable approximately four inches 10 cm above the patient pendant switch and rotate the cable three to four times while bending it approximately 30 degrees Verify the DMM continues to display continuity LifeCare PCA Plus and Plus II Series 5 8 Technical Service Manual PERFORMANCE VERIFICATION TEST 6 Press and hold the patient pendant switch Grasp the patient pendant cable approximately four inches 10 cm above the phone plug and rotate the cable three to four times while bending it approximately 30 degrees Verify the DMM continues to display continuity 7 Release the patient pendant switch Verify the DMM displays infinity maximum resistance 8 Connect the patient pendant cable to the patient control jack Secure the locking nut if applicable 5 2 10 BATTERY CHARGER TEST To perform the battery charger test proceed as follows 1 Disconnect the infuser from AC power Remove the battery cover and disconnect the battery Connect the parallel network to the charging circuit connector Ae wN Connect the infuser to AC power and turn on the infuser Measure voltage across the network The DMM should read 9 4 0 15 VDC 14 5
5. LifeCare PCA Plus and Plus II Series 5 6 Technical Service Manual PERFORMANCE VERIFICATION TEST 7 Observe fluid discharge at the end of the stopcock then close the stopcock 8 Verify the infuser sounds an alarm and flashes the OCCLUSION message when the pressure gauge indicates the following 12 5 17 5 psi 86 25 120 75 kPa 9 Open the stopcock to clear the OCCLUSION alarm 10 Press HISTORY and verify the correct time If the time is incorrect see the System Operating Manual for information on resetting the time 11 Clear all dose history data from memory by holding down OFF RECHG until the LCD screen including the backlighted grid goes blank 5 2 7 PCA CONTINUOUS TEST To perform the PCA CONTINUOUS test proceed as follows 1 Remove the vial from the cradle assembly and set up a standard water filled vial with a 21 gauge butterfly on the distal end of the set CAUTION Do not remove the protective cover from the butterfly needle 2 Insert the vial into the cradle assembly When the LCD screen displays PURGE THE SYSTEM NOW press SILENCE NO 4 When the LCD screen displays DRUG Rx MORPHINE 1 MG ML YES ORNO press YES ENTER 5 When the LCD screen displays ADMINISTER LOADING DOSE NOW press YES ENTER 6 Select loading dose of 1 mg Press YES ENTER then press LOADING DOSE 7 When the LCD screen displays SELECT MODE PCA ONLY press SILENCE NO 8 When the LCD screen displays SELECT MODE CONTINUOUS
6. AC POWER CORD AC POWER CORD RETAINER PLATE Figure 7 13 Rear Case Assembly Components 7 3 5 POLE CLAMP ASSEMBLY REPLACEMENT The recommended tool for this procedure is a No 2 Phillips screwdriver To replace the pole clamp assembly see Figure 7 13 and proceed as follows 1 Place the infuser face down on a soft surface 2 Remove the four 8 32 screws and associated lock washers 3 Remove the pole clamp assembly and install the replacement pole clamp assembly using the screws and lock washers that were removed in Step 2 Replacement of the pole clamp assembly is routine maintenance and no verification procedure is normally required However if the infuser may have been damaged during this procedure perform the PVT in Section 5 2 LifeCare PCA Plus and Plus Series 7 20 Technical Service Manual REPLACEMENT PROCEDURES 7 3 6 VELCRO STRAP AND RETAINER PLATE REPLACEMENT Velcro straps and retainer plates on the rear of the infuser secure the patient pendant and the AC power cord This procedure details the replacement of the Velcro strap and retainer plate in both locations Recommended tools for this procedure are a No 2 Phillips screwdriver and X acto knife To replace the Velcro strap and retainer plate see Figure 7 13 and proceed as follows 1 Remove the two 6 32 screws that attach the Velcro strap and retainer plate to the rear of the infuser then remove the retainer plate and strap Do not discard the strap
7. Reinstall the cradle assembly 10 oO Reassemble the infuser the exact reverse order of disassembly 8 Close and lock the security door To verify successful replacement of the slide clamp lever perform the PVT in Section 5 2 7 3 20 SYRINGE LOW AND SYRINGE EMPTY SWITCH REPLACEMENT The syringe low switch is functional only on PCA Plus Series infusers and does not require replacement on PCA Plus II Series infusers Recommended tools for this procedure are a small flat blade screwdriver No 2 Phillips screwdriver set of nutdrivers soldering iron solder and small cable tie To replace the syringe low or syringe empty switch proceed as follows 1 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Place the front case assembly face down on a soft surface N 008 and lower Using a 1 4 nutdriver or a standard screwdriver remove the two screws from the switch mounting bracket Remove the switch mounting bracket 5 Using a small flat blade screwdriver and 1 4 nutdriver remove the two screws that attach the switches to the mounting bracket 6 Cut and remove the cable tie that secures the switch wires to the wiring harness and unsolder the wires from the switch Note The syringe low switch is mounted next to the mounting bracket and the syringe empty switch is mounted on top of the syringe low switch Technical Service Man
8. 3 Using a small flat blade screwdriver and or 1 4 nutdriver remove the door lock switch from the door latch assembly Unsolder the wires from the door lock switch ol Mount the replacement door lock switch onto the door latch assembly 6 Solder the wires to the terminal of the replacement door lock switch as follows white wire with green and brown stripes to the center terminal white wire with blue and brown stripes to the rear terminal 7 Reassemble the infuser case assemblies in the exact reverse order of disassembly 8 Close and lock the security door To verify successful replacement of the door lock switch perform the PVT in Section 5 2 LifeCare PCA Plus and Plus II Series 7 48 Technical Service Manual REPLACEMENT PROCEDURES DOOR LOCK SWITCH DOOR LATCH TORSION SPRING DOOR LATCH SUPPORT RETAINING RING 2 EXPLODED VIEW ASSEMBLED VIEW Figure 7 24 Door Latch Assembly Type A DOOR LOCK SWITCH DOOR LOCK LATCH RETAINING RING 2 EXTENSION SPRING EXPLODED VIEW ASSEMBLED VIEW Figure 7 25 Door Latch Assembly Type B Technical Service Manual 7 49 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 3 37 DOOR LOCK ASSEMBLY REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver small flat blade screwdriver set of nutdrivers 7 16 box wrench and 7 8 open end wrench To replace the door lock assembly
9. Current is sensed across resistor R62 in the battery charging circuitry of the power supply PWA When current drops below approximately 20 mA the output of U3 B pin 1 which is also the input to comparator U3 A pin 6 is at 100 mV or below Pin 3 of U3 A is referenced at 500 mV from the battery charger circuitry on the power supply PWA Also when current drops below 20 mA U3 A switches to a logic high and turns on transistor Q2 disabling the charging circuit Q1 and Q19 on the power supply PWA Resistor R26 and capacitor C8 act as a noise filter to Q8 4 2 3 2 DC OPERATION When the infuser operates on battery power and the battery drains to approximately 8 VDC pin 4 of the voltage detector U1 switches to logic high this resets the timer U2 enabling transistors Q3 Q4 Q5 Transistor Q6 remains disabled because Ql is disabled Technical Service Manual 4 9 LifeCare PCA Plus and Plus II Series SECTION 4 THEORY OF OPERATION 4 3 MECHANICAL OVERVIEW Mechanical elements of the infuser consist of the slide assembly the syringe low 008 and lower and syringe empty alarm system the occlusion pressure alarm system and the vial and injector sensor alarm system 4 3 1 SLIDE ASSEMBLY The main components of the slide assembly are shown in Figure 4 1 and Figure 4 2 The following sections describe the operation of the slide assembly TOP PLATE LEFT LEAD SCREW CLAMP SPLIT NUT RIGHT LEAD SCREW CLAMP SPL
10. Figure 9 1 Illustrated Parts Breakdown DRAWING NO Hey N A NOT APPLICABLE LifeCare PCA Plus and Plus II Series SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 26 Technical Service Manual HOSPIRA INC igure 9 1 Illustrated Parts Breakdown Sheet 11 of 16 Y fr Ac Amy 22753 e ye DRAWING NOT APPLICABLE LifeCare PCA Plus and Plus II Series 9 27 Technical Service Manual SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 28 Technical Service Manual Sheet 12 of 16 HOSPIRA INC DRAWING NO NOT APPLICABLE LifeCare PCA Plus and Plus II Series Technical Service Manual SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 30 Technical Service Manual Technical Service Manual HOSPIRA INC Figure 9 1 Illustrated Parts Breakdown DRAWING NO Hey N A NOT APPLICABLE ERG MN LifeCare PCA Plus and Plus II Series SECTION 9 DRAWINGS This page intentionally left blank LifeCa
11. Reassemble the infuser in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the motor assembly perform the PVT in Section 5 2 Technical Service Manual 7 35 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 6 32 NUT 2 COUPLING TUBE MOTOR SHAFT MOTOR ASSEMBLY GEAR CASE 6 32 PHILLIPS SCREW 2 SLIDE ASSEMBLY MOUNTING BOLT SLIDE ASSEMBLY MOUNTING BOLT SLIDE ASSEMBLY MOUNTING BOLT MOTOR ASSEMBLY Figure 7 20 Location of Slide Assembly Mounting Bolts LifeCare PCA Plus and Plus II Series 7 36 Technical Service Manual 7 9 25 REPLACEMENT PROCEDURES SLIDE ASSEMBLY REPLACEMENT 008 AND LOWER Recommended tools for this procedure are a 9 64 Allen wrench No 2 Phillips screwdriver set of nutdrivers and grease To replace the slide assembly see Figure 7 20 then proceed as follows l 2 3 10 11 12 13 14 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Remove the following components using the procedures described in their corresponding sections Slide clamp knobs and levers Section 7 3 18 Cradle assembly Section 7 3 16 Vial sensor switch Section 7 3 17 Syringe low and syringe empty switches Section 7 3 20 Occlusion pressure switch Section 7 3 21 Using a 5 16 nutdriver remove the three bolts
12. see Figure 4 4 The motor case attaches to the gearbox The gearbox consists of reduction gears that provide a 50 to 1 reduction in the rotation of the motor shaft The reduction gears drive the lead screw Fifty revolutions of the motor produce one revolution of the lead screw The stepper motor receives its commands 1 MOTO2 from motor drivers the power supply PWA The MOTO1 MOTO2 MOTOS and MOTO4 commands are issued by the PPI U7 under control of the microprocessor on the CPU display PWA Data buffer U4 on the CPU display PWA inputs signals from the touchswitches on the infuser front panel The touchswitch signals represent delivery data placed on the microprocessor data bus by U4 DO through D7 when U4 is gated by the ANDed product of the bus read command BRD and chip select signal CS6 Digitized delivery data is interpreted by the microprocessor according to the program in EPROM The data provides the stepper motor commands for the delivery data set up by the touchswitches Technical Service Manual 4 11 LifeCare PCA Plus and Plus II Series SECTION 4 THEORY OF OPERATION A reduced diameter extension of the gear box shaft protrudes through the bottom of the gearbox this extension is flattened to allow an opto switch mounted on a bracket on the motor case to sense rotation of the lead screw The opto switch senses the flattened area of the extension For each rotation of the lead screw
13. Locate the plastic fuseholder directly above the AC power receptacle Insert a small flat blade screwdriver between the locking tab at one end of the fuseholder and the infuser housing Press the tab toward the center of the fuseholder to release it The fuseholder will move slightly outward when released from the one side Repeat Step 4 to release the other locking tab The spring loaded fuseholder will release and move outwards Grasp both locking tabs and remove the fuseholder from the receptacle Remove the fuse and replace with an approved fuse only see Section 8 Do not use any other fuse types Insert the fuseholder into the receptacle then press the fuseholder against the locking tabs until it clicks into position Reconnect the AC power cord to the infuser AC power receptacle Reinstall the AC power cord retainer plate with the screw that was removed in Step 2 To verify successful replacement of a fuse perform the PVT in Section 5 2 Technical Service Manual 7 19 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS AUDIBLE LEVEL SWITCH PRINTER DATAWAY PATIENT PENDANT JACK CONNECTOR 6 32 x 1 4 PAN HEAD PHILLIPS SCREW 4 PATIENT PENDANT VELCRO STRAP RETAINER PLATE POWER CORD VELCRO STRAP RETAINER PLATE POLE CLAMP ASSEMBLY FINAL ASSEMBLY NUMBER TEST CONNECTOR 8 32 x 5 8 FLAT HEAD PHILLIPS SCREW 4 10 32 x 3 3 16 FLAT HEAD SCREW 4 FUSEHOLDER
14. Q9 and associated logic transistors Q3 Q4 95 Q6 AC detector transistor Q1 The battery boost charger PWA functions during infuser AC power and battery power operation as described in the following sections 4 2 3 1 AC OPERATION Voltage detector 01 with associated capacitors and resistors functions as a window comparator with hysteresis When the battery is initially connected the output of U1 is at logic high After the battery voltage reaches 10 VDC the output of U1 goes low disabling transistors Q3 and Q4 and triggering the timer U2 The clock frequency of U2 is determined by C5 and R9 time out is pending the biasing of the U2 program inputs A B C and D Upon time out the DECODE signal on output pin 13 of U2 goes high this signal disables Q5 removes the supply to Q9 and causes battery charging to stop The DECODE signal also locks in U2 preventing operation by placing a logic high on the SET input pin 1 of U2 The AC DC detector consists of transistor Q1 and associated resistors When the infuser operates on AC power the collector of Q1 is at logic low enabling timer U2 and transistor Q6 During DC operation the VRDC signal is at ground level and keeps Q1 off Current is limited to 200 mA by the quotient of the VBE of transistor Q8 divided by R17 Transistor Q7 acts as a power switch that is enabled and disabled by transistor Q9 The IC U3 B acts as a differential amplifier with a gain of 20 decibels dB
15. SWITCH MONITOR VIAL BATTERY SWITCH PRINTER PRINTER BUFFER OUTPUT POWER INJECTOR MAINS SWITCH POWER FRONT PANEL SWITCHES PRESSURE LIMIT SWITCH SYRINGE LOW SWITCH READ ONLY MEMORY LCD DISPLAY SYRINGE EMPTY SWITCH WATCHDOG ADDRESS BUS PATIENT RANDOM PENDANT ACCESS i ANALOG MEMORY DIGITAL REAL TIME HE CONVERTER CLOCK SUPPLIES Technical Service Manual 9 39 HOSPIRA INC Figure 9 2 Block Diagram DRAWING NO Rev N A NOT APPLICABLE Sheet 1 of 1 LifeCare PCA Plus and Plus II Series SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 40 Technical Service Manual Section 10 INDEX Numerics 15 conductor diagnostic cable replacement 7 28 40 pin ribbon cable replacement 7 27 8255 programmable peripheral interface 4 8 A AC operation 4 9 AC power cord replacement 7 23 Acronyms and abbreviations 1 2 Adjustment procedures 7 1 Door lock switch adjustment 7 17 Injector sensor switch adjustment 7 4 LCD intensity adjustment 7 15 Lead screw lubrication 7 18 Occlusion alarm switch test and adjustment 7 11 Required tools and materials 7 2 Safety and equipment precautions 7 1 Separating front and rear case assemblies 7 2 Setting the real time clock 7 16 Syringe empty switch adjustment 7 9 Syringe low switch adjustment 7 8
16. and approximately one inch of 1 8 inch shrink tubing To replace the interconnect PWA see Figure 7 22 and proceed as follows 1 2 3 10 11 12 13 Disconnect the infuser from power Separate the front and rear case assemblies as described in Section 7 2 3 Disconnect the interconnect PWA cable from J10 the interconnect PWA and J8 on the power supply PWA Using a 5 16 nutdriver remove the nut that attaches the green ground wire to the control panel Using wire cutters cut the two wires that connect the door lock switch to the interconnect PWA Cut the wires between the interconnect PWA and the cable clamps mounted to the rear case Remove the eight Phillips screws that attach the control panel and interconnect PWA to the rear case Remove the control panel and interconnect PWA Install the replacement control panel and interconnect PWA using the eight Phillips screws that were removed in Step 6 Using wire strippers strip approximately 1 2 inch of insulation from the two wires that connect the door lock switch to the interconnect PWA Slip one inch of 1 8 inch shrink tubing over the door lock switch wires Solder the wires to the corresponding wires on the interconnect PWA Slip the shrink tubing over the solder joint and shrink in place Attach the green ground wire that was removed in Step 4 Connect the interconnect PWA cable that was disconnected in Step 3 Reassemble the case assemblies
17. and proceed as follows 1 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Remove the slide clamp knobs levers as described in Section 7 3 18 Remove the cradle assembly as described in Section 7 3 16 Remove the slide assembly as described in Section 7 3 25 Q a A CQ DN Remove the two 7 64 Allen screws that attach the motor gear case to the slide assembly then remove motor assembly Note A coupling tube and a coupling clip come off with the motor assembly 7 Place the coupling clip inside the coupling tube and install both parts on the motor gear case shaft 8 Line up the flats of the lead screw and the motor gear case shafts Press the motor assembly onto the lead screw shaft If necessary move the motor assembly fron side to side until the coupling pin engages the flats of the lead screw and motor gear case shafts When the motor assembly is flush against the bottom of the slide align the motor gear case holes with the holes tapped in the bottom of the slide 9 Reinstall the two screws that were removed in Step 6 10 Reassemble the infuser in the exact reverse order of disassembly 11 Close and lock the security door To verify successful replacement of the motor assembly perform the PVT in Section 5 2 VIEW OF COUPLING CLIP POSITIONED INSIDE COUPLING TUBE COUPLING TUBE COUPLING CLIP MOTOR SHAFT MOTOR ASSEMBLY GEAR CA
18. connect the infuser to AC power for 24 hours Note When plugging the device into an AC power outlet grasp the AC power cord plug and use a forward motion into the socket Do not use a sideways motion When unplugging the device grasp the AC power cord plug and pull straight out Do not pull out using the power cord cable and do not pull out at an angle AN CAUTION Do not place the infuser in service if the self test fails To perform the self test proceed as follows 1 Unlock and open the security door 2 Connect the AC power cord to a properly grounded AC outlet Confirm that the AC power symbol on the front panel is illuminated 3 Press and release the ON touchswitch The infuser performs a self test verifying its functional integrity If the infuser fails the self test contact Hospira 4 PCA Plus II only Set the real time clock as described in Section 7 2 9 Technical Service Manual 1 5 LifeCare PCA Plus and Plus II Series SECTION 1 INTRODUCTION This page intentionally left blank LifeCare PCA Plus and Plus II Series 1 6 Technical Service Manual Section 2 WARRANTY Subject to the terms and conditions herein Hospira Inc hereinafter referred to as Hospira warrants that the product shall conform to Hospira s standard specifications and be free from defects in material and workmanship under normal use and service for a period of one year after purchase and b the replaceable battery shall be f
19. of programming the infuser The infuser must be programmed before it will operate Technical Service Manual 4 1 LifeCare PCA Plus and Plus II Series SECTION 4 THEORY OF OPERATION 4 1 3 DELIVERY MECHANISM The delivery mechanism is actuated by a four phase stepper motor that controls delivery and constantly monitored by the infuser electronics 41 4 PATIENT CONTROLLED ANALGESIA When the infuser is operating in either the PCA or the PCA CONTINUOUS modes the patient can initiate a request for analgesia by pressing the patient pendant pushbutton The patient request is answered based on the status of the lockout interval and the four hour dose limit A dose is delivered only if the lockout interval has expired and the four hour dose limit has not been reached Timing of the lockout interval and the four hour dose limit is programmed by the medical professional and is maintained by the central processor unit CPU The four hour dose limit is the maximum PCA dose deliverable by the infuser in any rolling four hour period Note The PCA Plus II will not discontinue an individual dose upon reaching the four hour dose limit The dose continues until completion 41 5 STATUS MESSAGES Infuser status is displayed on the LCD screen during normal operation Status messages are listed in Table 4 1 Table 4 1 Status Messages and Definitions Message Definition DOOR LOCKED Displays for 30 seconds when the security door is closed and loc
20. the battery Transistor Q1 gates the unregulated voltage to U9 and U10 which are 5 VDC regulators for the logic power and motor power Operational amplifier U3 monitors the unregulated voltage and provides DISBATT and LOBAT signals to U11 The DISBATT and LOBAT signals are derived from two voltage thresholds produced from a precision resistor network Technical Service Manual 4 7 LifeCare PCA Plus and Plus II Series SECTION 4 THEORY OF OPERATION 4 2 2 3 ON OFF LATCH Unregulated DC voltage is present in the power supply when either AC or battery power is available A supply of 5 VDC is available from the unregulated DC voltage by precision voltage references U5 and U6 The voltage powers U13 and U14 which make up the ON OFF latch The ON OFF latch is a set reset flip flop set by the injector or vial switches being closed or by the ON touchswitch being pressed The output of the ON OFF latch drives the gate of Q5 Q5 drives the base of Q1 that connects the 5 VDC logic and motor regulators with the unregulated DC voltage Gates from U13 and U14 prevent the OFF RECHG touchswitch from resetting the ON OFF latch when a malfunction is being reported via the MALF line 4 2 2 4 PRINTER DATA LATCH The printer data latch latches data from U11 to send out of the printer port as printer data 4 2 2 5 MOTOR DRIVER The gates of U17 drive transistors Q9 through Q6 from the 8255 port A outputs and are disabled by MALF preventing
21. the supply voltage applied to the ADC 4 2 1 5 LCD INTERFACE The LCD subassembly connects to the system data bus address bits Al through AO and an I O chip select The LCD background lighting is provided by an electroluminescent panel EL powered by a DC to AC converter at U17 The converter converts the 5 VDC to approximately 90 VAC The background lighting is turned off by disabling transistor Q2 two minutes after a touchswitch is pressed or 30 seconds after the door is locked The viewing angle is set to provide maximum contrast by adjusting potentiometer R19 Potentiometer R19 is factory adjusted to give maximum contrast at a viewing angle perpendicular to the LCD screen U10 a DC to DC converter provides 5 VDC to allow a full 10 volt adjustment range of R19 4 2 1 6 LED DISPLAY CIRCUIT The LEDs are driven on a time multiplexed basis The pattern of segments to be illuminated is latched into 014 by U11 During the same CPU cycle the seven segment LED that displays the pattern is enabled by address bits written to the latch at U2 that is buffered by U3 The anodes of the single LED that provides the decimal point and the LED array that illuminates the battery symbol are illuminated by the DP signal from the U14 latch Information represented by the DP signal is displayed by the decimal point when itis enabled with the tenths display and by the battery LED when it is enabled with the units display 4 2 1 7 WATCHDOG CIRCUIT
22. 2 VDC with a battery boost charger PWA Note See Section 4 2 3to identify infuser configurations with a battery boost charger PWA 5 Remove the parallel network Reconnect and re install the battery Confirm the battery wires are not pinched 6 Re install the battery cover 5 2 11 ELECTRICAL SAFETY TEST Note The electrical safety test must be performed in accordance with the instructions contained in the safety analyzer user s guide To perform the electrical safety test see Table 5 4 and proceed as follows 1 Connect the infusion system AC mains power cord to a safety analyzer 2 Check the leakage current with the safety analyzer Leakage current must not exceed specifications in Table 5 4 3 Measure the resistance of the AC mains connector ground lug with the safety analyzer Resistance should not exceed specifications in Table 5 4 4 Connect the device to AC power and confirm the AC indicator is lit Technical Service Manual 5 9 LifeCare PCA Plus and Plus Series Section 5 MAINTENANCE AND SERVICE TESTS Table 5 4 Electrical Safety Measurements Measurement Not to Exceed Enclosure leakage current normal condition ground intact 300 mA Enclosure leakage current open neutral 500 mA Earth leakage current ground intact 500 mA Earth leakage current open neutral 1000 mA Chassis ground resistance cord connected 0 20 5 2 12 PRINTER TEST To perform the printer test
23. 809 47216 7 2 11 DOOR LOCK SWITCH ADJUSTMENT 7 17 7 2 12 LEAD SCREW LUBRICATION 748 7 5 REPLACEMENT PROCEDURES cR ec ee 78 7 3 1 SAFETY AND EQUIPMENT PRECAUTIONS a 7 3 2 REQUIRED TOOLS AND MATERIALS 7 19 7 8 5 BATTERY REPLACEMENT 7 19 7 34 FUSE REPLACEMENT oo be gd Se D cee yd ee 0 o3 ey 7 20 7 3 5 POLE CLAMP ASSEMBLY REPLACEMENT 29 335 0854 21 7 3 6 VELCRO STRAP AND RETAINER PLATE REPLACEMENT dw 722 7 3 7 SECURITY DOOR REPLACEMENT e 7 22 7 3 7 1 SECURITY DOOR LATCH REPLACEMENT dee uuo 7 23 7 3 8 PATIENT PENDANT ASSEMBLY REPLACEMENT 7 23 7 3 9 AC POWER CORD REPLACEMENT 7 23 7 3 10 GASKET SEAL REPLACEMENT a 7 24 7 3 11 POWER SUPPLY PWA REPLACEMENT 7 24 7 3 12 CPU DISPLAY PWA REPLACEMENT ee 7 25 73121 LED REPLACEMENT 7 26 7 3 13 LCD ASSEMBLY REPLACEMENT 7 26 7 3 14 40 PIN RIBBON CABLE REPLACEMENT 27 wr 7227 7 3 15 15 CONDUCTOR DIAGNOSTIC CABLE REPLACEMENT e s 7 28 7 3 16 CRADLE ASSEMBLY REPLACEMENT 7 29 7 3 17 VIAL SENSOR SWITCH REPLACEMENT sod xod aa ve 7 90 7 3 18 SLIDE CLAMP KNOB AND LEVER REPLACEMENT 008 AND LOWER e 7 30 7 3 19 SLIDE
24. ACTIONS The infuser will stop delivery when any of the following alarms occur CHECK VIAL CHECK INJECTOR CHECK SYRINGE EMPTY SYRINGE OCCLUSION MALFUNCTION These alarms their possible causes and corrective actions are detailed in Table 6 2 6 3 3 MALFUNCTION CODES Table 6 1 describes the malfunction codes as they appear when an alarm sounds and MALFUNCTION appears on the LCD screen Table 6 1 Malfunction Codes Malfunction Corrective Action MALF line went low and could not return to normal Replace CPU display PWA MALF line went low and could not return to normal Replace CPU display PWA MALF line did not go low soon enough after power up Replace CPU display PWA Malfunction line went high too soon Replace CPU display PWA Watchdog circuit failure during real time operation Replace CPU display PWA Power up diagnostic failed Replace CPU display PWA Technical Service Manual 6 3 LifeCare PCA Plus and Plus II Series Section 6 TROUBLESHOOTING Table 6 1 Malfunction Codes Malfunction Nonvolatile RAM checksum test failed Corrective Action Replace CPU display PWA Motor failed to rotate Lubricate lead screw Replace power supply PWA Replace motor assembly MOTOR BAD signal from motor driver circuitry Replace power supply PWA Replace motor assembly LCD timeout error Replace CPU display PWA LCD data readback error Replace CPU display PWA Nonvolatile RA
25. ALARM SYSTEM Note Software version 3 1 and higher deactivates the syringe low switch A syringe status microswitch mounted to the slide assembly provides a signal to the power supply PWA when activated by the downward movement of the cradle assembly see Figure 4 3 and Figure 4 4 When activated the syringe empty switch sends the SYRINGE EMPTYSW signal to data buffer U8 on the power supply PWA Data buffer U8 places switch status data on the microprocessor data bus as data bits D1 and D2 for processing by the CPU Display PWA microprocessor when the buffer is gated by SWSTSEL On infusers with final assembly number 008 and lower two bracket arms attach to the slide block two syringe status microswitches mount on a bracket attached to the base of the slide assembly The two bracket arms are oriented to the switches so that downward movement of the slide block causes the bracket arms to press against actuator arms on the switches The inner microswitch the syringe low switch is closed first by the longer innermost arm sending the SYRINGE LOSW signal to the power supply PWA Further downward movement causes the shorter of the two bracket arms the outer arm to press the actuator arm on the outer switch the syringe empty switch that sends the SYRINGE EMPTYSW signal to the power supply PWA LifeCare PCA Plus and Plus II Series 4 12 Technical Service Manual 4 3 MECHANICAL OVERVIEW Note Later configurations of 008 and lowe
26. CLAMP LEVER REPLACEMENT C 010 AND HIGHER Siue cw 7 92 7 3 20 SYRINGE LOW AND SYRINGE EMPTY SWITCH REPLACEMENT 7 32 7 3 21 OCCLUSION PRESSURE SWITCH REPLACEMENT 7 33 7 3 22 INJECTOR SENSOR SWITCH REPLACEMENT joue a 2575 28 7 3 23 MOTOR ASSEMBLY REPLACEMENT 008 AND LOWER Sp ist d Au 550539 7 3 24 MOTOR ASSEMBLY REPLACEMENT 010 AND HIGHER 7 36 7 3 25 SLIDE ASSEMBLY REPLACEMENT 008 AND LOWER 7 38 7 3 26 SLIDE ASSEMBLY REPLACEMENT 010 AND HIGHER 7 39 7 3 27 INJECTOR FLANGE CLAMP REPLACEMENT e 5 7 40 7 3 28 PRINTER DATAWAY CONNECTOR AND CONTROL PANEL HARNESS REPLACEMENT satel Sse SP 0 re y uo ur 7540 7 3 29 PIEZOELECTRIC ALARM REPLACEMENT 2 We 2 27342 7 3 30 PATIENT PENDANT JACK REPLACEMENT 7 43 7 3 31 AUDIBLE LEVEL SWITCH REPLACEMENT 7 44 7 3 32 INTERCONNECT PWA REPLACEMENT 7 45 7 3 33 INTERCONNECT PWA CABLE REPLACEMENT 7 46 7 3 34 BATTERY BOOST CHARGER PWA REPLACEMENT 7 47 7 3 35 FRONT PANEL REPLACEMENT 7 47 7 8 56 DOOR LOCK SWITCH REPLACEMENT 7 48 7 3 37 DOOR LOCK ASSEMBLY REPLACEMENT 7 50 7 3 38 CHANGING THE KEY NUMBER E SC oe Sho Ee pg 5L 7 3 39 DOOR LATCH ASSEMBLY REPLACEMENT eds geh ust xe ax en us vei ed 7 3 40 REAR CASE ASSEMBLY REPLACEMENT
27. Empty Switch 008 and Lower Syringe Empty Switch 010 Higher Occlusion Alarm Test Setup Occlusion Alarm Pressure Adjustment 008 and Lower Occlusion Alarm Pressure Adjustment 010 and Higher CPU Display PWA LED and LCD Battery Replacement ear Rear Case Assembly Components 2 Power Supply PWA and CPU Display PWA 15 Conductor Diagnostic Cable a Cradle Assembly Replacement Location of Slide Clamp Handle Allen Bciews 008 and Lower Motor Assembly Replacement 008 and Lower Motor Assembly Replacement 010 and Higher Location of Slide Assembly Mounting Bolts Printer Dataway Connector Control Panel Harness and Piezoelectric Alarm Interconnect PWA and Battery Boost Charger PWA Replacement Front Panel Replacement Door Latch Assembly Type A Door Latch Assembly Type B Door Lock Assembly Door Latch Torsion Spring Placement Type A Illustrated Parts Breakdown Block Diagram us and Plus Il Series vi 8 1 8 1 8 2 9 1 4 10 4 11 4 13 4 14 4 15 4 16 5 11 6 2 7 3 7 5 7 5 7 7 7 7 7 10 7 10 7 12 7 13 7 15 7 16 7 20 7 21 7 25 7 28 7 29 7 31 7 35 7 37 7 37 7 42 7 46 7 48 7 49 7 49 7 50 7 52 9 7 9 39 Technical Service Manual Table 1 1 Table 4 1 Table 4 2 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 6 1 Table 6 2 Table 6 3 Table 6 4 Table 9 1 Table 9 2 Tables Convention
28. Technical Service Manual REPLACEMENT PROCEDURES 7 3 38 CHANGING THE KEY NUMBER Note This procedure is applicable only to locks with the numbers 1 through 8 engraved on the lock face Recommended tools for this procedure are a master key black and keys numbered 2 through 8 To change a key number proceed as follows 1 Remove the door lock cylinder as described in Section 7 3 37 2 Completely insert the master key black into the keylock assembly at position 1 Confirm the longer wing of the master key is positioned upward 12 o clock 3 Turn the master key clockwise to the new key number position 4 Remove the master key from the keylock assembly 5 Completely insert the new position combination key into the keylock assembly Confirm an audible click sounds 6 To confirm the keylock is set correctly insert the key and lock then unlock the security door 7 If the key does not unlock the security door reinsert the master key into the keylock with the longer wing positioned at the new key number position 8 Turn the master key counterclockwise to position 1 Repeat Steps 3 through 5 9 Tag the PCA infuser with the new key number 10 Reassemble the infuser in the exact reverse order of disassembly then perform the PVT in Section 5 2 7 3 39 DOOR LATCH ASSEMBLY REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver small flat blade screwdriver set of nutdrivers 7 16 box wr
29. The replacement Velcro strap does not have holes for mounting screws Holes must be cut at the time of installation 2 Place the replacement Velcro strap with fuzzy side down on the work surface Place the retainer plate on the strap in the exact location as on the old strap Use the retainer plate as a template to mark hole locations on the strap 3 Using an X acto knife cut holes in the replacement strap at the marked locations 4 Inspect the retainer plate and replace if required 5 Install the replacement strap and retainer plate using the screws that were removed in Step 1 Replacement of the Velcro strap and retainer plate is routine maintenance and no verification procedure is normally required However if the infuser may have been damaged during this procedure perform the PVT in Section 5 2 7 3 7 SECURITY DOOR REPLACEMENT The recommended tool for this procedure is a No 2 Phillips screwdriver To replace the security door proceed as follows 1 Unlock and completely open the security door approximately 270 degrees to reveal four mounting screws 2 Using a Phillips screwdriver remove the screws and the door 3 Attach the replacement door using the screws that were removed in Step 2 4 Close and lock the security door Confirm the door aligns with the door latch assembly and that the door is locked Replacement of the security door is routine maintenance and no verification procedure is normally required Ho
30. UNREGULATED DC VOLTAGE 4 2 2 3 ON OFF LATCH 5 4 2 2 4 PRINTER DATA LATCH 4 2 2 5 MOTOR DRIVER 4 2 2 6 8255 PROGRAMMABLE PERIPHERAL INTERFACE 4 2 3 BATTERY BOOST CHARGER 4 2 3 1 ACOPERATION 4 2 3 2 DCOPERATION MECHANICAL OVER VIEW 4 3 1 SLIDE ASSEMBLY 4 3 11 MOTOR ASSEMBLY 4 31 2 SLIDE MECHANISM 4 3 13 CRADLE ASSEMBLY Contents 1 1 1 2 1 2 1 4 1 4 1 4 1 4 1 5 2 1 3 1 4 1 4 1 4 1 4 1 4 1 4 1 4 2 4 2 4 2 4 3 4 3 4 4 4 4 4 5 4 6 4 6 4 6 4 6 4 7 4 7 4 7 4 8 4 8 4 8 4 8 4 8 4 9 4 9 4 10 4 10 4 11 4 12 4 12 LifeCare PCA Plus and Plus II Series Contents 4 3 2 SYRINGE LOW AND SYRINGE EMPTY ALARM SYSTEM 4 3 3 OCCLUSION PRESSURE ALARM SYSTEM 43 4 VIAL AND INJECTOR SENSOR ALARM SYSTEM 4 3 4 1 CHECK VIAL ALARM 4 3 4 2 CHECK INJECTOR ALARM 4 3 4 3 CHECK SYRINGE ALARM Section 5 MAINTENANCE AND SERVICE TESTS 5 1 ROUTINE MAINTENANCE EE 5 11 CLEANING AND SANITIZING 5 2 PERFORMANCE VERIFICATION TEST 5 2 1 EQUIPMENT REQUIRED 5 2 2 INSPECTION A 5 2 3 TEST SETUP 5 2 4 SERVICE TEST MODE TESTS 5 2 5 DELIVERY ACCURACY TEST 5 2 6 OCCLUSION TEST EE 5 2 7 CONTINUOUS TEST 5 2 8 PATIENT CONTROL JACK TEST 5 2 9 PATIENT PENDANT ASSEMBLY TEST 5 2 10 BATTERY CHARGER TEST 5 2 11 ELECTRICAL SAFETY TEST 5 2 12 PRINTER TEST 5 213 END OF THE 5 3 PERIODIC MAINTENANCE INSPECTION 5 4 BATTERY OPERATION
31. Vial sensor switch adjustment 7 6 Alarm and display message overview 6 2 Alarm causes and actions 6 3 Alarm messages fault symptoms 6 5 Audible alarms 6 3 Malfunction codes 6 3 Alarm causes and actions 6 3 Alarm messages fault symptoms 6 5 Analog to digital converter 4 6 Artifacts 1 4 Audible alarms 6 3 Audible level switch replacement 7 44 B Battery boost charger PWA 4 8 Replacement 7 47 Battery charger test 5 9 Battery operation overview 5 12 Battery replacement 7 19 Technical Service Manual Changing the key number 7 51 Check injector alarm 4 17 Check syringe alarm 4 17 Check vial alarm 4 16 Chip select circuitry 4 5 Cleaning and sanitizing 5 1 Cleaning solutions 5 2 Cold start sequence 4 1 Contact Hospira 6 1 Conventions 1 2 CPU display PWA 4 3 Replacement 7 25 System interfaces 4 4 Cradle assembly 4 12 Replacement 7 29 D DC operation 4 9 Delivery accuracy test 5 6 Delivery mechanism 4 2 Diagnostic mode 6 1 Door latch assembly replacement 7 51 Door lock assembly replacement 7 50 Door lock switch Adjustment 7 17 Replacement 7 48 Drawings 9 1 E Electrical safety test 5 9 Electronics overview 4 3 Battery boost charger PWA 4 8 CPU display PWA 4 3 Power supply PWA 4 7 End of the PVT 5 12 Equipment required 5 3 F Front case assembly replacement 7 53 Front panel replacement 7 47 Fuse replacement 7 20 LifeCare PCA Plus and Plus II Series Se
32. address bits AO through 14 to read from or write to the system data bus data bits DO through D7 Read and write operations are controlled by the BRD and BWR signals derived from the CPU RD and WR signals LifeCare PCA Plus and Plus Series 4 4 Technical Service Manual 4 2 ELECTRONICS OVERVIEW U21 is mounted on a socket that contains a lithium battery a voltage monitor chip and a real time clock chip The lithium battery is used to retain the data stored in RAM during short periods of infuser power loss The voltage monitor chip monitors the power supplied to the socket and connects the lithium battery to the real time clock chip if the logic power supply shuts down U22 is a 32K x 8 EPROM that stores the infuser software program U22 places firmware instructions on the system data bus according to the status of address lines AO through A15 when enabled by the PSEN signal from the CPU The octal tri state bus receiver U12 and the octal D type transparent latch U13 provide an interface between the CPU and the system data and address busses U12 and U13 connect to the CPU lines ADO through AD7 U12 uses ADO through AD7 as a data interface between the CPU and the system data bus DO through D7 transmitting data to and receiving data from the various components throughout the system that connect to the data bus U13 latches in these lines and uses them with CPU lines AD8 through AD15 for the system address bus consisting
33. after all parameters are entered Adjust the door latch mechanism Replace the door lock switch OCCLUSION Technical Service Manual Kinked or otherwise occluded tubing occluded venipuncture device or closed slide clamp Occlusion pressure out of calibration 6 5 Open the security door Relieve back pressure by squeezing and releasing the cradle release handles Adjust occlusion pressure Replace the occlusion pressure switch LifeCare PCA Plus and Plus II Series Section 6 TROUBLESHOOTING Alarm Message Fault Symptom INFUSER IN RESET Message also appears after an alarm condition has been cleared Table 6 2 Alarm Messages Fault Symptoms Possible Cause RESET START touchswitch pressed when the security door is locked in CONTINUOUS or PCA CONTINUOUS mode and delivery is in progress Corrective Action Press RESET START to resume delivery LOW BATTERY flashing battery symbol Battery is near discharge level Connect the infuser to AC power No battery operation or short operating time to LOW BATTERY alarm Battery not fully charged Battery is defective or has exceeded useful life Recharge battery for 16 hours Test the battery charger circuit If the test passes replace the battery Ifthe test fails replace the power supply PWA Replace the battery No AC or battery operation Blown fuse Defective power supply PWA Replace the fuse Measure AC vol
34. assembly 6 Unsolder the two wires from the vial sensor switch 7 Solder wires to the replacement switch as follows red wire to lower switch terminal common white wire to center N O terminal 8 Replace the cradle clip removed in Step 5 9 Install the replacement vial sensor switch Mount the switch using the two screws that were removed in Step 4 10 008 and lower Mount the switch bracket to the slide assembly 11 Adjust the vial sensor switch as described in Section 7 2 5 as applicable 12 Reassemble the infuser in the exact reverse order of disassembly 13 Close and lock the security door To verify replacement of the vial sensor switch perform the PVT in Section 5 2 7 3 18 SLIDE CLAMP KNOB AND LEVER REPLACEMENT 008 AND LOWER Recommended tools for this procedure are a 3 32 Allen wrench No 2 Phillips screwdriver and set of nutdrivers To replace the slide clamp knob and lever see Figure 7 17 and proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3 3 Move the cradle to the top of its travel path Using a 3 32 inch Allen wrench remove the two Allen screws and lock washers that secure the lever of the left slide clamp knob Note Infusers with final assembly numbers 010 and higher do not contain slide clamp handle Allen screws Technical Service Manual 7 29 LifeCare PCA Plus and Plus II Series Section 7
35. diode LED displays five seven segment LEDs one single LED and two multi LEDs along with driving multiplexing and monitoring components Eight channel analog to digital converter that monitors the 5 VDC power supply the 2 5 VDC precision voltage reference used to regulate the 5 VDC supply and the battery monitoring circuits and the current consumption of the LEDs Technical Service Manual 4 3 LifeCare PCA Plus and Plus II Series SECTION 4 THEORY OF OPERATION 4 2 1 1 CPU DISPLAY PWA SYSTEM INTERFACES The CPU display PWA interfaces with the front panel touchswitches the LCD screen and the power supply The 12 front panel touchswitches interface with the CPU display PWA via P J13 The YES ENTER REV CHG ONSW and OFFSW touchswitch signals are routed off the CPU display PWA via P J12 to the power supply connector P J7 The YES ENTER and REV CHG signals input the data buffer U8 on the power supply PWA A similar data buffer U4 on the CPU display PWA inputs the remaining eight touchswitch signals U8 U4 place data on the system data bus 00 07 When one of the touchswitches is pressed a ground is applied to the corresponding touchswitch signal line that provides an active low signal at the appropriate data buffer input pin ONSW signal is used the power supply PWA as an input to the ON OFF latch consisting of U14B and U14C The OFFSW line is routed to the test port via connector P J9 pin 8 The LCD sc
36. gauge dial reads approximately 0 1 inch 5 Using a 3 16 nutdriver loosen the two screws securing the syringe low switch bracket Move the switch bracket until the switch clicks on then tighten the screws 6 Move the cradle up to the limit allowed by the gauge Program the infuser for normal operation and verify that the syringe low alarm occurs when the gauge dial reads between 0 05 inch and 0 15 inch 7 Apply red GLPT insulating varnish to the screw heads 8 Reassemble the infuser in the exact reverse order of disassembly 9 Close and lock the security door To verify successful adjustment of the syringe low switch perform the PVT in Section 5 2 727 SYRINGE EMPTY SWITCH ADJUSTMENT Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers syringe limit gauge and red GLPT insulating varnish To adjust the syringe empty switch see Figure 7 6 or Figure 7 7 and proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3 3 Install the syringe limit gauge in the cradle Squeeze the cradle clamps and move the cradle until the dial reads approximately 0 3 inch 4 When the LCD screen displays PURGE THE SYSTEM NOW press YES ENTER Purge the system until the gauge reads approximately 0 39 inch If the empty syringe alarm is activated before the system is purged loosen the syringe empty adjustment screws and move the sw
37. in fluids or cleaning solutions Do not spray cleaning solutions toward any openings in the device or directly on the device CAUTION Use only recommended cleaning solutions and follow manufacturers recommendations Using cleaning solutions not recommended A by Hospira may result in product damage Do not use compounds containing combinations of isopropyl alcohol and dimethyl benzyl ammonium chloride CAUTION Never use sharp objects such as fingernails paper clips or needles to clean any part of the infuser Use only soft cloths or sponges Do not sterilize by heat steam ethylene oxide ETO or radiation Technical Service Manual 5 1 LifeCare PCA Plus and Plus Series Section 5 MAINTENANCE AND SERVICE TESTS Note Disinfecting properties of cleaning solutions vary and not all cleaning solutions are sanitizers Check product labeling or consult the manufacturer for specific information Cleaning Solution Dispatch Hospital Cleaner Disinfectant with Bleach Table 5 1 Manufacturer Caltech Industries Cleaning Solutions Preparation Per manufacturer s recommendation Formula C JohnsonDiversey Per manufacturer s recommendation Precise Hospital Foam Cleaner Disinfectant Caltech Industries Per manufacturer s recommendation Sani Cloth HB Wipe Professional Disposables Per manufacturer s recommendation Sani Cloth Bleach Wipe Professional Disposables Per manufactu
38. in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the interconnect PWA perform the PVT in Section 5 2 Technical Service Manual 7 45 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS GROUND WIRE 6 32 SCREW 2 PHILLIPS SCREW 8 INTERCONNECT PWA J1 J2 INTERCONNECT PWA CABLE BATTERY BOOST CHARGER PWA TO DOOR SWITCH Figure 7 22 Interconnect PWA and Battery Boost Charger PWA Replacement 7 3 33 INTERCONNECT PWA CABLE REPLACEMENT This procedure applies to infusers with final assembly number 850 04250 008 and higher The recommended tools for this procedure are a No 2 Phillips screwdriver and set of nutdrivers To replace the interconnect PWA cable see Figure 7 22 and proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3 3 Disconnect the interconnect PWA cable from connector J10 on the interconnect PWA and from J8 on the power supply PWA 4 Connect the replacement interconnect PWA cable to connectors J8 and J10 5 Reassemble the infuser case assemblies in the exact reverse order of disassembly 6 Close and lock the security door To verify successful replacement of the interconnect PWA cable perform the PVT in Section 5 2 LifeCare PCA Plus and Plus II Series 7 46 Technical Service Manual REPLACEMENT PROCEDURES 7 3 34 BA
39. lubrication perform the PVT in Section 5 2 LifeCare PCA Plus and Plus Series 7 16 Technical Service Manual REPLACEMENT PROCEDURES 7 3 REPLACEMENT PROCEDURES This section contains safety and equipment precautions required tools and materials and step by step procedures for replacing parts in the infuser Several replacement procedures in this section require separating the front and rear case assemblies See Section 7 2 3 as indicated in the procedures Figures are rendered as graphic representations to approximate actual product Therefore figures may not exactly reflect the product Unless otherwise stated always perform the PVT after a replacement procedure 7 3 1 SAFETY AND EQUIPMENT PRECAUTIONS Before opening the front enclosure of the infuser take all necessary precautions for working on high voltage equipment WARNING EXPLOSION HAZARD EXISTS IF THE INFUSER IS SERVICED IN THE PRESENCE OF FLAMMABLE SUBSTANCES WARNING UNLESS OTHERWISE INDICATED DISCONNECT THE INFUSER FROM AC POWER BEFORE PERFORMING ADJUSTMENT OR REPLACEMENT PROCEDURES CAUTION Use proper ESD grounding techniques when handling components Wear an antistatic wrist strap and use an ESD protected workstation Store PWAs in antistatic bags before placing them on any surface 7 3 2 REQUIRED TOOLS AND MATERIALS The following tools and materials or equivalents are required for the replacement procedures in this section In addition the tool
40. motor movement during a malfunction The gates of U15 generate the MOTORBAD signal if the inputs to U17 are not of opposite polarity to the drive signals to the motor 4 2 2 6 8255 PROGRAMMABLE PERIPHERAL INTERFACE The 8255 programmable peripheral interface chip U7 is an I O peripheral that is written to and read from by 011 via the microprocessor data bus when addresses AO 1 are properly decoded U7 contains three 8 bit I O ports port A port B and port C Port A PAO through PA7 is used for motor control the strobe for the printer port and the signal that enables the LCD backlighting Port B is used for the printer data input and parity bit I O Port is a general purpose input port that monitors most critical switches and indicators 4 2 3 BATTERY BOOST CHARGER PWA The battery boost charger PWA is installed in infusers with the following final assembly numbers and service revision letters 850 04250 005 L and above 850 04250 008 C and above The final assembly number and service revision letter are located on the lower right side on the back of the infuser LifeCare PCA Plus and Plus Series 4 8 Technical Service Manual 4 2 ELECTRONICS OVERVIEW The battery boost charger PWA contains the following circuitry Differential amplifier U3 20 mA shut off circuitry 02 Window comparator with hysteresis U1 60 minute battery charger timer U2 200 mA constant current source transistors Q7 Q8
41. of addresses AO through A15 4213 CHIP SELECT CIRCUITRY U6 is a 3 to 8 multiplexer that decodes address bits A6 through A4 when gated by A7 and A15 to provide eight I O chip select signals CSO through CS7 These chip select signals the bus read command BRD and the bus write command BWR are used as system control signals see Table 4 2 Table 4 2 CPU Display Control Signals Function NANDed with BWR to gates U2 and U14 NANDed with BRD to enable output of U19 Routed to power supply PWA used as chip select input CS to PPI U7 ANDed with BRD to gate front panel switch data buffer U4 CPU bus read command a function of the CPU RD command Technical Service Manual 4 5 LifeCare PCA Plus and Plus II Series SECTION 4 THEORY OF OPERATION 4 2 1 4 ANALOG TO DIGITAL CONVERTER The analog to digital converter ADC U19 inputs the enable signals to the LEDs The ADC provides data outputs that represent LED display status to the microprocessor data bus by decoding addresses AO Al and A2 The ADC provides a digital representation of eight analog inputs INO through IN7 to U11 INO monitors the current consumption of U3 and the LED display buffer through differential amplifier U18A Analog inputs through 6 monitor the outputs of U3 cathodes of the LED displays to check for shorted or open LEDs IN7 monitors the 2 5 VDC precision voltage reference to compare it against
42. proceed as follows _ uy e Connect the infuser to AC power Connect the printer cable to the printer port located on the back of the infuser Power on the printer and verify it is on line Open the infuser security door then insert the syringe into the cradle assembly Verify the infuser begins the self test After the self test completes the PURGE SYSTEM NOW prompt displays then press PRINT Confirm END OF RECORD is printed on the history and event log printout It may be necessary to take the printer off line then form feed the last partial page of the printout from the printer Compare the printout to Figure 5 1 Date time and parameters will vary Depending on the infuser configuration or the software revision level the printout may not have an HOUR BY HOUR entry LifeCare PCA Plus and Plus II Series 5 10 Technical Service Manual Technical Service Manual EK KEK LIFECARE 4100 PATIENT RECORD x PATIENT PATIENT ID DRUG ADMINISTERED 10 41 NOV 17 04 MODE NOT SET SETTINGS CONC NOT SET DELIVERED LOADING 0 0 MG TOTAL 0 0 MG LAST 1 HOUR PCA DEMANDS PCA INJECTED PCA PARTIAL LOADING DOSE DEL TOTAL LAST 24 HOURS PCA DEMANDS PCA INJECTED PCA PARTIAL LOADING DOSE DEL TOTAL HOUR BY HOUR EVENT LOG 10 41 PRINTOUT 10 41 ON VERIFIED BY END RECORD PERFORMANCE VERIFICATION T
43. see Figure 7 26 and proceed as follows 1 2 3 9 10 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Remove the door lock switch from the door lock assembly as described in Section 7 3 36 Using a 7 16 box wrench remove the nut from the end of the door lock cylinder Remove the lock washer the door latch pawl and the locking washer Using a 7 8 open end wrench remove the retainer nut that attaches the lock cylinder to the door lock assembly Remove the lock cylinder then remove the door lock assembly from the rear case Install the new door lock cylinder into the double D hole in the cover and door lock assembly Confirm the keyway slot is in the upward 12 o clock position Assemble the retainer nut on the door lock cylinder and tighten it against the door lock assembly Replace the locking washer latch pawl lock washer and nut on the door lock cylinder Confirm the latch pawl hook is in the upward position Attach the replacement door lock assembly to the rear case in the exact reverse order of disassembly Reassemble the case assemblies in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the door lock assembly perform the PVT in Section 5 2 NUT DOOR LATCH PAWL LOCKING WASHER Figure 7 26 Door Lock Assembly LifeCare PCA Plus and Plus Series 7 50
44. that attach the slide assembly to the front case Lift the slide assembly from the front case and carefully place it on its right side on a soft surface Do not damage the vial switch that protrudes from the slide assembly Remove the injector sensor switch as described in Section 7 3 22 Remove the plastic cable clamp from the slide assembly then remove the switch wiring harness Remove the motor assembly from the slide assembly as described in Section 7 3 23 Mount the motor assembly on the replacement slide assembly Replace the injector sensor switch removed in Step 6 Using the three bolts that were removed in Step 4 mount the replacement slide assembly on the front case Lubricate the lead screw with grease Reinstall the occlusion pressure switch syringe low switch syringe empty switch and vial sensor switch in the exact reverse order of disassembly Reattach the plastic cable clamp that was removed in Step 7 on the replacement slide assembly Reinstall the cradle assembly and the slide clamp knobs and levers in the exact reverse order of disassembly Technical Service Manual 7 37 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 15 16 17 Adjust the following switches using the procedures described in their corresponding sections Injector sensor switch Section 7 2 4 Vial sensor switch Section 7 2 5 Syringe low switch as applicable Section 7 2
45. the retainer nut that attaches the audible level switch to the control panel Using a 1 2 box wrench remove the retainer nut that attaches the patient pendant jack to the control panel Remove the plastic cable clip that attaches the harness to the piezoelectric alarm mounting screw Place the clip on the replacement harness in the same location Using a 1 2 box wrench attach the patient pendant jack on the replacement harness to the control panel Using a 5 16 box wrench attach the audible level switch on the replacement harness to the control panel Using a 5 16 box wrench attach the piezoelectric alarm on the replacement harness to the control panel Attach the harness clamp to the alarm with the longer mounting screw in the upper position Using a small flat blade screwdriver and a 3 16 nutdriver attach the printer Dataway connector J10 on the replacement harness to the control panel Remount the control panel on the rear case with the eight Phillips screws that were removed in Step 7 LifeCare PCA Plus and Plus Series 7 40 Technical Service Manual 19 20 21 22 23 REPLACEMENT PROCEDURES Using a 5 16 nutdriver attach the green ground wire in the replacement harness to the control panel Replace the adhesive backed cable tie clamp that was removed in Step 5 Use care to place it in the same location Using the cable tie secure the replacement harness to the clamp Connect connector P8 on the re
46. 3 of 16 LifeCare PCA Plus and Plus II Series SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 12 Technical Service Manual HOSPIRA INC igure 9 1 Illustrated Parts Breakdown Sheet 4 of 16 DRAWING NO NOT APPLICABLE LifeCare PCA Plus and Plus II Series 9 13 Technical Service Manual SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 14 Technical Service Manual D S ERI HOSPIRA INC c o 5 5 9 2 T m o g c c a v 9 g 5 Sheet 5 of 16 DRAWING NO NOT APPLICABLE LifeCare PCA Plus and Plus II Series 9 15 Technical Service Manual SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 16 Technical Service Manual Technical Service Manual HOSPIRA INC Figure 9 1 Illustrated Parts Breakdown DRAWING NO Hey N A NOT APPLICABLE ENEE LifeCare PCA Plus and Plus II Series SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 18 Technical Service Manual Technical Service Manual
47. 4 24 x 3 8 Thread Cutting Screw 6 19 x 3 8 Pan Head Phillips Screw Cap 4 40 x 31 Socket Head SS Screw 8 32 x 5 8 Pan Head Flange Washer Lock 8 External Tooth w Conical Washer Screw 6 32 x 3 8 Flat Head Screw 10 32 x 3 3 16 Flat Head SS Screw 4 40 x 3 8 Flat Head Screw 6 32 x 1 2 Hex Head Slotted w Washer Nut KEP 4 40 w Conical Washer Nut Hex 4 40 Screw 4 40 x 7 16 Pan Head Phillips Screw 6 24 x 5 8 Pan Head Phillips Screw 1 4 Pan Head Thread Cutting Washer Flat 4 032 Thk Screw 4 24 x 5 8 Pan Head Phillips Screw 6 32 x 1 4 Hex Head Slotted w Washer Screw 10 32 x 1 Hex Head Slotted w Washer Screw 10 32 x 1 75 Hex Head Slotted w Washer Screw 2 56 x 1 4 Pan Head Phillips w Conical Washer Standoff Hex 2 56 x 1 2 Nickel Plate Technical Service Manual Spacer Hex 6 32 x 1 125 M F 9 5 LifeCare PCA Plus and Plus II Series Section 9 DRAWINGS Table 9 2 Illustrated Parts Breakdown Index Number Nomenclature Washer Flat 6 Nylon Screw Cap 8 32 x 1 2 Socket Head Spring 180 x 188 Screw Shoulder 4 40 x 3 16 Socket Head Screw 2 32 x 1 2 Pan Head Thread Cutting Screw 10 32 x 1 14 Hex Head w Washer Washer 10 022 Thk Internal Tooth Screw 10 32 x 2 5 Hex Head Weathered Washer Lock 10 022 Thk Intern
48. 6 Syringe empty switch Section 7 2 7 Occlusion pressure switch Section 7 2 8 2 Reassemble the infuser case assemblies in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the slide assembly perform the PVT in Section 5 2 7 3 26 SLIDE ASSEMBLY REPLACEMENT 010 AND HIGHER Recommended tools for this procedure are a 9 64 Allen wrench set of Phillips screwdrivers set of nutdrivers and grease To replace the slide assembly see Figure 7 20 and proceed as follows 1 a 10 11 12 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Remove the cradle assembly as described in Section 7 3 16 Remove the slide clamp levers as described in Section 7 3 19 Using a No 1 Phillips screwdriver and a 1 8 nutdriver remove the two wire harnesses that contain the occlusion pressure switch vial sensor switch injector sensor switch and empty vial syringe switch Mark P J numbers on the connectors prior to removing Cut the cable ties to remove the harnesses if necessary Using a 5 16 nutdriver remove the three screws that attach the slide assembly to the front case Lift the slide assembly out of the front case and carefully place it on its right side on a soft surface Do not damage the vial switch plunger that protrudes from the slide assembly Install the replaceme
49. 9 10 Reassemble the infuser in the exact reverse order of disassembly 11 Close and lock the security door To verify successful replacement of the CPU display PWA perform the PVT in Section 5 2 7 3121 LED REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers 1 4 open end wrench and set of Allen wrenches To replace an LED on the CPU display PWA see Figure 7 11 and proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3 3 Remove the power supply PWA as described in Section 7 3 11 and the CPU display PWA as described in Section 7 3 12 Note LEDs are socketed and may initially be difficult to remove Do not bend the connector pins 4 Remove the LED and install the replacement LED Note assure proper alignment when replacing a seven segment LED DS2 DS3 DS4 DS5 or DS7 assure the decimal point is in the lower right corner 5 Reinstall the power supply PWA and the CPU display PWA 6 Reassemble the infuser in the exact reverse order of disassembly 7 Close and lock the security door To verify successful replacement of the LED perform the PVT in Section 5 2 7 3 13 LCD ASSEMBLY REPLACEMENT Recommended tools for this procedure are a set of Phillips screwdrivers and set of nutdrivers To replace the LCD assembly see Figure 7 11 and proceed as follows 1 Disconnect th
50. AC power Separate the front and rear case assemblies as described in Section 7 2 3 Place the front case assembly face down on a soft surface Remove the slide assembly as described in Section 7 3 25 or Section 7 3 26 Using a 3 16 nutdriver remove the two switch mounting screws that attach the injector sensor switch bracket as applicable and switch to the slide assembly Remove the injector sensor switch Note Some infusers do not contain an injector sensor switch bracket Using a 1 4 nutdriver remove the screws that attach the injector flange clamp to the front case Mount the replacement injector flange clamp to the front case using the screws that were removed in Step 6 Mount the injector sensor switch and switch bracket as applicable to the injector flange clamp using the screws that were removed in Step 5 Reinstall the slide assembly as described in Section 7 3 25 or Section 7 3 26 Adjust the injector sensor switch as described in Section 7 2 4 Reassemble the case assemblies in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the injector flange clamp perform the PVT in Section 5 2 Technical Service Manual 7 39 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 3 28 PRINTER DATAWAY CONNECTOR AND CONTROL PANEL HARNESS REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdr
51. CEDURES DIRECTION OF TRAVEL SYRINGE EMPTY SWITCH ARM Figure 7 7 Syringe Empty Switch 010 and Higher 7 2 8 OCCLUSION ALARM SWITCH TEST AND ADJUSTMENT Recommended tools for this procedure are as follows Set of Phillips screwdrivers Digital pressure meter DPM Set of nutdrivers Red GLPT insulating varnish Set of open end wrenches Water filled syringe 5 6 Allen wrench Three way stopcock X acto knife IV administration set 7 2 8 1 OCCLUSION ALARM SWITCH TEST To perform the occlusion alarm switch test see Figure 7 8 and proceed as follows 1 2 3 4 Disconnect the infuser from power Using a three way stopcock attach the DPM to the end of the patient line Install a water filled syringe and an IV administration set into the infuser Purge the set until water flows out of the stopcock valve then close the valve When the LCD screen displays DRUG Rx MORPHINE 1 MG ML YES OR NO press YES ENTER Technical Service Manual 7 9 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 5 Program a loading dose of 10 mg Allow the infuser to operate until an occlusion alarm sounds 6 Note the reading on the meter when the occlusion alarm occurs If the reading is not between 14 19 psig 96 6 and 131 1 kPa for 008 and lower 12 5 and 17 5 psig 86 25 and 120 75 kPa for 010 and higher perform the occlusion alarm adjustment procedure in Sectio
52. EST Figure 5 1 Sample Printer Test LifeCare PCA Plus and Plus II Series Section 5 MAINTENANCE AND SERVICE TESTS 5 2 13 END OF THE PVT At the end of the PVT clear all dose history data from memory by pressing OFF RECHG until the display goes blank If all tests have been successful return the infuser to service If any of the tests fail see Section 6 or contact Hospira 5 3 PERIODIC MAINTENANCE INSPECTION Periodic maintenance inspections should be performed per hospital procedures for compliance to accreditation requirements It is recommended that JCAHO and or hospital protocol be followed for establishing a periodic maintenance inspection schedule Product specifications for this inspection are listed in Section 8 To perform the periodic maintenance inspection complete the PVT in Section 5 2 5 4 BATTERY OPERATION OVERVIEW The infusion system is intended to operate on battery power on an exception basis only such as emergency backup or temporary portable operation Examples of emergency backup include AC power failure or inadvertent disconnection of the AC power cord An instance of temporary portable operation includes patient transfer from one location to another The device should be connected to AC power whenever possible to allow the battery to remain fully charged The battery indicator illuminates when the infuser is operating on battery power Factors that most commonly affect battery life are the depth and
53. IT NUT LEFT CLAMP KNOB UPPER SYRINGE MOUNT RIGHT CLAMP KNOB CRADLE ASSEMBLY SYRINGE EMPTY BRACKET ARM SYRINGE LOW BRACKET ARM SYRINGE LOW SWITCH SYRINGE EMPTY SWITCH LEAD SCREW SWITCH MOUNTING BRACKET MOTOR GEARBOX MOTOR CASE INJECTOR FLANGE CLAMP OPTO SWITCH Figure 4 1 Infuser Slide Assembly 008 and Lower LifeCare PCA Plus and Plus II Series 4 10 Technical Service Manual 4 3 MECHANICAL OVERVIEW SWITCH ACTUATOR i OCCLUSION ALARM SWITCH I THUMB NUT A CRADLE ASSEMBLY a 1 h I 27 VIAL SENSOR SWITCH 2 VIAL LEAD SCREW I 7 E A SYRINGE EMPTY SWITCH b ues gt SYRINGE EMPTY SWITCH ACTUATOR ARM 0 BEHIND SWITCH i SYRINGE EMPTY SWITCH ADJUSTMENT SCREW 2 4 PLUNGER MOTOR GEARBOX MOTOR CASE INJECTOR FLANGE CLAMP INJECTOR SENSOR SWITCH Figure 4 2 Infuser Slide Assembly 010 and Higher 4 3 1 1 MOTOR ASSEMBLY The motor assembly consists of a four phase stepper motor housed in the motor case
54. L p B B 9 B B B 5 5 B 5 9 B 5 5 p B B 95 B S 5 EL 5 B B B B 5 B SYRINGE EMPTY SWITCH ARM Figure 4 4 Syringe Empty Alarm System 010 and Higher 4 3 3 OCCLUSION PRESSURE ALARM SYSTEM The occlusion alarm occurs when a back pressure of 15 5 psig 103 5 34 5 kPa is exceeded Back pressure is sensed by the occlusion pressure microswitch on the top plate of the slide assembly see Figure 4 5 Figure 4 6 During a normal delivery cycle rotation of the lead screw moves the slide block downward which moves the cradle assembly downward and forces fluid out of the syringe If there is an occlusion in the administration set back pressure builds up in the delivery system and downward motion of the slide block is restricted A longitudinal slack in the lead screw exists so that when the downward movement of the slide block is restricted rotation of the lead screw forces the slide block upwards against a compression spring between the top of the lead screw and the top plate When a given amount of pressure is applied against the compression spring the upper end of the lead screw presses against the switch actuator and causes it to pivot upward thereby closing the occlusion alarm switch On infusers with final assembly number 010 and higher the switch opens When the occlusion alarm switch closes the PRESSURESW signal goes active low The PRESSURESW signal is applied to the in
55. LARM SYSTEM The vial sensor microswitch between the cradle assembly and slide block senses the presence or absence of a vial in the cradle assembly The injector sensor switch behind the injector flange clamp senses whether or not the vial injector flange is properly seated in the injector flange clamp when a vial is clamped in the cradle assembly When open the vial sensor switch generates the CHECK VIAL alarm 4 3 4 1 CHECK VIAL ALARM When a vial is properly seated in the cradle assembly the vial sensor rod is forced towards the rear of the infuser and presses against the vial sensor microswitch actuator arm causing the switch to close If the vial is improperly seated i e the vial sensor rod is not forced rearward and the switch remains open and the injector flange is properly seated an attempt to start the infuser causes logic circuitry on the power supply PWA to sense set the infuser is prevented from starting the audible alarm sounds and the CHECK VIAL message is displayed on the LCD The SILENCE touchswitch has no effect on this alarm the alarm is cleared by properly seating the vial in the cradle assembly LifeCare PCA Plus and Plus Series 4 16 Technical Service Manual 4 3 MECHANICAL OVERVIEW 4 3 4 2 CHECK INJECTOR ALARM When a vial is mounted in the cradle assembly and the injector flange is properly seated in the injector flange clamp the vial sensor rod is forced towards the rear of the infuser and presses aga
56. LEVER THUMB NUT PIVOT POST BEHIND LEAD SCREW LEAD SCREW DIRECTION OF LEAD SCREW Figure 7 10 Occlusion Alarm Pressure Adjustment 010 and Higher 7 2 9 LCD INTENSITY ADJUSTMENT The recommended tool for this procedure is a trim pot adjustment tool To adjust the LCD intensity see Figure 7 11 and proceed as follows 1 Remove the power supply PWA as described in Section 7 3 11 2 Remove the four spacers from the CPU display PWA 3 Lift the CPU display PWA from the front enclosure Remove the flexible circuit cable from J13 on the CPU display PWA Technical Service Manual 7 13 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 4 7 Position the power supply PWA the CPU display PWA so the resistor R19 adjustment screw is accessible Connect P3 of the power cable to J3 on the power supply PWA Connect the 40 pin ribbon cable to J7 on the power supply PWA CAUTION Assure the power supply PWA and the CPU display PWA A remain separated during the adjustment procedure Connect the infuser to AC power Using the trim pot tool adjust resistor R19 so the LCD screen can be read from a distance of approximately three feet Disconnect the infuser from AC power Connect the flexible circuit cable to J13 Insert the CPU display PWA in the front enclosure and replace the four spacers Replace the power supply PWA in the exact reverse order of its removal To verify successful ad
57. LifeCare 4100 PCA PLUS AND PLUS II SERIES INFUSERS For use with list numbers 1950 04 and 1950 13 Technical Service Manual Hospira Inc 275 North Field Drive Lake Forest IL 60045 430 04502 006 A 2013 04 This page intentionally left blank LifeCare PCA Plus and Plus Series Technical Service Manual Part Number 430 04502 001 Rev 06 93 430 04502 A01 430 04502 01 430 04502 002 Rev 02 95 430 04502 003 Rev 04 99 430 04502 004 Rev 09 06 430 04502 005 Rev 11 10 430 04502 006 A 2013 04 Technical Service Manual Change History Description of Change Original Issue Replaces 430 04461 001 and 430 04287 002 Change Page Issue Update Cover Copyright and Change History Update PCA continuous test in Section 5 Update syringe empty switch adjustment procedure Change Page Issue Update Cover Copyright and Change History Revise Section 1 Update Section 4 3 3 Update Table 5 1 Update Section 6 1 Update Section 7 2 7 4 Section 7 3 19 and Section 7 3 43 Add Index Update back page Second Issue Third Issue Fourth Issue Incorporate Hospira name change and update to current style Fifth Issue Update Occlusion Test and Electrical Safety Test in Section 5 Update Troubleshooting tables in Section 6 Update AC Power Cord replacement procedure in Section 7 Update Specifications in Section 8 Update graphics throughout Sixth Issue Add Hospira address to front cover and updat
58. M test failed Replace CPU display PWA EPROM checksum test failed Replace CPU display PWA Not used LED segment defective Replace CPU display PWA Real time clock stopped Replace CPU display PWA Touchswitch stuck on front panel Replace front panel Replace CPU display PWA Not used Not used LED error Replace CPU display PWA Voltage error Replace power supply PWA Not used Error in timer T1 Replace CPU display PWA Error in timer T2 Replace CPU display PWA Program error Replace CPU display PWA CPU stack error Replace CPU display PWA Analog to digital converter error Replace CPU display PWA Undetermined error LifeCare PCA Plus and Plus II Series 6 4 Contact Hospira Technical Service Manual 6 3 4 ALARM AND DISPLAY MESSAGE OVERVIEW ALARM MESSAGES FAULT SYMPTOMS Table 6 2 lists alarm message fault symptoms that require technical service Before troubleshooting turn off the infuser then on and allow the self test to complete If an alarm or malfunction persists carefully inspect the infuser for damage as described in Section 5 1 1 If the alarm or malfunction persists perform the corrective action specified in Table 6 2 or contact Hospira Alarm Message Fault Symptom CHECK VIAL Table 6 2 Alarm Messages Fault Symptoms Possible Cause Vial is improperly installed or missing Corrective Action P
59. N FLAT WASHER 4 6 32 HEX M F SPACER 4 d POWER SUPPLY PWA 6 32 HEX HEAD SCREW 4 J7 Figure 7 14 Power Supply PWA and CPU Display PWA CPU DISPLAY PWA REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers 1 4 open end wrench and set of Allen wrenches To replace the CPU display PWA see Figure 7 14 and proceed as follows l a Disconnect the infuser from power Separate the front and rear case assemblies as described in Section 7 2 3 Remove the power supply PWA as described in Section 7 3 11 Using a 1 4 nutdriver remove the CPU display PWA spacers and nylon washers Pivot the CPU display PWA on its right edge to access the flexible circuit cable Loosen the flexible circuit cable from J13 on the CPU display PWA Remove the 40 pin ribbon cable from J12 on the CPU display PWA then remove the CPU display PWA from the front panel assembly Reconnect P3 of the power cable to J3 of the power supply PWA Using a 5 16 nutdriver reconnect the ground wire to the motor gear case LifeCare PCA Plus and Plus Series 7 24 Technical Service Manual REPLACEMENT PROCEDURES 9 Reconnect the infuser to AC power and press ON Verify the LCD screen can be read from a distance of approximately three feet If necessary adjust the LCD intensity see Section 7 2
60. OVERVIEW Section 6 TROUBLESHOOTING 6 1 TECHNICAL ASSISTANCE 6 2 DIAGNOSTIC MODE 6 3 ALARM AND DISPLAY MESSAGE OVERVIEW 63 1 AUDIBLE ALARMS 6 3 2 ALARM CAUSES AND ACTIONS 6 3 3 MALFUNCTION CODES 6 3 4 ALARM MESSAGES FAULT SYMPTOMS 6 4 SERVICE TEST AND PVT TROUBLESHOOTING Section 7 REPLACEABLE PARTS AND REPAIRS 7 4 REPLACEABLE PARTS 7 2 ADJUSTMENT PROCEDURES 7 2 1 SAFETY AND EQUIPMENT PRECAUTIONS 7 22 REQUIRED TOOLS AND MATERIALS 7 2 3 SEPARATING FRONT AND REAR CASE ASSEMBLIES 7 24 INJECTOR SENSOR SWITCH ADJUSTMENT 7 2 5 VIAL SENSOR SWITCH ADJUSTMENT 7 2 6 SYRINGE LOW SWITCH ADJUSTMENT PCA PLUS ONLY 7 2 7 SYRINGE EMPTY SWITCH ADJUSTMENT 4 12 4 14 4 16 4 16 4 17 4 17 5 1 5 1 5 1 5 2 5 3 5 3 5 4 5 4 5 6 5 6 5 7 5 8 5 8 5 9 5 9 5 10 5 12 5 12 5 12 6 1 6 1 6 1 6 2 6 3 6 3 6 3 6 5 6 7 7 1 7 1 7 1 7 1 7 2 7 2 7 4 7 6 7 8 7 9 LifeCare PCA Plus and Plus Series iv Technical Service Manual Contents 7 2 8 OCCLUSION ALARM SWITCH TEST AND Ys eo FEEL 7 2 8 1 OCCLUSION ALARM SWITCH TEST e 5 5 7411 7 2 8 2 OCCLUSION ALARM SWITCH AND PRESSURE ADJUSTMENT 008 AND LOWER bo Sy uncut 212 7 2 8 3 OCCLUSION ALARM SWITCH AND PRESSURE ADJUSTMENT 010 AND HIGHER 7 14 7 2 9 LCD INTENSITY ADJUSTMENT 7 2 10 SETTING THE REAL TIME CLOCK PCA PLUS I V Yon
61. Plus II Series 5 12 Technical Service Manual TECHNICAL ASSISTANCE 2 Section 6 TROUBLESHOOTING This section contains information on technical assistance diagnostic mode alarm and display messages and troubleshooting procedures 6 1 TECHNICAL ASSISTANCE For technical assistance product return authorization and to order parts accessories or manuals within the United States contact Hospira 1 800 241 4002 For additional technical assistance technical training and product information visit the website at www hospira com For technical assistance product return authorization and to order parts accessories or manuals from outside the United States contact the nearest Hospira sales office 6 2 DIAGNOSTIC MODE A printer must be connected to the infuser when using the diagnostic mode The PCA Plus II infuser with 3 1 software and above has a diagnostic mode that allows retrieval of the last 200 events and malfunction codes This information is retained indefinitely in a battery backed RAM on the CPU display PWA The diagnostic mode event log lists the last 200 events The malfunction log lists the last 200 malfunction codes see Figure 6 1 To access diagnostic information confirm the infuser is in storage mode cold start condition see Section 4 2 1 2 then proceed as follows 1 Simultaneously press and hold the PURGE SYSTEM and ON touchswitches for approximately three seconds The LCD screen first disp
62. RAWINGS Table 9 2 Illustrated Parts Breakdown Index Number Nomenclature Actuator Inside Outside Washer Flat 94 x 25 Nut Hex 2 56 Self Locking Assembly Gear Mot Opto Switch Washer Lock Split 6 031 Thk Screw 2 56 x 1 2 Hex Head w Washer Screw 2 56 x 50 Hex Head w Washer Washer Lock Split 2 020 Thk Tube Coupling Clip Coupling Screw Cap 6 32 x 1 2 Socket Head Assembly Control Panel Washer Lock Split 025 Thk Standoff Hex 19 x 69 4 40 M F Panel Control Jack Phone Screw 4 40 x 3 8 Hex Head Slotted w Washer Clip Cable 1 4 in 10 Bolt Hole Screw 4 40 x 1 2 Hex Head Slotted w Washer Assembly Control Panel Screw 4 40 x 5 16 Hex Head Slotted w Washer Washer Lock 6 External Tooth Panel Control PWA Boost Charger PWA Interconnect Washer Flat 625 Fiber Assembly Cable 26 Conductor LifeCare PCA Plus and Plus Il Series 9 2 Technical Service Manual Table 9 2 Illustrated Parts Breakdown Index Number Nomenclature Assembly Door Lock Pawl Latch Door Ring Retaining 219 x 025 Thk Washer Flat 253 x 050 Thk Spring Extension Piggyback Pawl Ratchet Pole Clip Plate Door Lock Lock Barrel Key Modified Pin Pivot Door Latch Support Latch Spring Torsion 025 Dia
63. REPLACEABLE PARTS AND REPAIRS 4 Remove the two Allen screws and lock washers that secure the lever of the right slide clamp knob Press the two knobs together and remove them 5 Slowly release the tension of the springs between the slide clamp knobs Note the configuration of the spring assembly two per handle and spring retainer sleeves 6 Install the spring and spring retainer in the replacement knob 7 Press the knobs together and reinstall 8 Reassemble the infuser case assemblies in the exact reverse order of disassembly 9 Close and lock the security door To verify successful replacement of the slide clamp knob and lever perform the PVT in Section 5 2 LEFT SIDE CLAMP HANDLE ALLEN SCREWS RIGHT SIDE CLAMP HANDLE ALLEN SCREWS Figure 7 17 Location of Slide Clamp Handle Allen Screws 008 and Lower LifeCare PCA Plus and Plus Series 7 30 Technical Service Manual REPLACEMENT PROCEDURES 7 3 19 SLIDE CLAMP LEVER REPLACEMENT 010 AND HIGHER Recommended tools for this procedure are a No 2 Phillips screwdriver and set of nutdrivers To replace the slide clamp levers proceed as follows 1 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Remove the cradle assembly as described in Section 7 3 16 Lift the slide clamp lever off the pivot post and pull through the front of the infuser Install the replacement slide clamp lever
64. SE COUPLING CLIP MAY BE CURVED ON SOME ASSEMBLIES 7 64 ALLEN SCREW Figure 7 18 Motor Assembly Replacement 008 and Lower LifeCare PCA Plus and Plus II Series 7 34 Technical Service Manual 7 3 24 REPLACEMENT PROCEDURES MOTOR ASSEMBLY REPLACEMENT 010 AND HIGHER Recommended tools for this procedure are a 7 64 Allen wrench No 2 Phillips screwdriver and set of nutdrivers To replace the motor assembly see Figure 7 19 and proceed as follows 1 10 11 12 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Remove the slide clamp levers as described in Section 7 3 19 Remove the cradle assembly as described in Section 7 3 16 Disconnect the connectors from the power supply PWA and CPU display PWA Using a 5 16 nutdriver remove the three screws that attach the slide assembly to the front case see Figure 7 20 Lift the slide assembly from the front case and carefully place it on its right side on a soft surface Note Do not damage the vial switch plunger that protrudes from the slide assembly and do not damage the injector switch wires that remain attached Remove the two 6 32 screws and nuts that secure the motor assembly to the motor support Remove the motor assembly and coupler Install the replacement motor assembly in the slide assembly with the coupler Replace the coupler if required
65. TCH BRACKET SWITCH MOUNTING SCREW 2 FRONT CASE Figure 7 2 Injector Sensor Switch 008 and Lower LifeCare PCA Plus and Plus II Series 7 4 Technical Service Manual 7 2 5 ADJUSTMENT PROCEDURES MOTOR ASSEMBLY SWITCH MOUNTING SCREW 2 FRONT CASE Figure 7 3 Injector Sensor Switch 010 and Higher VIAL SENSOR SWITCH ADJUSTMENT Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers and red GLPT insulating varnish To adjust the vial sensor switch see Figure 7 4 and proceed as follows Infusers with final assemblies 850 04250 010 and higher do not contain a vial sensor switch bracket Therefore no adjustment is required on infusers with final assembly number 010 and higher see Figure 7 5 1 2 3 5 6 7 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Using a 3 16 nutdriver loosen the two vial sensor switch adjustment screws until the switch holder can be easily moved Do not loosen the screws so much that the switch bracket rocks from side to side Place the switch bracket upright Move the switch up slowly until it clicks off then move the switch down slowly until it clicks on Move the switch down further approximately 1 16 inch to verify the switch detects a vial Tighten the screws while keeping the switch bracket level Apply red GLPT insulating varnish to the screw heads Reas
66. TTERY BOOST CHARGER PWA REPLACEMENT Recommended tools for this procedure are a set of Phillips screwdrivers and set of nutdrivers To replace the battery boost charger PWA see Figure 7 22 and proceed as follows 1 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Disconnect and 2 from J1 and J2 on the battery boost charger PWA N Using a No 1 Phillips screwdriver remove the two 6 32 screws that secure the battery boost charger PWA on the control panel assembly Remove the battery boost charger PWA 5 Mount the replacement battery boost charger PWA on the control panel assembly with the screws that were removed in Step 4 6 Reassemble the infuser case assemblies in the exact reverse order of disassembly 7 Close and lock the security door To verify successful replacement of the battery boost charger PWA perform the PVT in Section 5 2 7 3 35 FRONT PANEL REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers 1 4 open end wrench set of Allen wrenches X acto knife lint free cloth and isopropyl alcohol To replace the front panel see Figure 7 23 and proceed as follows 1 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Remove the power supply PWA as described in Section 7 3 11 Remove the CPU display PWA as described in S
67. The watchdog circuit consists of the dual one shot at U15 and the two NAND gates from 016 that form a set reset flip flop The one shot is periodically triggered 011 as part of its firmware program Before the one shot times out and causes the flip flop to set the MALF line U11 must activate RWAT which resets the flip flop and prevents it from activating MALF The watchdog circuit assures that the firmware contains the correct code and that U11 is executing code The watchdog circuit also assures that U11 is the correct length and that the real time clock that sets U11 to activate RWAT is keeping correct time and can be accessed by U11 LifeCare PCA Plus and Plus Series 4 6 Technical Service Manual 4 2 ELECTRONICS OVERVIEW 4 2 2 POWER SUPPLY PWA The power supply PWA contains the following Power supply circuitry that converts the low voltage 11 to 17 VAC from the line transformer to regulated DC Battery charging and monitoring circuitry that keeps the battery at full charge and provides the LOW BATT alarm 8255 programmable peripheral interface PPI U7 that contains three 8 bit I O ports to allow U11 to control the motor read data from and send data to the printer port and read the state of the switches Set reset flip flop ON OFF latch U14B U14C that monitors the state of the vial and injector switches and the ON touchswitch to control power to the logic circuitry and is powered by the battery when AC pow
68. Using a 3 8 wood chisel or an X acto knife remove the rubber foot pad and scrape the enclosure recess to remove adhesive residue Each adhesive backed rubber foot pad is bonded in its recess Do not damage the recess 3 Using isopropyl alcohol clean any adhesive residue from the enclosure recess 4 Remove the protective backing from the self adhesive surface of the replacement foot pad and press the pad in place 5 After approximately five minutes verify the foot pad is secure Replacement of a rubber foot pad is routine maintenance and no verification procedure is normally required However if the infuser may have been damaged during the replacement procedure perform the PVT in Section 5 2 LifeCare PCA Plus and Plus II Series 7 54 Technical Service Manual EMI Section 8 SPECIFICATIONS 8 1 PCA PLUS Dimensions Weight Casing Power Requirements Power Cord Fuses Battery Battery Life PCA Only Mode Continuous Only Mode PCA Continuous Lockout Interval Range Backpressure Range Operating Environment Electrical Safety Administration Sets Technical Service Manual Approximately 8 in W x 13 in Hx 6 in D excluding pole clamp and power cord Approximately 15 Ibs with battery High density polyurethane structural foam 110 120 V 50 60 Hz 25 W Hospital grade AC cord 10 ft 0 25 A 250 V Slo Blo One sealed lead acid rechargeable 8 V internal to the device A fully c
69. aintenance and no verification procedure is normally required However if the infuser may have been damaged during this procedure perform the PVT in Section 5 2 7 3 9 AC POWER CORD REPLACEMENT The recommended tool for this procedure is a No 2 Phillips screwdriver To replace the AC power cord see Figure 7 13 and proceed as follows 1 Disconnect the infuser from AC power 2 Using the Phillips screwdriver remove the screw that attaches the AC power cord retainer plate to the rear of the infuser 3 Disconnect the AC power cord by grasping the plug Do not pull on the power cord 4 Install the replacement AC power cord by connecting it to the infuser AC power receptacle 5 Reinstall the power cord retainer plate with the screw that was removed in Step 2 6 Press ON OFF and verify the infuser powers on To verify successful AC power cord replacement perform the Electrical Safety Test in Section 5 2 11 LifeCare PCA Plus and Plus Series 7 22 Technical Service Manual REPLACEMENT PROCEDURES 7 3 10 GASKET SEAL REPLACEMENT Note Do not disconnect ribbon cables as part of this procedure Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers isopropyl alcohol and cotton swabs To replace the gasket seal proceed as follows 1 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Set the rear case assembly upright w
70. al Tooth Screw 2 56 x 1 4 Hex Holder Spring Knob Spring 180 x 625 x 024 Screw Cap 4 40 x 3 8 Socket Head LifeCare PCA Plus and Plus Il Series 9 6 Technical Service Manual ERU SJ S 572 A77 A 9467 NS 4 2 HOSPIRA INC x 5 2 To 2 5 E Lo 2 5 eo 3 Rev N A Sheet 1 of 16 DRAWING NO NOT APPLICABLE LifeCare PCA Plus and Plus II Series 9 7 Technical Service Manual SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 8 Technical Service Manual Ti 30 Technical Service Manual RH S ss lt gt s ES HOSPIRA INC Figure 9 1 Illustrated Parts Breakdown DRAWING NO Hey NOT APPLICABLE LifeCare PCA Plus and Plus II Series SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 10 Technical Service Manual Technical Service Manual PPO SY os 52 S sv c SD a gt 0 gt HOSPIRA INC Figure 9 1 Illustrated Parts Breakdown DRAWING NO NOT APPLICABLE Rev N A Sheet
71. ary AC power is routed through line fuses F1 and F2 to the primary of the power transformer T1 Low level alternating current AC from the secondary of T1 is applied to a rectifier CR14 on the power supply PWA The direct current DC output of CR14 connects to the battery input and battery charger circuitry on the power supply PWA The power supply PWA provides 5 VDC logic power drivers for the drive motor power to the audible alarm access to test points throughout the system through a test port and a printer Dataway port 42 1 CPU DISPLAY PWA The CPU display PWA contains the following 8032 single chip microprocessor containing read only memory ROM random access memory RAM 8 bit input output I O port two timer circuits 64K addressing capability and 8 bit data bus 32K erasable programmable read only memory EPROM for firmware program storage including all CPU firmware 8K static RAM mounted in a socket that contains a real time clock chip that can be read from and written to by the 8032 microprocessor A battery in the socket supplies power to the real time clock when logic power is turned off Watchdog circuit that sounds an alarm if the 8032 microprocessor does not execute a code as designed or does not start up properly DC to AC converter that provides power for the electroluminescent panel on the LCD screen LCD containing its own controlling circuitry on a PWA connected to the CPU display PWA Light emitting
72. by electromagnetic N interference EMI from devices such as electrosurgical units cellular phones and two way radios Operation of the infusion system under such conditions should be avoided Infusion system installation consists of unpacking inspection and self test Note Do not place the infuser in service if the battery is not fully charged To make certain the battery is fully charged connect the infuser to AC power for 24 hours 1 6 1 UNPACKING Inspect the shipping container as described in Section 1 6 2 Use care when unpacking the infusion system Retain the packing slip and save all packing material in the event it is necessary to return the infuser to the factory Verify the shipping container contains a copy of the System Operating Manual LifeCare PCA Plus and Plus II Series 1 4 Technical Service Manual 1 6 INFUSION SYSTEM INSTALLATION 1 6 2 INSPECTION Inspect the shipping container for damage Should any damage be found contact the delivering carrier immediately AN CAUTION Do not use the device if it appears to be damaged Inspect the infusion system periodically for signs of defects such as worn accessories broken connections or damaged cable assemblies Also inspect the infuser after repair or during cleaning Replace any damaged or defective external parts 1 6 3 SELF TEST Note Do not place the infuser in service if the battery is not fully charged To make certain the battery is fully charged
73. ch 7 48 Front case assembly 7 53 Front panel 7 47 Fuse 7 20 Gasket seal 7 24 Injector flange clamp 7 40 Injector sensor switch 7 34 Interconnect PWA 7 45 Interconnect PWA cable 7 46 LCD assembly 7 26 LED 7 26 Motor assembly 7 35 7 36 Occlusion pressure switch 7 33 Patient pendant assembly 7 23 Patient pendant jack 7 43 Piezoelectric alarm 7 42 Pole clamp assembly 7 21 Power supply PWA 7 24 Printer Dataway connector and control panel harness 7 40 Rear case assembly 7 53 Required tools and materials 7 19 Rubber foot pad 7 54 Safety and equipment precautions 7 18 Security door latch 7 23 Security door 7 22 Slide assembly 7 38 7 39 Technical Service Manual Slide clamp knob and lever 7 30 7 32 Syringe low and syringe empty switch 7 32 Velcro strap and retainer plate 7 22 Vial sensor switch 7 30 Required tools and materials 7 2 7 19 Routine maintenance 5 1 Cleaning and sanitizing 5 1 Rubber foot pad replacement 7 54 5 Safety and equipment precautions 7 1 7 18 Scope 1 1 Security door latch replacement 7 23 Security door replacement 7 22 Self test 1 5 Separating front and rear case assemblies 7 2 Service test and PVT troubleshooting 6 7 Service test mode tests 5 4 Setting the real time clock 7 16 Setup 4 1 Slide assembly 4 10 Replacement 7 38 7 39 Slide clamp knob and lever replacement 7 30 7 32 Slide mechanism 4 12 Specifications 8 1 Starting operat
74. connect the 4 pin connector from J3 on the power supply PWA Oo O 9 1 series only Disconnect the 4 pin and 6 pin ribbon cables from J1 and J2 on the battery boost charger PWA at the back of the rear case assembly Note Ribbon cables are hard wired to the power supply PWA Use care and do not damage the cables when disconnecting them LifeCare PCA Plus and Plus II Series 7 2 Technical Service Manual ADJUSTMENT PROCEDURES 10 Place the front assembly on the work surface 11 Using a 5 16 nutdriver remove the nut and star lock washer that secure the ground wire green with yellow stripe to the motor gear case then remove the nut that secures the ground wire to the front panel The nut may be hidden by the ribbon cable connecting the bottom of the two PWAs 12 Disconnect connectors J4 J5 J6 and J7 on the power supply PWA 13 Reassemble the infuser in the exact reverse order of disassembly 14 Close and lock the security door To verify successful separation and reassembly of the front and rear case assemblies perform the PVT in Section 5 2 REAR COVER CASE ATTACHMENT SCREW 4 FRONT COVER REAR VIEW FRONT VIEW Figure 7 1 Separating Front and Rear Case Assemblies 7 2 4 INJECTOR SENSOR SWITCH ADJUSTMENT The injector sensor switch is adjustable on most PCA Plus Series infusers w
75. ction INDEX G Gasket seal replacement 7 24 General functions 4 1 Delivery mechanism 4 2 Patient controlled analgesia 4 2 Setup 4 1 Starting operation 4 1 Status messages 4 2 I Illustrated parts breakdown 9 1 Infusion system installation 1 4 Inspection 1 5 Self test 1 5 Unpacking 1 4 Injector flange clamp replacement 7 40 Injector sensor switch Adjustment 7 4 Replacement 7 34 Inspection 1 5 5 3 Interconnect PWA cable replacement 7 46 Interconnect PWA replacement 7 45 Introduction 1 1 Acronyms and abbreviations 1 2 Artifacts 1 4 Conventions 1 2 Infusion system installation 1 4 Scope 1 1 User qualification 1 4 L LCD Interface 4 6 Intensity adjustment 7 15 Replacement 7 26 Lead screw lubrication 7 18 LED display circuit 4 6 LED replacement 7 26 M Maintenance and service tests 5 1 Battery operation overview 5 12 Performance verification test 5 2 Periodic maintenance inspection 5 12 Routine maintenance 5 1 Malfunction codes 6 3 LifeCare PCA Plus and Plus II Series Mechanical overview 4 10 Occlusion pressure alarm system 4 14 Slide assembly 4 10 Syringe low and syringe empty alarm system 4 12 Vial and injector sensor alarm system 4 16 Microprocessor circuitry 4 4 Motor assembly 4 11 Replacement 7 35 7 36 Motor driver 4 8 O Occlusion alarm switch and pressure adjustment 7 12 7 14 Occlusion alarm switch test 7 11 Occlusion alarm switch test and ad
76. der the supervision of licensed physicians or certified healthcare professionals who are trained in the use of the infuser and the administration of parenteral or enteral fluids or drugs 1 5 5 Nonhazardous low level electrical potentials are commonly observed when fluids are administered using infusion devices These potentials are well within accepted safety standards but may create artifacts on voltage sensing equipment such as ECG EMG and EEG machines These artifacts vary at a rate that is associated with the infusion rate If the monitoring machine is not operating correctly or has loose or defective connections to its sensing electrodes these artifacts may be accentuated so as to simulate actual physiological signals To determine if the abnormality in the monitoring equipment is caused by the infuser instead of some other source in the environment set the device so that it is temporarily not delivering fluid Disappearance of the abnormality indicates that it was probably caused by electronic noise generated by the infusion device Proper setup and maintenance of the monitoring equipment should eliminate the artifact Refer to the appropriate monitoring system documentation for setup and maintenance instructions 1 6 INFUSION SYSTEM INSTALLATION CAUTION Infusion system damage may occur unless proper care is exercised during product unpacking and installation CAUTION Infusion system performance may be degraded
77. dvance beyond the PCA SETTINGS screen o Press NO to advance beyond the CHANGE ANY SETTINGS MODE screen _ _ Press YES ENTER to select the CHANGE screen to reset time and date If the fields stop flashing before the correct time and date are set press NO to restart the flashing 12 Press or to enter the correct value 13 Press REVIEW CHANGE to advance the flashing field to the next field to be changed 14 When all fields have been set the LCD screen displays ACCEPT Press YES ENTER to accept the values Setting the real time clock is routine maintenance and no verification procedure is normally required However if the infuser may have been damaged during this procedure perform the PVT in Section 5 2 Technical Service Manual 7 15 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 2 11 DOOR LOCK SWITCH ADJUSTMENT The recommended tool for this procedure is needle nose pliers To adjust the door lock switch proceed as follows l N 7 8 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Press the door lock actuator arm and listen for switch actuation Close and lock the security door and confirm the door hook and the door lock actuator hold the door closed With the security door closed turn the key to the unlocked and locked positions while listening for switch ac
78. e infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Disconnect the LCD ribbon cable from J15 on the CPU display PWA Remove the power supply PWA as described in Section 7 3 11 Remove the CPU display PWA as described in Section 7 3 12 oa wo Pull the adhesive backed plastic insulator from the LCD window Technical Service Manual 7 25 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 Using a No 0 Phillips screwdriver remove the screws from each corner of the LCD assembly 8 Grasp the CPU display PWA and carefully remove the LCD from the connector J14 socket Do not bend the connector pins 9 Mount the adhesive backed plastic insulator on the replacement LCD Center the insulator window on the LCD so the insulator covers the edges of the metal bracket 10 Reinstall the LCD assembly power supply PWA and CPU display PWA 11 Reassemble the infuser in the exact reverse order of disassembly 12 Close and lock the security door To verify successful replacement of the LCD assembly perform the PVT in Section 5 2 7 3 14 40 PIN RIBBON CABLE REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers 1 4 open end wrench and set of Allen wrenches To replace the 40 pin ribbon cable see Figure 7 14 and proceed as follows 1 Disconnect the infuser from AC power Separate the front and rear ca
79. e manual number Add regulatory symbols to Warnings and Cautions Replace with numerous places Add Note to PVT in Section 5 2 Add Note to Section 5 2 6 per CAPA Update Electrical Safety Test in Section 5 2 11 Add patient pendant Caution to Section 7 3 8 and Section 7 3 30 Add Note to Drawings in Section 9 i LifeCare PCA Plus and Plus II Series CHANGE HISTORY This page intentionally left blank LifeCare PCA Plus and Plus II Series ii Technical Service Manual Contents Section 1 INTRODUCTION 11 1 2 1 3 1 4 1 5 1 6 SCOPE CONVENTIONS ACRONYMS AND ABBREVIATIONS USER QUALIFICATION ARTIFACTS INFUSION SYSTEM INSTALLATION 1 61 UNPACKING 1 6 2 INSPECTION 1 6 3 SELF TEST Section 2 WARRANTY Section 3 SYSTEM OPERATING MANUAL Section 4 THEORY OF OPERATION 4 1 4 2 4 3 Technical Service Manual iii GENERAL FUNCTIONS 4 141 STARTING OPERATION 4 1 1 1 WARM START SEQUENCE 411 2 COLD START 4 1 2 SETUP 41 3 DELIVERY MECHANISM RET 4 14 PATIENT CONTROLLED ANALGESIA 4 1 5 STATUS MESSAGES ELECTRONICS OVERVIEW 4 2 1 CPU DISPLAYPWA 4 2 11 CPU DISPLAY PWA SYSTEM INTERFACES 4 21 2 MICROPROCESSOR CIRCUITRY 4 2 13 CHIP SELECT CIRCUITRY 4 214 ANALOG TO DIGITAL CONVERTER 4 21 5 LCD INTERFACE 4 2 1 6 LED DISPLAY CIRCUIT 4 217 WATCHDOG CIRCUIT 4 2 2 POWER SUPPLY PWA 4 2 2 1 POWER SUPPLY SYSTEM INTERFACES 4 2 2 2
80. e plastic cable clip Cut the cable tie nearest to the piezoelectric alarm on the wire harness The piezoelectric alarm has a black wire and a red wire The red wire connects to the gray wire on the wire harness The black wire connects to the white wire on the wire harness Remove the shrink wrap from the solder joints and unsolder the wires 5 Remove the piezoelectric alarm 10 11 12 To ve Slip one inch of 1 8 inch shrink tubing over the gray and white wires on the wire harness Solder the red wire of the replacement piezoelectric alarm to the gray wire on the harness Solder the black wire of the replacement piezoelectric alarm to the white wire on the harness Slip the shrink tubing over the solder joints and shrink into place Mount the piezoelectric alarm to the control panel with the screws that were removed in Step 3 Place the clamp around the harness wires routed to the rear of the printer connector on the control panel Attach the plastic cable clip with the upper screw Install a new cable tie on the wire harness Use care to place it in the same location Reassemble the case assemblies in the exact reverse order of disassembly Close and lock the security door rify successful replacement of the piezoelectric alarm perform the PVT in Section 5 2 LifeCare PCA Plus and Plus Series 7 42 Technical Service Manual REPLACEMENT PROCEDURES 7 3 30 PATIENT PENDANT JACK REPLACEMENT This procedure a
81. ection 7 3 12 a Using a 1 4 nutdriver remove the four screws that attach the front panel assembly to the front case Remove the front panel assembly 6 Using an X acto knife pry the front panel from the sub panel Remove the adhesive from the sub panel with isopropyl alcohol 7 Remove the protective backing from the replacement front panel then place the replacement front panel over the sub panel Assure the front panel is properly seated on the sub panel then press it into place Confirm that no air bubbles are trapped between the two surfaces and that the surfaces bond securely 8 Reinstall the power supply PWA and the CPU display PWA 9 Reassemble the case assemblies in the exact reverse order of disassembly 10 Close and lock the security door To verify successful replacement of the front panel perform the PVT in Section 5 2 Technical Service Manual 7 47 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS FRONT PANEL SUB PANEL FLEXIBLE CIRCUIT CABLE Figure 7 23 Front Panel Replacement 7 3 36 DOOR LOCK SWITCH REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver small flat blade screwdriver 1 4 nutdriver soldering iron and solder To replace the door lock switch see Figure 7 24 or Figure 7 25 and proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3
82. ection describes the general functions of the infuser 41 1 STARTING OPERATION The infuser is powered on by inserting or removing a vial or by pressing the ON touchswitch Once powered on the infuser begins a warm start or a cold start sequence depending on the time elapsed since the OFF RECHG touchswitch was last pressed 4 1 1 1 WARM START SEQUENCE The infuser initiates a warm start sequence if it is powered on within 60 minutes of previous operation In the warm start sequence all previous therapy parameters and dose history information are retained in memory Before the infuser can operate previous settings must be confirmed or cleared If previous settings are cleared the user must program the infuser with new therapy parameters 4 1 1 2 COLD START SEQUENCE The infuser initiates a cold start sequence if it is powered on after 60 minutes since previous operation The infuser also initiates a cold start sequence if the OFF RECHG touchswitch is pressed for approximately four seconds to clear all memory After 60 minutes most major electronic circuits turn off and all therapy settings and dose history data are lost During a cold start sequence a self test is performed to verify the functional integrity of the infuser After successful completion of the self test the infuser must be reprogrammed with new therapy parameters 4 1 2 SETUP During setup the liquid crystal display LCD screen displays prompts for each step
83. ed as follows 1 WwW N Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Place the front case assembly face down on a soft surface Using a 3 16 nutdriver remove the two switch mounting screws that attach the injector sensor switch bracket as applicable and switch to the injector flange clamp Remove the injector sensor switch Note Some infusers do not contain an injector sensor switch bracket 5 Unsolder the wires from the injector sensor switch terminals Solder the wires to replacement injector sensor switch as follows two black wires to center terminal brown wire to outside switch terminal Mount the injector sensor switch and switch bracket as applicable to the injector flange clamp using the screws that were removed in Step 4 8 Adjust the injector sensor switch as described in Section 7 2 4 9 Reassemble the infuser in the exact reverse order of disassembly 10 Close and lock the security door To verify successful replacement of the injector sensor switch perform the PVT in Section 5 2 Technical Service Manual 7 33 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 3 23 MOTOR ASSEMBLY REPLACEMENT 008 AND LOWER Recommended tools for this procedure are a 7 64 Allen wrench No 2 Phillips screwdriver and set of nutdrivers To replace the motor assembly see Figure 7 18
84. efective CPU display PWA Replace CPU display PWA 12 24 Hour Clock Selection PCA Plus Defective CPU display PWA Replace CPU display PWA Select RX Concentration 3 1 software and higher LifeCare PCA Plus and Plus II Series Incorrect software version 6 8 Verify software version Technical Service Manual Service Test Failure Delivery Accuracy Test Section 5 2 5 SERVICE TEST AND PVT TROUBLESHOOTING Table 6 4 Troubleshooting with the PVT Possible Cause PCA set not primed properly Defective power supply PWA Defective motor assembly Corrective Action Prime set check clamps Replace power supply PWA Replace motor assembly Occlusion Test Section 5 2 6 Set not installed or primed properly Occlusion pressure switch out of adjustment or defective Defective power supply PWA Prime set Adjust or replace occlusion pressure switch Replace power supply PWA PCA Continuous Test Section 5 2 7 Set not installed or not primed properly Infuser not set up properly Check installation and prime set Check infuser settings Patient Control Jack Test Section 5 2 8 Loose connection Defective interconnect PWA cable Defective patient pendant jack Check connector J8 on the power supply PWA Replace interconnect PWA cable Replace patient pendant jack or interconnect PWA Patient Pendant Assembly Test Section 5 2 9 Defective patient pendant as
85. eight Phillips screws that attach the control panel to the rear case then remove the control panel Unsolder the harness wires from the audible level switch terminals Using a 5 16 nutdriver remove the nut that attaches the audible level switch to the control panel Install the replacement audible level switch in the control panel Using a 1 2 box wrench secure the switch with the retaining nut Solder the wires from the harness to the audible level switch as follows white wire with orange stripe to the upper terminal white wire with black stripe to the center terminal white wire with brown stripe to the lower terminal Remount the control panel on the rear case with the eight Phillips screws that were removed in Step 4 Replace the adhesive backed cable tie clamp on the inside of the rear case Use care to place the clamp in the same location Reassemble the case assemblies in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the audible level switch perform the PVT in Section 5 2 LifeCare PCA Plus and Plus Series 7 44 Technical Service Manual REPLACEMENT PROCEDURES 7 3 32 INTERCONNECT PWA REPLACEMENT This procedure applies to infusers with final assembly number 850 04250 008 and higher Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers wire cutters wire strippers soldering iron solder
86. ench and 7 8 open end wrench To replace the door latch assembly proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3 3 Using a small flat blade screwdriver and or 1 4 nutdriver remove the door lock switch from the door latch assembly 4 Make sure the key is in the upward 12 o clock position then remove the two 1 4 inch screws that attach the door latch and door latch spacer as applicable to the support plate Remove the door latch assembly 5 For type B locks only remove the extension spring from the door lock bracket and latch see Figure 7 24 Technical Service Manual 7 51 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 6 Remove the retaining ring from the pivot pin Remove the pivot pin torsion spring type A locks only and the door lock actuator 7 Reassemble the door latch assembly in the exact reverse order of disassembly For type A locks make certain the torsion spring is compressed as shown in Figure 7 27 before replacing the pivot pin 8 Reinstall the door lock switch and reassemble the infuser in the exact reverse order of disassembly 9 Close and lock the security door To verify successful installation of the door latch assembly perform the PVT in Section 5 2 PIVOT PIN RETAINING RING TORSION SPRING TORSION SPRING ENDS COMPRESSED Figure 7 27 Door Latch Torsion Spr
87. er is off Motor drivers U17A U17B U17C and U17D that step the motor through its phases and motor monitoring circuitry U15A U15B U15C U15D that detects driver and motor malfunctions 4 2 2 1 POWER SUPPLY SYSTEM INTERFACES The power supply PWA receives input from either the isolation transformer T1 or the battery via P J3 The power supply PWA interfaces with the CPU display PWA through a ribbon cable connected at P J7 that consists of the microprocessor data bus lines address lines AO and Al 5 VDC power and various signal lines The power supply PWA receives the VIALSW signal from P J6 and the other microswitch signals PRESSURESW SYRINGELO SYRINGE EMPTYSW and INJECTORSW from P J4 The motor drive signals and the shaft sensor feedback signals are routed to the power supply PWA via P J 5 The audible alarm signal audible level switch inputs door switch signal and patient pendant input interface with the power supply PWA through a connector P J8 P J8 also routes lines to the printer Dataway connector 410 Test port J11 interfaces with the power supply PWA via P J9 to provide external access to test points throughout the system 4 2 2 2 UNREGULATED DC VOLTAGE The output of AC power transformer is applied to CR14 via connector P J3 CR14 is a full wave rectifier capacitor C16 filters the resulting DC voltage When AC power is on operational amplifier U12A transistors Q4 and Q2 and voltage reference U18 charge
88. er supply PWA Check connection at J8 on power supply PWA Inspect interconnect PWA cable for damage and replace if required Replace audible level switch or interconnect PWA Replace piezoelectric alarm or interconnect PWA Motor Rotation Defective power supply PWA Defective CPU display PWA Lead screw dirty or needs lubrication Loose connection Defective motor assembly Replace power supply PWA Replace CPU display PWA Lubricate lead screw Check connector J5 on power supply PWA Replace motor assembly Security Door Loose connection Doorlock switch out of adjustment or defective Defective power supply PWA Check connector J8 and J7 on power supply PWA Adjust or replace door lock switch Replace power supply PWA Syringe Test Loose connection Injector sensor switch defective Vial sensor switch out of adjustment or defective Defective power supply PWA Check connector J6 or J4 on power supply PWA Replace injector sensor switch Adjust or replace vial sensor switch Replace power supply PWA Low Empty Syringe Loose connection Syringe low sensor switch out of adjustment or defective PCA only Syringe empty sensor switch out of adjustment or defective Defective power supply PWA Check connector J4 on power supply PWA Adjust or replace syringe low switch Adjust or replace syringe empty switch Replace power supply PWA Patient Pendent Tone Selection D
89. erminal 9 Using a 1 2 box wrench remove the retainer nut that attaches the patient pendant jack to the control panel 10 Remount the control panel on the rear case with the eight Phillips screws removed in Step 4 11 Replace the adhesive backed cable tie clamp on the inside of the rear case Use care to place it in the same location 12 Reassemble the infuser case assemblies in the exact reverse order of disassembly 13 Close and lock the security door To verify successful replacement of the patient pendant jack perform the PVT in Section 5 2 Technical Service Manual 7 43 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 3 31 AUDIBLE LEVEL SWITCH REPLACEMENT This procedure applies to infusers with final assembly numbers 850 04250 002 through 007 Infusers with final assembly number 850 04250 008 and higher require replacement of the Interconnect PWA if the audible level switch is defective see Section 7 3 32 Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers soldering iron and solder To replace the audible level switch proceed as follows 1 2 3 10 11 12 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Place the rear case assembly on a soft surface with the interior facing up Remove the adhesive backed cable tie clamp from the rear case Remove the
90. ernal RAM Defective CPU display PWA Replace CPU display PWA External RAM ADRS Defective CPU display PWA Replace CPU display PWA External RAM Cell Defective CPU display PWA Replace CPU display PWA CPU Defective CPU display PWA Replace CPU display PWA ROM Defective CPU display PWA Replace CPU display PWA Real Time Clock Defective CPU display PWA Replace CPU display PWA LED Defective CPU display PWA Replace CPU display PWA LCD Defective CPU display PWA Replace CPU display PWA Keypad Loose connection damaged Check ribbon cable from touchswitch ribbon cable to J13 on CPU display PWA Defective touchswitch Replace front panel if required Check ribbon cable from J12 on CPU display PWA to J7 on power supply PWA Replace ribbon cable if required Replace front panel Defective CPU display PWA Replace CPU display PWA Indicator Loose connection defective Check ribbon cable from J12 Technical Service Manual ribbon cable 6 7 on CPU display PWA to J7 on power supply PWA Replace ribbon cable if required LifeCare PCA Plus and Plus II Series Section 6 TROUBLESHOOTING Service Test Failure Table 6 3 Possible Cause Defective CPU display PWA Defective power supply PWA Loose connection defective ribbon cable Defective audible level switch Defective piezoelectric alarm Service Test Troubleshooting Corrective Action Replace CPU display PWA Replace pow
91. frequency of discharge and the length of the recharge period As a general rule the more often the battery is discharged and recharged the sooner it will need replacement The primary cause of damage is leaving the battery in a less than fully charged state for any period of time Battery damage can occur in a matter of hours and cause a permanent loss of battery capacity The amount of lost capacity depends on the degree of discharge the storage temperature and the length of time the battery was stored in a discharged state Note permanently damaged battery cannot be recharged to full capacity When the battery discharges below an acceptable level while the infuser is operating an alarm sounds and the LOW BATTERY message displays Although it is not recommended to continue operating the infuser on battery power at this point the battery continues providing power until it is depleted When the battery is depleted the infuser enters the battery discharged mode and operation ceases CAUTION As soon as the low battery alarm occurs connect the infuser to AC power Recharging can occur any time the infuser is connected to AC power It is recommended that the infuser be connected to AC power whenever practical to maximize available battery charge during patient transport or ambulation The power switch does not have to be on for the battery to recharge Recharging while the infuser is operating is rate dependent LifeCare PCA Plus and
92. ght for the adjustment procedure 4 Install a water filled syringe into the infuser Connect an IV administration set DPM and stopcock Open the stopcock valve 5 Purge the system until water flows out of the stopcock valve then close the valve When the LCD screen displays DRUG Rx MORPHINE 1 MG ML YES OR NO press YES ENTER LifeCare PCA Plus and Plus Series 7 12 Technical Service Manual ADJUSTMENT PROCEDURES 6 Set and initiate a loading dose of 10 mg Allow the infuser to operate until an occlusion alarm sounds or the pressure reaches 17 5 psig 120 75 kPa 7 If the occlusion alarm sounds before the pressure reaches 12 5 psig 86 25 kPa relieve the fluid pressure by opening the stopcock valve Loosen the set screw on the thumb nut and turn the thumb nut clockwise to tighten then repeat Step 5 8 If the occlusion alarm does not sound at or before 17 5 psig 120 75 kPa relieve the fluid pressure by opening the stopcock valve Loosen the set screw on the thumb nut and turn the thumb nut counterclockwise to loosen then repeat Step 5 9 When the infuser occludes at between 12 5 and 17 5 psig 86 25 and 120 75 kPa retighten the set screw on the thumb nut 10 Close and lock the security door To verify successful adjustment of the occlusion switch and pressure perform the PVT in Section 5 2 SWITCH NO 0 PHILLIPS ACTUATOR SCREW OCCLUSION ALARM SWITCH SLIDE CLAMP COMPRESSION SPRING RELEASE
93. grams Drugs milligrams and micrograms 5 2 5 DELIVERY ACCURACY TEST To perform the delivery accuracy test proceed as follows l Using a PCA vial syringe with a primed PCA administration set and a 21 gauge butterfly insert the vial into the infuser vial holder and injector cradle 2 Purgethe infuser at start up then set up the infuser for 1 mg mL Place the butterfly in the graduate Initiate two loading doses of 10 mL each Verify the infuser delivers 20 1 mL in the graduate 5 2 6 OCCLUSION TEST Note Ensure that performance testing for occlusion pressure uses either only new vials or vials that are not stored with water in them Note A light coating of medical fluid P N 743 35070 001 may be applied to the vial plunger to reduce friction as needed To perform the occlusion test proceed as follows l Insert the water filled vial with the primed PCA administration set into the cradle assembly Lubricate the vial with silicone oil before each use 2 Attach the DPM to the distal end of the administration set through the three way stopcock 3 Allow the infuser self test to complete When the LCD screen displays PURGE THE SYSTEM NOW press SILENCE NO 4 When the LCD screen displays DRUG Rx MORPHINE 1 MG ML YES OR NO press YES ENTER 5 WhentheLCD screen displays ADMINISTER LOADING DOSE NOW press YES ENTER 6 Select loading dose of 5 mg Press YES ENTER then press LOADING DOSE
94. harged battery provides approximately four hours of operation with up to 30 mL of delivery Approximately 1 mL in 35 seconds Variable from 0 5 x concentration to 20 x concentration mg hr Variable from 0 5 x concentration to 20 x concentration mg hr plus PCA rate 5 to 100 minutes in 1 minute increments 10 to 20 psi 50 to 104 F 10 to 40 C ambient temperature 5 95 relative humidity non condensing Meets UL ANSI and CSA standards Use only compatible Hospira PCA sets with integral anti siphon valve 8 1 LifeCare PCA Plus and Plus II Series SECTION 8 SPECIFICATIONS 8 2 PCA PLUS II Dimensions Weight Casing Power Requirements Power Cord Fuses Battery Battery Life PCA Only Mode Continuous Only Mode PCA Continuous Lockout Interval Range Backpressure Range Operating Environment Electrical Safety Administration Sets LifeCare PCA Plus and Plus Series Approximately 8 in W x 13 in Hx 6 in D excluding pole clamp and power cord Approximately 15 Ibs with battery High density polyurethane structural foam 110 120 V 50 60 Hz 25 W Hospital grade AC cord 10 ft 0 25 A 250 V Slo Blo One sealed lead acid rechargeable 8 V internal to the device A fully charged battery provides approximately four hours of operation with up to 30 mL of delivery Approximately 1 mL in 35 seconds Variable from 0 1 x concentration to 20 x concentration mg hr o
95. ing Placement Type A 7 3 40 REAR CASE ASSEMBLY REPLACEMENT Note The infuser serial number is required when ordering a new rear case The serial number is located on the back of the infuser Hospira will place a duplicate serial number label on the replacement rear case Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers set of box wrenches and small flat blade screwdriver To replace the rear case assembly proceed as follows 1 Disconnect the infuser from AC power 2 Verify that the serial number on the replacement rear case matches the serial number on the original rear case 3 Separate the front and rear case assemblies as described in Section 7 2 3 LifeCare PCA Plus and Plus Series 7 52 Technical Service Manual 4 5 6 7 REPLACEMENT PROCEDURES Remove the following components using the procedures described in their corresponding sections Battery and battery cover Section 7 3 3 Pole clamp assembly Section 7 3 5 Velcro strap and retainer plate Section 7 3 6 Security door Section 7 3 7 AC power cord Section 7 3 9 Printer Dataway connector and control panel harness Section 7 3 28 Battery Boost charger PWA if applicable Section 7 3 34 Door lock switch Section 7 3 36 Door lock assembly Section 7 3 37 Reassemble the rear case assembly in the exact reverse order of disassembly Reassemble the infuser in the exact reverse order of disasse
96. inst the injector sensor microswitch which causes the switch to close If a vial is installed in the cradle but the injector flange is improperly seated i e the vial sensor rod is not forced rearward and the switch remains open and an attempt is made to start the infuser logic circuitry on the power supply PWA senses the status of the INJECTORSW signal and sets the ON OFF latch U14B U14C When the ON OFF latch is set the infuser is prevented from starting the audible alarm sounds and the CHECK INJECTOR message is displayed on the LCD The SILENCE touchswitch has no effect on this alarm the alarm is cleared by properly seating the injector flange in the injector flange clamp 4 3 4 3 CHECK SYRINGE ALARM When no syringe is installed in the infuser or when a syringe is installed but both the vial and the injector flange are improperly seated the vial sensor switch and the injector sensor microswitch remain open If an attempt is made to start the infuser under these conditions logic circuitry on the power supply PWA senses the status of the INJECTORSW signal and sets the ON OFF latch U14B U14C When the ON OFF latch is set the infuser is prevented from starting the audible alarm sounds and the CHECK SYRINGE message is displayed on the LCD The SILENCE touchswitch has no effect on this alarm The alarm is cleared by installing a syringe so that the vial is properly seated in the cradle assembly and the injector flange is properl
97. ion 4 1 Status messages 4 2 Syringe empty switch adjustment 7 9 Syringe low and syringe empty alarm system 4 12 Syringe low and syringe empty switch replacement 7 32 Syringe low switch adjustment 7 8 System operating manual 3 1 T Technical Assistance 6 1 Test Setup 5 4 Theory of operation 4 1 Electronics overview 4 3 General functions 4 1 Mechanical overview 4 10 Troubleshooting 6 1 Alarm and display message overview 6 2 Diagnostic mode 6 1 Service test and PVT troubleshooting 6 7 Technical assistance 6 1 LifeCare PCA Plus and Plus II Series Section INDEX U Unpacking 1 4 Unregulated DC voltage 4 7 User qualification 1 4 V Velcro strap and retainer plate replacement 7 22 Vial and injector sensor alarm system 4 16 Vial sensor switch Adjustment 7 6 Replacement 7 30 Warm start sequence 4 1 Warranty 2 1 Watchdog circuit 4 6 LifeCare PCA Plus and Plus II Series Technical Service Manual For technical assistance product return authorization and to order parts accessories or manuals within the United States contact Hospira 1 800 241 4002 For additional services and technical training courses visit the website www hospira com For technical assistance and services outside the United States contact the local Hospira sales office WARNING EXPLOSION HAZARD EXISTS IF THE INFUSION SYSTEM IS USED IN THE PRESENCE OF FLAMMABLE SUBSTANCES CAUTION Federal USA la
98. itch bracket up until the switch clicks off and the alarm stops 5 Loosen the adjustment screws as necessary Move the switch bracket down slowly until the switch clicks on then tighten the screws 6 Adjust the cradle until the gauge dial reads approximately 0 3 inch Set the infuser for PCA Only mode delivery When the LCD screen displays SELECT MODE PCA ONLY press YES ENTER Technical Service Manual 7 7 LifeCare PCA Plus and Plus Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 Set a PCA dose of 5 mg 8 Close and lock the security door 9 When three asterisks appear on the LCD screen press the patient pendant pushbutton 10 Verify the empty syringe alarm occurs when the dial reads between 0 39 and 0 41 inch If the alarm does not occur within these parameters return to Step 4 and vary the setting to less than or greater than 0 39 inch as appropriate 11 Tighten the screws and apply red GLPT insulating varnish to the screw heads 12 Reassemble the infuser in the exact reverse order of disassembly 13 Close and lock the security door To verify successful adjustment of the syringe empty switch perform the PVT in Section 5 2 SYRINGE EMPTY BRACKET ARM DIRECTION OF TRAVEL SYRINGE LOW BRACKET ARM SYRINGE EMPTY SWITCH ARM SYRINGE LOW SWITCH ARM Figure 7 6 Syringe Empty Switch 008 and Lower LifeCare PCA Plus and Plus II Series 7 8 Technical Service Manual ADJUSTMENT PRO
99. ith final assemblies 850 04250 002 through 850 04250 008 PCA Plus II Series infusers with final assemblies 850 04250 010 and higher do not contain an injector sensor switch bracket Therefore the injector switch is not adjustable Some configurations of PCA Plus Series infusers with final assembly numbers 850 04250 006 through 850 04250 008 may not contain an injector sensor switch bracket Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers and red GLPT insulating varnish Technical Service Manual 7 3 LifeCare PCA Plus and Plus Series Section 7 REPLACEABLE PARTS AND REPAIRS To adjust the injector sensor switch see Figure 7 2 or Figure 7 3 and proceed as follows 1 2 3 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Using a 3 16 nutdriver loosen the two switch mounting screws until the switch holder can be easily moved Do not loosen the screws so much that the switch bracket rocks from side to side Position the switch bracket parallel to the surface and 1 32 inch from the infuser case and tighten the screws 5 Apply red GLPT insulating varnish to the screw heads 6 7 Reassemble the infuser in exact reverse order of disassembly Close and lock the security door To verify successful adjustment of the injector sensor switch perform the PVT in Section 5 2 MOTOR ASSEMBLY INJECTOR SENSOR SWI
100. ith the security door open Remove the gasket seal and install the replacement gasket seal Wipe the replacement gasket seal with isopropyl alcohol Q a F WwW N Reassemble the infuser in the exact reverse order of disassembly and close and lock the security door To verify successful replacement of the gasket seal perform the PVT in Section 5 2 7 3 11 POWER SUPPLY PWA REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers 1 4 open end wrench and set of Allen wrenches To replace the power supply PWA see Figure 7 14 and proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3 3 Using a 1 4 nutdriver remove the four screws that secure the power supply PWA to the spacers If necessary hold the power supply PWA spacers with a 1 4 open end wrench while removing the screws 4 Lift the power supply PWA from the spacers 5 Install the replacement power supply PWA in the exact reverse order of removal 6 Reassemble the infuser in the exact reverse order of disassembly and close and lock the security door To verify successful replacement of the power supply PWA perform the PVT in Section 5 2 Technical Service Manual 7 23 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS Q 40 PIN RIBBON CABLE j 7 3 12 FLEXIBLE CIRCUIT CABLE CPU DISPLAY PWA NYLO
101. iver set of nutdrivers set of box wrenches and small flat blade screwdriver To replace the printer Dataway connector and control panel harness see Figure 7 21 and proceed as follows 1 a 10 11 12 13 14 15 16 17 18 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Place the infuser rear case assembly on a soft surface with interior facing up Disconnect the harness connector from J8 on the power supply PWA Pull the adhesive backed cable tie clamp from the rear case Cut and remove the cable tie that attaches the door lock switch wires to the rear case Using a small flat blade screwdriver and a 1 4 nutdriver remove the two screws that attach the door lock switch to the door latch To ease disassembly and reassembly remove the eight Phillips screws that attach the control panel to the rear case the remove the control panel Using a small flat blade screwdriver and a 3 16 nutdriver remove the two screws that attach the printer Dataway connector J10 to the control panel Using a 5 16 nutdriver remove the nut that attaches the green wire to the control panel Using a 3 16 nutdriver remove the screws that attach the piezoelectric alarm to the control panel The longer of the two screws is used in the upper mounting hole to accommodate the plastic cable clip Using a 5 16 box wrench remove
102. justment 7 11 Occlusion pressure alarm system 4 14 Occlusion pressure switch replacement 7 33 Occlusion test 5 6 On off latch 4 8 P Patient control jack test 5 8 Patient controlled analgesia 4 2 Patient pendant assembly Replacement 7 23 Test 5 8 Patient pendant jack replacement 7 43 PCA continuous test 5 7 Performance verification test 5 2 Battery charger test 5 9 Delivery accuracy test 5 6 Electrical safety test 5 9 End of the PVT 5 12 Equipment required 5 3 Inspection 5 3 Occlusion test 5 6 Patient control jack test 5 8 Patient pendant assembly test 5 8 PCA continuous test 5 7 Printer test 5 10 Service test mode tests 5 4 Test setup 5 4 Technical Service Manual Periodic maintenance inspection 5 12 Piezoelectric alarm replacement 7 42 Pole clamp assembly replacement 7 21 Power supply PWA 4 7 Replacement 7 24 Power supply system interfaces 4 7 Printer data latch 4 8 Printer test 5 10 Printer Dataway connector and control panel harness replacement 7 40 PVT troubleshooting 6 7 R Rear case assembly replacement 7 53 Replaceable parts and repairs 7 1 Replacement procedures 7 18 15 conductor diagnostic cable 7 28 40 pin ribbon cable 7 27 AC power cord 7 23 Audible level switch 7 44 Battery boost charger PWA 7 47 Battery 7 19 Changing the key number 7 51 CPU display PWA 7 25 Cradle assembly 7 29 Door latch assembly 7 51 Door lock assembly 7 50 Door lock swit
103. justment of the LCD intensity perform the PVT in Section 5 2 255 ADHESIVE BACKED lt PLASTIC INSULATOR 22 LCD ASSEMBLY Le gt 3 LA STANDOFF 4 LCD RIBBON CABLE 40 PIN RIBBON CABLE R19 ADJUSTMENT SCREW CPU DISPLAY PWA Figure 7 11 CPU Display PWA LED and LCD Assembly LifeCare PCA Plus and Plus II Series 7 14 Technical Service Manual ADJUSTMENT PROCEDURES 7 2 10 SETTING THE REAL TIME CLOCK PCA PLUS The PCA Plus II Series Infuser real time clock tracks time Therefore infuser operations require that the real time clock be operating properly At start up after successful completion of the self test the time and date are displayed on the LCD screen The real time clock must be set under the following circumstances Initial installation Time change Following complete battery discharge No tools are required for this procedure To reset the real time clock proceed as follows 1 Press NO to advance beyond the CLEAR screen Press NO to advance beyond the PURGE SYSTEM NOW screen Press YES ENTER to select the first available drug screen Press NO to advance beyond the ADMINISTER LOADING DOSE screen Press YES ENTER to select PCA ONLY mode Press YES ENTER to select the displayed PCA dose Press YES ENTER to select the displayed LOCKOUT INTERVAL Press NO to advance beyond the 4 HOUR DOSE LIMIT o ODN OA A WwW Press REVIEW CHANGE to a
104. k List Number 3233 Digital Pressure Meter DPM O to 50 psi Fluke Biomedical DPM3 Safety Analyzer Fluke Biomedical 232D 21 gauge butterfly needle latex free List No 4492 01 or 18 gauge blunt cannula Test cable P N 561 88416 001 fitted with phone jack with individual banana plugs compatible with patient control connector on rear of infuser Parallel network P N 561 88419 001 Digital Multimeter DMM Fluke 187 X acto knife 5 2 2 INSPECTION Inspect the infusion system periodically for signs of defects such as worn accessories broken connections or damaged cables In addition inspect the infusion system after repair or during cleaning Replace any damaged or defective external parts Inspect the following areas for missing or damaged parts and for cosmetic defects Labels AC power cord Velcro straps Touchswitches LCD LEDs Technical Service Manual External screws Case Pole clamp and pads Front panel Security door Accessories 5 3 LifeCare PCA Plus and Plus II Series Section 5 MAINTENANCE AND SERVICE TESTS 5 2 3 TEST SETUP WARNING A PATIENT SHOULD NEVER BE CONNECTED TO THE INFUSER DURING DEVICE TESTING To set up the infuser for the PVT proceed as follows 1 Using the dual lock mechanism secure the infuser to an IV pole Note When the security door is locked the infuser locks to the pole clamp and prevents its removal without a key 2 Connect the s
105. ked PATIENT LOCKOUT Displays after a successful patient initiated dose delivery Message remains until the lockout interval elapses Message appears only when the security door is locked and the infuser is in PCA or PCA CONTINUOUS mode 4HR LIMIT REACHED Displays if four hour dose limit is enabled and the limit is reached with the security door locked uides Indicates the patient can initiate a dose in PCA or PCA CONTINUOUS mode PCA Displays when the infuser is in PCA mode CONTINUOUS Displays when the infuser is in CONTINUOUS mode PCA CONTINUOUS Displays when the infuser is delivering a PCA dose in addition to a continuous delivery in the PCA CONTINUOUS mode LifeCare PCA Plus and Plus II Series 4 2 Technical Service Manual 4 2 ELECTRONICS OVERVIEW 4 2 ELECTRONICS OVERVIEW Note vinculum overscore above signal designation e g BWR denotes an active low signal The infuser electronics system contains the CPU display printed wiring assembly PWA and the power supply PWA The microprocessor on the CPU display PWA communicates with components both PWAs through an 8 bit data bus D7 DO and a 16 bit address bus 15 Low level signals from the front panel touchswitches and sensor switches are input directly by the CPU display PWA where they are placed in buffers on the microprocessor data bus Data buffers on the CPU display PWA also receive input from the power supply PWA Prim
106. lays INT RAM TEST then DIAGNOSTIC MODE The LCD screen also displays the software revision and the total elapsed days since the infuser was placed into service 2 Press YES ENTER 3 Press PRINT to print out the event log or press SILENCE NO to continue to the malfunction log screen Technical Service Manual 6 1 LifeCare PCA Plus and Plus II Series Section 6 TROUBLESHOOTING KKEKKKKKKKKKKKKKKKKKK DIAGNOSTIC MODE KKEKKKKKKKKKKKKKKKKKK S W VERSION X XX KKEKKKKKKKKKKKKKKKKKK DIAGNOSTIC MODE KKEKKKKKKKKKKKKKKKKKK S W VERSION X XX ELAPSE DAYS 0 ELAPSE DAYS 0 12 01 NOV 12 09 12 06 NOV 12 09 FOO A IK EVENT LOG MALFUNCTION LOG FOO AM 08 28 OFF ML 00 00 MALF 1A 09 19 4 HR LIMIT NOT SELECTED 09 19 LOCKOUT 09 19 PCA DOSE NOV 07 09 NEW DATE PM 12 16 OFF PM 12 15 CHK SYR ALM PM 12 15 INJECTR ALM PM 12 14 CHK SYR ALM PM 12 14 VIAL ALM 5 MIN 5 0 MG ML 09 14 MALF 2B ML 0910 MALF 3A ML 09 09 MALF AF KKEKKKKKKKKKKKKKKKKKK VERIFIED BY KKEKKKKKKKKKKKKKKKKKK KKEKKKKKKKKKKKKKKKKKK END OF RECORD kkkxkkxkxkxkkkkkkkkkkkkxk VERIFIED BY kkkxkkkxkxkkkkkkkkkkkkk KKEKKKKKKKKKKKKKKKKKK END OF RECORD Figure 6 1 Sample Event Log and Malfunction Log 6 3 ALARM AND DISPLAY MESSAGE OVERVIEW Under most alarm conditions the infuser stops operating generates an audible alarm and disp
107. lays an alarm message on the LCD screen CAUTION For those patients who are likely to be adversely affected by unintended operations and failures including interrupted medication A or fluid delivery from the device close supervision and provision for immediate corrective action should be provided A CAUTION Do not return the infuser to service after an alarm or malfunction without determining and correcting the cause of the alarm or malfunction LifeCare PCA Plus and Plus II Series 6 2 Technical Service Manual ALARM AND DISPLAY MESSAGE OVERVIEW 6 3 1 AUDIBLE ALARMS The infuser sounds an alarm in the event of any abnormal condition The alarm volume can be set to low medium or high by a three way switch on the back of the infuser The infuser produces five different tones as follows A single short tone indicates the infuser senses a touchswitch being pressed Two short tones indicate the start of a power up sequence Three short tones indicate that a touchswitch was pressed that is invalid for the infuser s current state of operation or is not an allowable response to a prompt on the LCD screen Two short tone long tone sequences repeating every few seconds indicate an alarm condition The LCD screen displays the type of alarm in flashing letters Acontinuous tone indicates an infuser malfunction The LCD screen may or may not display further information depending on the malfunction 6 3 2 ALARM CAUSES AND
108. mbly Close and lock the security door To verify successful replacement of the rear case assembly perform the PVT in Section 5 2 7 3 41 FRONT CASE ASSEMBLY REPLACEMENT Recommended tools for this procedure are a 1 4 inch nutdriver and X acto knife To replace the front case assembly proceed as follows 1 N 7 Remove the power supply PWA as described in Section 7 3 11 Remove the CPU display PWA as described in Section 7 3 12 Remove the slide assembly as described in Section 7 3 25 or Section 7 3 26 Using a 1 4 nutdriver remove the four screws that attach the front panel assembly to the front case Remove the front panel assembly and install onto the new case assembly Install the slide assembly into the new front case as described in Section 7 3 25 or Section 7 3 26 Reinstall the power supply PWA and the CPU display PWA in the exact reverse order of disassembly Reassemble the infuser in the exact reverse order of disassembly To verify successful front case assembly replacement perform the PVT in Section 5 2 Technical Service Manual 7 53 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 3 42 RUBBER FOOT PAD REPLACEMENT Recommended tools for this procedure are a 3 8 inch wood chisel or X acto knife isopropyl alcohol and cotton swabs To replace the rubber foot pad see Figure 7 12 and proceed as follows 1 Place the infuser on its side 2
109. n 7 2 8 2 or Section 7 2 8 3 If the reading is between the specified parameters perform the PVT in Section 5 2 WATER FILLED VIAL aLa PURGE SYSTEM STOPCOCK E YES ENTER g LOAD REVIEW DOSE CHANGE PRESSURE METER om OF HO all INCHES OF 4957015 SILENCE PRINT Pd mS 4351075 l OFF RESET REGIS START HISTORY PRESSURE NT S Hospira LIFECARE e 100 DRAIN Figure 7 8 Occlusion Alarm Test Setup 7 2 8 2 OCCLUSION ALARM SWITCH AND PRESSURE ADJUSTMENT 008 AND LOWER To adjust the occlusion alarm switch and pressure see Figure 7 9 and proceed as follows 1 Separate the front and rear case assemblies as described in Section 7 2 3 2 Examine the position of the occlusion alarm switch If the switch button is in contact with the switch actuator proceed to Step 5 If the switch button is not making contact with the switch actuator use an 11 32 open end wrench to loosen the bracket locknut at the top of the bracket Using a 9 32 Allen wrench adjust the set screw so the switch button makes contact with the switch actuator but does not open the switch LifeCare PCA Plus and Plus II Series 7 10 Technical Service Manual ADJUSTMENT PROCEDURES 4 Tighten the bracket locknut using the 11 32 open end wrench and apply red GLPT insulating varnish to
110. nfusion system infuser and device are used interchangeably throughout the manual Figures are rendered as graphic representations to approximate actual product Therefore figures may not exactly reflect the product Screen representations are examples only and do not necessarily reflect the most current software version Technical Service Manual 1 1 LifeCare PCA Plus and Plus II Series SECTION 1 INTRODUCTION 12 CONVENTIONS The conventions listed in Table 1 1 are used throughout this manual Convention Italic Table 1 1 Conventions Application Example Reference to a section figure see Section 6 1 table website or publication ALL CAPS ALL CAPS In text references to keys LOADING DOSE touchswitches and display messages ADMINISTER LOADING DOSE NOW Bold Emphasis CAUTION Use proper ESD grounding techniques when handling components Throughout this manual warnings cautions and notes are used to emphasize important information as follows WARNING A WARNING CONTAINS SPECIAL SAFETY EMPHASIS AND MUST BE OBSERVED AT ALL TIMES FAILURE TO OBSERVE A WARNING MAY RESULT IN PATIENT INJURY AND BE LIFE THREATENING CAUTION A CAUTION usually appears in front of a procedure or statement It contains information that could prevent hardware failure irreversible damage to equipment or loss of data Note A note highlights information that helps explain a concept or pr
111. nish Flat blade screwdriver Water filled and empty syringe Set of Phillips screwdrivers Three way stopcock IV administration set Needle nose pliers X acto knife Syringe limit gauge Grease Braycote 804 Digital pressure meter DPM Trimpot tool Isopropyl alcohol or Electro Wash 2000 Permanent marker 7 2 3 SEPARATING FRONT AND REAR CASE ASSEMBLIES The front and rear case assemblies must be separated before performing any adjustment procedure Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers and permanent marker To separate the front and rear case assemblies see Figure 7 1 and proceed as follows 1 Disconnect the infuser from AC power 2 Set the infuser upright on a flat surface Confirm the security door is unlocked 3 Using the No 2 Phillips screwdriver remove the AC power cord retainer plate by removing the screw that attaches the retainer plate to the back of the infuser 4 Using the No 2 Phillips screwdriver remove the long 10 32 flat head Phillips screws from each corner of the infuser rear case assembly 5 Separate the front case from the rear case Note Prior to disconnecting a connector verify the connector is numbered If the connector contains no identifier number it with a permanent marker Disconnect the 28 pin 2 row connector from J8 on the power supply PWA Disconnect the 16 pin connector from J9 on the power supply PWA Dis
112. nt slide assembly and replace the screws removed in Step 6 Lubricate the lead screw with grease Reinstall the wire harnesses in the exact reverse order of disassembly Reconnect the ribbon cables to the power supply PWA Replace the slide clamp knobs levers that were removed in Step 4 if required Replace the cradle assembly that was removed in Step 3 if required LifeCare PCA Plus and Plus Series 7 38 Technical Service Manual 13 14 15 REPLACEMENT PROCEDURES Adjust the following switches using the procedures described in their corresponding sections Injector sensor switch Section 7 2 4 Vial sensor switch Section 7 2 5 Syringe low switch as applicable Section 7 2 6 Syringe empty switch Section 7 2 7 Occlusion pressure switch Section 7 2 8 3 Reassemble the case assemblies in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the slide assembly perform the PVT in Section 5 2 7 3 27 INJECTOR FLANGE CLAMP REPLACEMENT Two configurations of injector flange clamps are used depending on the final assembly number of the infuser This procedure may be followed for both configurations Recommended tools for this procedure are a No 2 Phillips screwdriver and set of nutdrivers To replace the injector flange clamp see Figure 7 16 and proceed as follows 1 a 9 10 11 12 Disconnect the infuser from
113. ocedure 13 ACRONYMS AND ABBREVIATIONS Acronyms and abbreviations used in this manual are as follows AC ADC BRD BWR cm CPU CS dB DC DPM LifeCare PCA Plus and Plus II Series Alternating current Analog to digital converter Bus read Bus write Centimeter Central processor unit Chip set Decibel Direct current Digital pressure meter 1 2 Technical Service Manual ECG EKG EMG EPROM ESD ETO Hr IC kPa LCD LED LIM MALF MCS mg MHz mL mV PCA PPI psi psig PVT PWA RD ROM VAC WR 5 us Technical Service Manual 1 3 ACRONYMS AND ABBREVIATIONS ELectroencephalogram Electrocardiograph Electromyogram Erasable programmable read only memory Electrostatic discharge Ethylene oxide Hour Integrated circuit Input output Kilopascal Liquid crystal display Light emitting diode Limit Milliampere Malfunction Main control switch Milligram Megahertz Milliliter Millisecond Millivolt Patient controlled analgesia Programmable peripheral interface Pounds per square inch Pounds per square inch gauge Performance verification test Printed wiring assembly Random access memory Read Read only memory Volt Voltage direct current Voltage alternating current Write Microampere Microgram Microsecond 1 3 LifeCare PCA Plus and Plus II Series SECTION 1 INTRODUCTION 14 USER QUALIFICATION The infusion system is intended for use at the direction or un
114. or other service means any repair or service other than the replacement of accessory items such as batteries and detachable AC power cords In providing any parts for repair or service of the product Hospira shall have no responsibility or liability for the actions or inactions of the person performing such repair or service regardless of whether such person has been trained to perform such repair or service It is understood and acknowledged that any person other than a Hospira representative performing repair or service is not an authorized agent of Hospira Technical Service Manual 2 1 LifeCare PCA Plus and Plus II Series SECTION 2 WARRANTY This page intentionally left blank LifeCare PCA Plus and Plus II Series 2 2 Technical Service Manual Section 3 SYSTEM OPERATING MANUAL A copy of the System Operating Manual is included with every LifeCare PCA Plus and Plus II Series infusion system If a copy is not available contact Hospira see Section 6 1 Technical Service Manual 3 1 LifeCare PCA Plus and Plus II Series SECTION 3 SYSTEM OPERATING MANUAL This page intentionally left blank LifeCare PCA Plus and Plus II Series 3 2 Technical Service Manual m Section 4 THEORY OF OPERATION This section describes the theory of operation for the LifeCare PCA Plus and Plus II Series infusers The theory of operation details the general functions electronics overview and mechanical overview 41 GENERAL FUNCTIONS This s
115. ose and lock the security door To verify successful adjustment of the occlusion alarm switch and pressure perform the PVT in Section 5 2 Technical Service Manual 7 11 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS ADJUSTMENT LOCKNUTS ADJUSTMENT BRACKET SET SCREW LOCKNUT NOT SHOWN OCCLUSION ALARM SWITCH TOP PLATE SWITCH LEFT CLAMP LEVER ACTUATOR SWITCH BUTTON COMPRESSION Lolo SPRING Lox s ee CRADLE CLAMP SPLIT NUTS lt EI RIGHT CLAMP LEVER DIRECTION OF LEAD SCREW LEAD SCREW Figure 7 9 Occlusion Alarm Pressure Adjustment 008 and Lower 7 2 8 3 OCCLUSION ALARM SWITCH AND PRESSURE ADJUSTMENT 010 AND HIGHER To adjust the occlusion alarm switch and pressure see Figure 7 10 and proceed as follows 1 Separate the front and rear case assemblies as described in Section 7 2 3 2 Examine the position of the occlusion alarm switch If the switch actuator is in contact with the switch button proceed to Step 3 If the switch actuator is not making contact with the switch button use a No O Phillips screwdriver to loosen the screw on the switch actuator Adjust the screw until the switch actuator contacts the switch button but does not trip the switch 3 Connect the cables from the rear case assembly to the PWAs and slide assembly to allow the infuser to operate with the case open Support the front case assembly to keep it upri
116. place the bottom cover Confirm the battery leads are tucked inside Replace the two screws that were removed in Step 2 PCA Plus II only Reset the real time clock as described in Section 7 2 10 To verify successful replacement of the battery press ON with the infuser disconnected from AC power and verify the front panel battery symbol is lit Replacement of the battery and battery cover is routine maintenance and no additional verification procedure is normally required However if the infuser may have been damaged during this procedure perform the PVT in Section 5 2 BATTERY BATTERY COVER REAR CASE __ RUBBER FOOT PAD 2 m FRONT CASE 6 32 x 5 16 HEX HEAD SCREW w WASHER 6 32 x 1 2 HEX HEAD SCREW w WASHER Figure 7 12 Battery Replacement LifeCare PCA Plus and Plus II Series 7 18 Technical Service Manual 7 3 4 REPLACEMENT PROCEDURES FUSE REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver and small flat blade screwdriver To replace a fuse see Figure 7 13 and proceed as follows 1 2 8 9 Disconnect the infuser from AC power Place the infuser face down on a soft surface and remove the 6 32 screw that attaches the AC power cord retainer plate to the infuser rear case To access a fuse remove the AC power cord from its receptacle by grasping the plug Do not pull on the cord
117. placement harness to J8 on the power supply PWA Reassemble the case assemblies in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the printer Dataway connector and control panel harness perform the PVT in Section 5 2 DATAWAY CONNECTOR PATIENT PENDANT JACK CABLE CLIP PIEZOELECTRIC ALARM AUDIBLE LEVEL SWITCH Figure 7 21 Printer Dataway Connector Control Panel Harness and Piezoelectric Alarm Technical Service Manual 7 41 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 3 2 9 PIEZOELECTRIC ALARM REPLACEMENT This procedure applies to infusers with final assembly numbers 850 04250 002 through 007 Infusers with final assembly number 850 04250 008 and higher require replacement of the Interconnect PWA if the piezoelectric alarm is defective see Section 7 3 32 Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers wire cutters soldering iron solder 1 8 inch shrink tubing and small cable wrap To replace the piezoelectric alarm see Figure 7 21 and proceed as follows 1 2 3 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Using a 3 16 nutdriver remove the screws that attach the piezoelectric alarm to the control panel The longer of the two screws is used in the upper mounting hole to accommodate th
118. pplies to infusers with final assembly numbers 850 04250 002 through 007 Infusers with final assembly number 850 04250 008 and higher require replacement of the Interconnect PWA if the patient pendant jack is defective see Section 7 3 32 CAUTION Do not bend the patient pendant cord near the patient pendant or connector jack at an angle of 90 or greater Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers 1 2 box wrench soldering iron and solder To replace the patient pendant jack see Figure 7 21 and proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3 3 Place the rear case assembly on a soft surface with the interior facing up Remove the adhesive backed cable tie clamp from the rear case 4 Remove the eight Phillips screws that attach the control panel to the rear case then remove the control panel 5 Unsolder the harness wires from the patient pendant jack 6 Using a 1 2 box wrench remove the nut that attaches the patient pendant jack to the control panel then remove the patient pendant jack 7 Install the replacement patient pendant jack on the control panel Using a 1 2 box wrench secure the jack with the retaining nut 8 Solder the wires from the harness to the patient pendant jack as follows white wire with red stripe to the ring terminal white wire with green stripe to the tip t
119. press SILENCE NO 9 When the LCD screen displays SELECT MODE PCA CONTINUOUS press YES ENTER 10 Set a dose of 1 mg then press YES ENTER 11 Select a lockout interval of five minutes then press YES ENTER 12 Select a continuous rate of 20 mg hr then press YES ENTER 13 When the LCD screen displays 4 HOUR DOSE LIMIT SET press YES ENTER 14 Select a 4 HOUR DOSE LIMIT of 1 5 mg then press YES ENTER 15 Press HISTORY to confirm the infuser settings are as specified 16 Close and lock the security door The display should read DOOR LOCKED TOTAL DELIVERED 1 mg 17 Press RESET START Verify the walking bar appears in the LED window indicating CONTINUOUS mode delivery Verify that three asterisks appear in the upper left corner The asterisks indicate PCA dosing is available 18 Press the patient pendant pushbutton to deliver a PCA dose Verify a beep sounds and PCA CONTINUOUS displays Verify the walking bar appears in the LED window Technical Service Manual 5 7 LifeCare PCA Plus and Plus II Series Section 5 MAINTENANCE AND SERVICE TESTS 19 After approximately two minutes verify the four hour dose limit has been reached and the KVO rate has begun Verify the TOTAL DELIVERED displays 2 5 mg Note If delivered prior to setup the loading dose is not included in the four hour dose limit 20 Press the patient pendant pushbutton three times the infuser should not respond 21 Unlock the
120. prevent the set screw from turning 5 Using a 5 16 open end wrench loosen the lower locknut below the compression spring 6 Connect the cables from the rear case assembly to the PWAs and slide assembly to allow the infuser to operate with the case open Support the front case assembly to keep it upright for the adjustment procedure 7 Install a water filled syringe into the infuser Connect an IV administration set DPM and stopcock Open the stopcock valve 8 Purge the system until water flows out of the stopcock valve then close the valve When the LCD screen displays DRUG Rx MORPHINE 1 MG ML YES OR NO press YES ENTER 9 Program a loading dose of 10 mg Allow the infuser to operate until an occlusion alarm sounds or the pressure reaches 19 psig 131 1 kPa 10 If the occlusion alarm sounds before the pressure reaches 14 psig 96 6 kPa relieve the fluid pressure by opening the stopcock valve Tighten the upper locknut one half turn against the compression spring then repeat Step 8 11 If the occlusion alarm does not sound at 19 psig 131 1 kPa relieve the fluid pressure loosen the upper locknut one half turn then repeat Step 8 12 When the infuser occludes at between 14 and 19 psig 96 6 and 131 1 kPa tighten the lower locknut against the upper locknut Use one 5 16 inch open end wrench to hold the upper locknut and another 5 16 inch open end wrench to tighten the lower locknut against the upper locknut 13 Cl
121. put of data buffer U8 on the power supply PWA When U8 is gated by the SWSTSEL signal the microprocessor on the CPU display PWA reads data bit DO for occlusion pressure status and generates an OCCLUSION alarm In setup mode the OCCLUSION alarm is cleared by releasing the cradle assembly In patient mode the OCCLUSION alarm is cleared by opening the front door and releasing the cradle assembly The SILENCE touchswitch may be pressed to mute the occlusion audible alarm for one minute Occlusion pressure is adjusted as described in Section 7 2 7 LifeCare PCA Plus and Plus II Series 4 14 Technical Service Manual 4 3 MECHANICAL OVERVIEW ADJUSTMENT LOCKNUTS ADJUSTMENT BRACKET SET SCREW LOCKNUT NOT SHOWN OCCLUSION ALARM SWITCH TOP PLATE SWITCH LEFT CLAMP LEVER ACTUATOR SWITCH BUTTON COMPRESSION MMC Hm SPRING Ex 1 CRADLE CLAMP SPLIT NUTS RIGHT CLAMP LEVER LEAD SCREW DIRECTION OF LEAD SCREW Figure 4 5 Occlusion Pressure Alarm System 008 and Lower Technical Service Manual 4 15 LifeCare PCA Plus and Plus II Series SECTION 4 THEORY OF OPERATION SWITCH NO 0 PHILLIPS ACTUATOR SCREW OCCLUSION ALARM SWITCH SLIDE CLAMP COMPRESSION SPRING RELEASE LEVER THUMB NUT PIVOT POST BEHIND LEAD SCREW LEAD SCREW DIRECTION OF LEAD SCREW Figure 4 6 Occlusion Pressure Alarm System 010 and Higher 4 3 4 VIAL AND INJECTOR SENSOR A
122. r g hr Variable from 0 1 x concentration to 20 x concentration mg hr or g hr plus PCA rate 5 to 100 minutes in 1 minute increments 10 to 20 psi 50 to 104 F 10 to 40 C ambient temperature 5 9596 relative humidity non condensing Meets UL ANSI and CSA standards Use only compatible Hospira PCA sets with integral anti siphon valve 8 2 Technical Service Manual Section 9 DRAWINGS Figure 9 1 shows the Illustrated Parts Breakdown IPB and Figure 9 2is a block diagram for the infusion system see Table 9 1 Table 9 2identifies infuser parts by index numbers that correlate to Figure 9 1 Drawings in Section 9are provided as information only and may not exactly reflect current product configuration Note PWA schematic drawings are available from Hospira upon request Table 9 1 Drawings Illustrated Parts Breakdown 16 Sheets Block Diagram Table 9 2 Illustrated Parts Breakdown Index Number Nomenclature Assembly Mechanism Assembly Gear Mot Opto Switch Screw 6 32 x 3 4 Pan Head Phillips Screw 2 56 x 7 16 Hex Head w Washer Nut KEP 6 32 w Conical Washer Coupling Mechanism Screw 2 24 x 3 8 Pan Head Plastic Screw 2 56 x 7 16 Hex Head w Washer Assembly Slide Screw 4 40 x 1 4 Hex Head Slotted w Washer Actuator Outside Actuator Inside Technical Service Manual 9 1 LifeCare PCA Plus and Plus Il Series Section 9 D
123. r have one bracket arm containing both actuators allowing both the syringe low and syringe empty alarms to be adjusted with a single adjustment on the one bracket arm The SYRINGE LOSW signal occurs when the distance between the bottom of the syringe vial stop and the bottom of the syringe injector flange groove is 4 628 0 062 inches 11 57 0 155 centimeters which indicates approximately 5 mL of fluid is left in the vial The SYRINGE LOSW signal generates the syringe low alarm and the LOW SYRINGE message on the LCD The SYRINGE EMPTYSW signal occurs when the distance between the bottom of the syringe vial stop and the bottom of the syringe injector groove is 4 328 0 062 inches 10 82 0 155 cm which indicates approximately 1 mL remaining in the vial The SYRINGE EMPTYSW signal generates the syringe empty alarm and the EMPTY SYRINGE message on the LCD On infusers with final assembly number 010 and higher the slide block moves down on the switch causing the switch arm to activate the syringe empty switch Note Infusers with final assembly number 010 and higher do not have a syringe low switch SYRINGE EMPTY BRACKET ARM DIRECTION OF TRAVEL SYRINGE LOW BRACKET ARM SYRINGE EMPTY SWITCH SYRINGE LOW SWITCH Figure 4 3 Syringe Low and Syringe Empty Alarm System 008 and Lower Technical Service Manual 4 13 LifeCare PCA Plus and Plus II Series SECTION 4 THEORY OF OPERATION DIRECTION OF TRAVE
124. re PCA Plus and Plus II Series 9 32 Technical Service Manual Technical Service Manual 9 33 LifeCare PCA Plus and Plus II Series SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 34 Technical Service Manual HOSPIRA INC igure 9 1 Illustrated Parts Breakdown Sheet 15 of 16 DRAWING NO NOT APPLICABLE LifeCare PCA Plus and Plus II Series 9 35 Technical Service Manual SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 36 Technical Service Manual Technical Service Manual HOSPIRA INC Figu igure 9 1 Illustrated Parts Breakdown DRAWING NO NOT APPLICABLE Rev N A Sheet 16 of 16 LifeCare PCA Plus and Plus II Series SECTION 9 DRAWINGS This page intentionally left blank LifeCare PCA Plus and Plus II Series 9 38 Technical Service Manual AUDIBLE ALARM BIDIRECTIONAL DATA BUS INPUT ee 5 pie LED BUFFER IN di CONTROL DISLPLAY A0 A7 ADO AD7 INPUT ADDRESS LED BUFFER DECODER DISPLAY CS0 CS7 DRIVER MICROPROCESSOR MOTOR MONITOR POWER CONTROL MOTOR SHAFT i SENSOR PROGRAMMABLE PERIPHERAL INTERFACE SYRINGE DEVICE MOTOR DRIVE DRIVERS MOTOR DOOR BATTERY
125. ree from defects in material and workmanship under normal use and service for a period of 90 days after purchase Hospira makes no other warranties express or implied and specifically disclaims the implied warranties of merchantability and fitness for a particular purpose Purchaser s exclusive remedy shall be at Hospira s option the repair or replacement of the product In no event shall Hospira s liability arising out of any cause whatsoever whether such cause be based in contract negligence strict liability other tort or otherwise exceed the price of such product and in no event shall Hospira be liable for incidental consequential or special damages or losses or for lost business revenues or profits Warranty product returned to Hospira must be properly packaged and sent freight prepaid The foregoing warranty shall be void in the event the product has been misused damaged altered or used other than in accordance with product manuals so as in Hospira s judgment to affect its stability or reliability or in the event the serial or lot number has been altered effaced or removed The foregoing warranty shall also be void in the event any person including the Purchaser performs or attempts to perform any major repair or other service on the product without having been trained by an authorized representative of Hospira and using Hospira documentation and approved spare parts For purposes of the preceding sentence major repair
126. reen interfaces with the CPU display PWA via P J15 and P J14 AC power from the DC to AC converter U17 is supplied to the LCD screen via P J15 The LCD screen also receives addresses AO and Al and data bits DO through D7 via P J14 for display control The primary interface between the CPU display PWA and the power supply PWA interface is through the power supply PWA connector P J12 on the CPU display PWA that connects via a ribbon cable with connector P J7 on the power supply PWA The CPU display PWA interface consists of address lines Al and A2 data lines DO through D7 5 VDC power 2 5 VDC reference voltage and various signals 4212 MICROPROCESSOR CIRCUITRY The microprocessor circuitry consists of the following 8032 single chip CPU 011 10 MHz crystal oscillator Y1 Bus transceiver U12 Transparent latch U13 8K x 8 RAM chip 021 32K x 8 EPROM chip U22 U11 the 8032 single chip CPU controls all functions of the infuser U11 has internal RAM for the program stack and for storage of temporary variables 1711 uses a multiplexed 16 bit address bus an 8 bit data bus and a built in 8 bit I O port The microprocessor is clocked by a parallel resonant 10 MHz crystal oscillator Test points 1 2 E3 E4 are used to disconnect Y1 during depot level repair in order to single step U11 for control All operating parameters for the infuser are stored in U21 the nonvolatile 8K x 8 RAM chip that decodes the 8032
127. rer s recommendation Sporicidin Sporicidin Per manufacturer s recommendation TM Vesphene Ilse Steris Per manufacturer s recommendation Household Bleach Various Use per hospital procedures Do not exceed one part bleach in ten parts water Note At the time of printing Hospira recommends only the cleaning solutions in Table 5 1 For updated listings of approved cleaners visit www hospiraparts com 5 2 PERFORMANCE VERIFICATION TEST Note Perform the PVT every 12 months The Performance Verification Test PVT consists of the tests described in the following sections The PVT is designed to assure the infusion system is operating properly and can also be used for diagnostic purposes during troubleshooting The PVT should be used for performance verification before an infuser is returned to service after repair Note Perform the PVT exactly as described in this manual to assure effective and reliable product evaluation information If any malfunction is detected as a result of the PVT see Section 6 LifeCare PCA Plus and Plus II Series 5 2 Technical Service Manual 5 2 1 EQUIPMENT REQUIRED The PVT requires the following equipment and materials or equivalents Door key PCA vial standard List Number 6021 03 PCA set List Number 3559 01 PERFORMANCE VERIFICATION TEST Graduate or marked test tube readable to 0 2 mL increments or smaller Three way stopcoc
128. ries Section 7 REPLACEABLE PARTS AND REPAIRS Note Infusers 010 and higher are configured with Phillips screws 4 Install the replacement cradle assembly using the screws removed in Step 4 5 Close and lock the security door To verify successful replacement of the cradle assembly perform the PVT in Section 5 2 CRADLE RELEASE MECHANISM 22 UPPER VIAL RETAINER VIAL SENSOR SWITCH VIAL CRADLE CLIPS LOWER VIAL RETAINER SPRING LOADED INJECTOR FLANGE CLAMP TYPE A INJECTOR SENSOR SWITCH LOWER VIAL RETAINER TYPE B Figure 7 16 Cradle Assembly Replacement LifeCare PCA Plus and Plus II Series 7 28 Technical Service Manual REPLACEMENT PROCEDURES 7 3 17 VIAL SENSOR SWITCH REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers soldering iron and solder To replace the vial sensor switch see Figure 7 4 or Figure 7 5 and Figure 7 17 and proceed as follows 1 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Place the front case assembly face down on a soft surface N 008 and lower Using a 3 16 nutdriver remove the two vial sensor adjustment screws that attach the vial sensor switch bracket and switch to the slide assembly 5 Using a Phillips screwdriver remove the screw that attaches the vial sensor switch cradle clip to the slide
129. roperly insert the vial in the vial cradle Adjust the vial sensor switch CHECK INJECTOR Injector is improperly installed or missing Properly insert the injector in the driver retainer assembly Adjust the injector sensor switch CHECK SYRINGE Syringe vial and injector improperly installed or missing Properly insert the syringe in the cradle Replace the injector sensor switch Replace the vial sensor switch LOW SYRINGE PCA Plus only Approximately 5 mL of solution remaining in syringe Message occurs too soon or too late Note the alarm and press SILENCE NO to silence the alarm Adjust the syringe low switch EMPTY SYRINGE Syringe empty approximately 1 mL may remain Alarm occurs too soon or too late Press SILENCE NO to silence the alarm Unlock and open the security door remove the empty syringe and turn off the infuser Prepare and insert the vial injector then complete the setup Adjust the syringe empty switch CHECK SETTINGS Security door closed and locked before setup was complete Open the security door and verify settings are properly entered CHECK 4 HR LIMIT Four hour dose limit is set less than PCA dose Confirm PCA dose is less than or equal to four hour dose limit DOOR OPEN Security door has been left open for more than two minutes without a touchswitch being pressed Infuser does not sense door closure Close and lock the security door
130. s Status Messages and Definitions CPU Display PWA Control Cleaning Solutions E Service Tests Service Options Electrical Safety Measurements Malfunction Codes R Alarm Messages Fault Symptons Service Test Troubleshooting Troubleshooting with the PVT Drawings Illustrated Parts Breakdown Technical Service Manual vii Contents 1 2 4 2 4 5 5 2 5 5 5 6 5 10 6 3 6 5 6 7 6 9 9 1 9 1 LifeCare PCA Plus and Plus II Series Contents This page intentionally left blank LifeCare PCA Plus and Plus II Series viii Technical Service Manual T Section 1 INTRODUCTION The LifeCare PCA Plus and Plus II Series infusers provide analgesic delivery to patients through the intravenous or epidural routes in a wide range of clinical settings 1 1 SCOPE This manual is organized into the following sections T Section 1 Introduction Section 2 Warranty Section 3 System Operating Manual Section 4 Theory of Operation Section 5 Maintenance and Service Tests Section 6 Troubleshooting Section 7 Replaceable Parts and Repairs Section 8 Specifications Section 9 Drawings Le ep ee Index L Technical Service Bulletins If a problem in device operation cannot be resolved using the information in this manual contact Hospira see Section 6 1 Specific instructions for operating the device are contained in its respective System Operating Manual The terms i
131. s and materials required for a specific adjustment procedure are listed at the beginning of each procedure Set of Allen wrenches Wire cutters Set of nutdrivers Wire strippers Set of open end wrenches Soldering iron Solder tin lead RMA type Shrink tubing 1 8 inch Set of box wrenches Small and medium flat blade screwdriver Set of Phillips screwdrivers Optional heat gun Needle nose pliers Small cable tie wraps Electrician s knife Grease Braycote 804 X acto knife Isopropyl alcohol Technical Service Manual 7 17 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 3 3 BATTERY REPLACEMENT The recommended tool for this procedure is a 1 4 nutdriver To replace the battery see Figure 7 12 and proceed as follows 1 2 Disconnect the infuser from AC power Place the infuser face down on a soft surface Using the 1 4 nutdriver remove the two 6 32 screws from the battery cover 3 Remove and inspect the battery cover and replace if required 7 8 9 Separate the battery cable from the charger circuit cable Remove the battery and dispose of it in accordance with local battery disposal practices Connect the leads of the replacement battery to the battery connector Assure the connection is tight Install the replacement battery into the housing so that the bottom is visible Assure the wires are not kinked or crushed under the battery Re
132. se assemblies as described in Section 7 2 3 Remove the power supply PWA as described in Section 7 3 11 Remove the CPU display PWA as described in Section 7 3 12 a Remove the 40 pin ribbon cable from 47 on the power supply PWA 412 on the CPU display PWA Install the replacement 40 pin ribbon cable Connectors are keyed for pin 1 Reinstall the power supply PWA and the CPU display PWA Reassemble the infuser in the exact reverse order of disassembly 9 Close and lock the security door To verify successful replacement of the 40 pin ribbon cable perform the PVT in Section 5 2 7 3 15 15 CONDUCTOR DIAGNOSTIC CABLE REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver flat blade screwdriver set of nutdrivers 1 4 open end wrench and set of Allen wrenches To replace the 15 conductor diagnostic cable see Figure 7 15 and proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3 3 Disconnect the diagnostic cable from J9 on the power supply PWA LifeCare PCA Plus and Plus Series 7 26 Technical Service Manual REPLACEMENT PROCEDURES Using a 3 16 nutdriver and a flat blade screwdriver remove the two screws and nuts that retain the diagnostic connector on the transformer receptacle assembly Disconnect the cable from the diagnostic connector and remove the cable from
133. security door and remove the injector from the holder Verify the CHECK INJECTOR message flashes Reseat the injector and verify the CHECK INJECTOR message disappears 22 With the security door unlocked pull the top of the vial away from the vial holder and verify the CHECK VIAL message flashes Reinsert the vial and verify the CHECK VIAL message disappears 23 Remove the vial from the cradle Clear all dose history data from memory by holding down OFF RECHG touchswitch until the LCD screen including the backlighted grid goes blank 5 2 8 PATIENT CONTROL JACK TEST To perform the patient control jack test proceed as follows 1 Disconnect the patient pendant cable from the patient control jack on the back of the infuser 2 Connect the test cable phone jack to the patient control connector Connect the leads on the other end of the cable to the terminals of the DMM as appropriate Set the DMM to 10 volt DC scale 3 Turn on the infuser and verify a DMM reading of greater than or equal to 4 5 VDC Remove the test cable from the infuser 5 2 9 PATIENT PENDANT ASSEMBLY TEST To perform the patient pendant assembly test proceed as follows 1 Disconnect the patient pendant from the patient control jack on the back of the infuser 2 Unscrew the shield from the patient pendant phono plug 3 Set the DMM to measure continuity then attach a DMM test lead to each patient pendant phone plug connection Polarity is not critical
134. semble the infuser in the exact reverse order of disassembly Close and lock the security door To verify successful adjustment of the vial sensor switch perform the PVT in Section 5 2 Technical Service Manual 7 5 LifeCare PCA Plus and Plus 11 Series Section 7 REPLACEABLE PARTS AND REPAIRS VIAL SENSOR ROD SYRINGE LOW SWITCH VIAL SENSOR SWITCH ACTUATOR ARM SYRINGE EMPTY SWITCH ADJUSTMENT SCREWS FOR VIAL SENSOR SWITCH VIAL SENSOR SWITCH BRACKET Figure 7 4 Vial Sensor Switch and Syringe Low Switch 008 and Lower VIAL SENSOR SWITCH VIAL SENSOR ROD VIAL SENSOR SWITCH ACTUATOR ARM Figure 7 5 Vial Sensor Switch and Syringe Low Switch 010 and Higher LifeCare PCA Plus and Plus II Series 7 6 Technical Service Manual ADJUSTMENT PROCEDURES 7 2 6 SYRINGE LOW SWITCH ADJUSTMENT PCA PLUS ONLY Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers syringe limit gauge and red GLPT insulating varnish To adjust the syringe low switch see Figure 7 4 and proceed as follows 1 Disconnect the infuser from AC power 2 Separate the front and rear case assemblies as described in Section 7 2 3 3 Install the syringe limit gauge in the cradle Squeeze the cradle clamps and move the cradle up to the limit allowed by the gauge Verify that the gauge dial reads approximately 0 05 inch 0 127 cm 4 Start the infuser using any drug concentration setting Purge the system until the
135. sembly Replace patient pendant assembly Battery Charger Test Section 5 2 10 Loose connection Defective boost charger PWA Defective power supply PWA Check connector J3 on the power supply PWA Check connector P1 and P2 on the boost charger PWA Replace boost charger PWA Replace power supply PWA Electrical Safety Test Section 5 2 11 Technical Service Manual Insufficient earth connection Defective AC power cord plug Defective AC power cord 6 9 Check for adequate earth connection Replace AC power cord plug Replace AC power cord LifeCare PCA Plus and Plus II Series Section 6 TROUBLESHOOTING This page intentionally left blank LifeCare PCA Plus and Plus II Series 6 10 Technical Service Manual REPLACEABLE PARTS Section 7 REPLACEABLE PARTS AND REPAIRS This section describes adjustment procedures and replacement procedures for parts and subassemblies of the infusion system that are repairable within the scope of this manual 71 REPLACEABLE PARTS Replaceable parts for the infusion system are itemized in the Illustrated Parts Breakdown IPB and are identified in Figure 9 1 Table 9 2 identifies each part by an index number that correlates to Figure 9 1 To view the online replacement parts list visit the website at www hospiraparts com 72 ADJUSTMENT PROCEDURES This section contains safety and equipment precautions required tools and materials and step by step adjustment proced
136. st patient pendant pushbutton Indicator Test verifies battery and AC symbols are turned on and off when the power cord is connected and disconnected Alarm Audible alarm signal is generated to verify the alarm circuitry Motor Rotation Motor is rotated a given amount and the shaft sensor signal is checked by the motor control circuitry Security Door Test verifies the microcomputer recognizes when the security door is locked or unlocked Syringe Test Test verifies the microcomputer can detect the presence and proper positioning of the vial and injector in the syringe driver mechanism Empty Syringe Test verifies the microcomputer detects an empty syringe Low Syringe Technical Service Manual Test verifies the microcomputer detects a low syringe PCA Plus only 5 5 LifeCare PCA Plus and Plus II Series Section 5 MAINTENANCE AND SERVICE TESTS Table 5 3 Service Options Option Description Patient pendant tone selection Selection provides one of the following options Tone with successful PCA dose only default Tone on all attempted PCA doses placebo 12 hour clock selection PCA Plus only Selection provides one of the following options 12 24 hour clock selection PCA Plus Series Clock format 12 hour Clock format 24 hour Select RX concentration Selection provides one of the following options 3 1 software and higher Milligrams only Milligrams and micro
137. t case assembly face down on a soft surface Cut the cable tie on the three wires connected to the occlusion pressure switch and unsolder the wires from the switch terminals Using a small flat blade screwdriver remove the two screws that attach the occlusion switch to the lower end of the slide assembly then remove the switch Install the replacement switch using the screws removed in Step 5 7 008 and lower Solder the wires to the replacement switch as follows orange wire to front terminal black wire common to center terminal blue wire to front terminal 010 and higher Solder the wires to the replacement switch as follows orange wire to front terminal blue wire common to center terminal black wire to front terminal LifeCare PCA Plus and Plus Series 7 32 Technical Service Manual 10 11 12 REPLACEMENT PROCEDURES Place a small cable tie around the switch wires Perform the occlusion alarm switch test and adjustment procedure in Section 7 2 8 as applicable Reassemble the infuser case assemblies in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the occlusion pressure switch perform the PVT in Section 5 2 7 3 22 INJECTOR SENSOR SWITCH REPLACEMENT Recommended tools for this procedure are a No 2 Phillips screwdriver set of nutdrivers soldering iron and solder To replace the injector sensor switch proce
138. tage between J3 pins 2 and 3 If voltage is between 11 and 17 VAC replace the power supply PWA If voltage is not between 11 and 17 VAC contact Hospira MALFUNCTION XX Error code displayed in place of XX Infuser self test programs have detected an internal failure Note malfunction code displayed then press OFF RECHG to silence the alarm turn off the infuser and remove the infuser from service No audible alarm or audible alarm level control Defective audible level switch Defective power supply PWA LifeCare PCA Plus and Plus II Series 6 6 Replace the audible level switch Replace the power supply PWA Technical Service Manual 6 4 SERVICE TEST AND PVT TROUBLESHOOTING Table 6 3 describes failures that may be detected during service tests see Section 5 2 4 SERVICE TEST AND PVT TROUBLESHOOTING Table 6 4 describes failures that may be detected during the PVT see Section 5 2 If a malfunction code displays see Section 6 3 3 Service Test Failure Table 6 3 Possible Cause Service Test Troubleshooting Corrective Action Service test mode tests Section 5 2 4 Infuser not in cold start Defective touchswitch Defective CPU display PWA Hold OFF RECHG for six seconds Replace front panel Replace CPU display PWA Software Version Defective CPU display PWA Replace CPU display PWA Elapsed Days Defective CPU display PWA Replace CPU display PWA Int
139. the adhesive pad above the AC power connector next to the battery case Remove and inspect the adhesive pad and replace if required Press the connector on the replacement cable into place on the diagnostic connector Do not bend the connector pins Snap the retainer clip into position on the diagnostic connector Fold the cable 90 degrees and press it onto the adhesive pads to assure clearance of the slide assembly during reassembly Reassemble the infuser in the exact reverse order of disassembly and close and lock the security door To verify successful replacement of the 15 conductor diagnostic cable perform the PVT in Section 5 2 BATTERY CASE TO POWER SUPPLY PWA J9 ADHESIVE PAD 2 HEX HEAD SCREW AND NUT 2 15 CONDUCTOR DIAGNOSTIC CABLE Figure 7 15 15 Conductor Diagnostic Cable 7 3 16 CRADLE ASSEMBLY REPLACEMENT There are two versions of the cradle assembly Type A and Type see Figure 7 16 The recommended tool for this procedure is a 5 64 inch Allen wrench or No 2 Phillips screwdriver To replace the cradle assembly see Figure 7 16 and proceed as follows 1 2 3 Disconnect the infuser from power Open the security door then place the infuser face up on a soft surface Using the 5 64 Allen wrench or Phillips screwdriver remove the two screws that secure the cradle assembly then remove the cradle assembly Technical Service Manual 7 27 LifeCare PCA Plus and Plus II Se
140. the next test LifeCare PCA Plus and Plus II Series 5 4 Technical Service Manual PERFORMANCE VERIFICATION TEST Table 5 2 Service Tests Test Description Software Version Displays the software version to identify the revision level of the infuser program stored in EPROM Elapsed Days Displays total days the infuser has been in operation Internal RAM Microcomputer RAM is tested to assure data can be reliably written to and read from specific memory cells External RAM ADRS Test is performed to determine the integrity of the address lines used to select specific memory locations for data access External RAM Cell Microcomputer RAM memory is tested CPU Test routine is performed and test results are verified to assure the microcomputer is executing instructions properly ROM Checksum is calculated and compared to a pre stored and pre calculated value to assure the operating program residing in EPROM is intact Real Time Clock Real time clock is tested to verify its accuracy LED Pattern of 1s through 9s is displayed by the LEDs to verify operation LCD Non displaying test pattern is written to the LCD RAM and compared with a stored pattern to assure that the LCD screen can accurately display data Keypad Stuck key test determines if any keys are permanently shorted Press individual keys to determine if the key operates and the microcomputer recognizes the correct key Te
141. the opto switch generates a signal SHAFT that is routed to data buffer U8 on the power supply PWA The SHAFT signal is read by the microprocessor on the CPU display PWA as data bit D6 when U8 is gated by the SWSTSEL signal from the CPU display PWA The SHAFT signal provides a feedback loop to allow the microprocessor to control the rotation of the lead screw for the delivery data set up by the touchswitches 43 12 SLIDE MECHANISM The slide block connects to the lead screw by a half nut The surface of the half nut that contacts the lead screw is machined so that it engages the threads on the lead screw When the lead screw is rotated and the half nut is engaged the slide block moves downward towards the motor assembly Squeezing the arm above the cradle with no syringe mounted in the cradle causes the half nut to disengage from the lead screw The slide mechanism can then be moved up and down on the two guide shafts to the full extent of cradle travel 4 3 1 3 CRADLE ASSEMBLY When an inverted vial is inserted in the cradle assembly the injector flange is held stationary in the injector flange clamp When the slide block is driven downward by the rotation of the lead screw the vial is forced downward and the stationary injector plunger moves further into the vial Fluid in the vial is forced into the administration set in an amount proportional to the downward movement of the cradle and slide mechanism 4 3 2 SYRINGE LOW AND SYRINGE EMPTY
142. tuation If the door lock switch is adjusted properly switch actuation should be heard each time the door is locked or unlocked If the door lock switch does not require adjustment proceed to Step 7 Using needle nose pliers carefully bend the door lock actuator or the switch actuator arm as applicable until proper adjustment is achieved Be careful not to damage the switch Reassemble the infuser in the exact reverse order of disassembly Close and lock the security door To verify successful adjustment of the door lock switch perform the PVT in Section 5 2 7 2 12 LEAD SCREW LUBRICATION Recommended tools for this procedure are Electro Wash 2000 or isopropyl alcohol lint free cloth or cotton swabs Braycote grease and a small brush 1 2 3 Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Using Electro Wash 2000 or isopropyl alcohol and a small brush or cotton swabs remove all old grease and residue from the lead screw Note If using isopropyl alcohol use extra care to assure that all residual lubricant is removed Apply a thin coating of grease and work it into the threads along the length of the shaft Do not fill the threads Move the slide clamp as necessary to clean and lubricate the length of the lead screw Reassemble the front and rear case assemblies in the exact reverse order of disassembly To verify successful lead screw
143. ual 7 31 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 10 11 12 13 14 Solder the wires to the replacement switch as follows black wire common to the center terminal of both switches yellow wire to the top terminal of the syringe low switch green wire to the top terminal of the syringe empty switch 008 and lower Reinstall the switches on the switch mounting bracket Note the two flat washers between the switches Reattach the switch mounting bracket 008 and lower or switch 010 and higher to the slide assembly Secure the switch wires to the wiring harness with a small cable tie Adjust the syringe low switch as described in Section 7 2 6 as required Adjust the syringe empty switch as described in Section 7 2 7 as required Reassemble the infuser case assemblies in the exact reverse order of disassembly Close and lock the security door To verify successful replacement of the syringe low and syringe empty switch perform the PVT in Section 5 2 7 3 21 OCCLUSION PRESSURE SWITCH REPLACEMENT Recommended tools for this procedure are a small flat blade screwdriver No 2 Phillips screwdriver set of nutdrivers soldering iron solder and small cable tie To replace the occlusion pressure switch proceed as follows 1 M Disconnect the infuser from AC power Separate the front and rear case assemblies as described in Section 7 2 3 Place the fron
144. ures Unless otherwise stated always perform the PVT after an adjustment procedure Unless otherwise indicated adjustment procedures require an empty syringe to be installed in the cradle Figures are rendered as graphic representations to approximate actual product Therefore figures may not exactly reflect the product 721 SAFETY AND EQUIPMENT PRECAUTIONS Before opening the front enclosure of the infuser take all necessary precautions for working on high voltage equipment WARNING EXPLOSION HAZARD EXISTS IF THE INFUSER IS SERVICED IN THE PRESENCE OF FLAMMABLE SUBSTANCES WARNING UNLESS OTHERWISE INDICATED DISCONNECT THE INFUSER FROM AC POWER BEFORE PERFORMING ADJUSTMENT OR REPLACEMENT PROCEDURES CAUTION Use proper ESD grounding techniques when handling components Wear an antistatic wrist strap and use an ESD protected workstation Store PWAs in antistatic bags before placing them on any surface Technical Service Manual 7 1 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 722 REQUIRED TOOLS MATERIALS The following tools and materials or equivalents are required for the adjustment procedures in this section In addition the tools and materials required for a specific adjustment procedure are listed at the beginning of each procedure Set of Allen wrenches Small brush Lint free cloth or cotton swabs Set of nutdrivers Set of open end wrenches Red GLPT insulating var
145. w restricts this infuser to sale by or on the order Z of a physician or other licensed practitioner Attention consult accompanying documents Provides adequate degree of protection against electrical shock and suitable for application to patient Type CF IPX 1 Protected against dripping water Class 1 Mains supply equipment using protective earth the product has been evaluated to the applicable CSA and ANSI UL 9 CSA601 1 Standards for use in Canada and the U S respectively This US MCN 160992 indicator includes products eligible to bear the NRTL indicator NRTL National Recognized Testing Laboratory is a designation lt UL 60601 1 C and US indicators adjacent to the CSA Mark signify that 05 granted by the U S Occupational Safety and Health Administration IEC 60601 1 OSHA to laboratories which have been recognized to perform IEC 60601 2 24 certification to U S Standards Hospira Inc Printed in USA Technical Service Manual 430 04502 006 END
146. wever if the infuser may have been damaged during this procedure perform the PVT in Section 5 2 Technical Service Manual 7 21 LifeCare PCA Plus and Plus II Series Section 7 REPLACEABLE PARTS AND REPAIRS 7 3 7 1 SECURITY DOOR LATCH REPLACEMENT The recommended tool for this procedure is a No 2 Phillips screwdriver To replace the security door latch proceed as follows 1 Unlock and completely open the security door as described in Section 7 3 7 From inside the door remove the screw that secures the latch to the door 2 From the front of the door peel back the nameplate label and remove the latch 3 Install the replacement latch and reattach it from inside the door using the screw that was removed in Step 2 4 Press the nameplate label back in place and close and lock the security door Replacement of the security door latch is routine maintenance and no verification procedure is normally required However if the infuser may have been damaged during this procedure perform the PVT in Section 5 2 7 3 8 PATIENT PENDANT ASSEMBLY REPLACEMENT CAUTION Do not bend the patient pendant cord near the patient pendant or connector jack at an angle of 90 or greater No tools are required for this procedure To replace the patient pendant disconnect the control cable from the PATIENT CONTROL jack on the rear of the infuser and connect the replacement patient pendant Replacement of the patient pendant assembly is routine m
147. y seated in the injector flange clamp Technical Service Manual 4 17 LifeCare PCA Plus and Plus II Series SECTION 4 THEORY OF OPERATION This page intentionally left blank LifeCare PCA Plus and Plus Series 4 18 Technical Service Manual ROUTINE MAINTENANCE sy Section 5 MAINTENANCE AND SERVICE TESTS A complete maintenance program promotes infusion system longevity and trouble free operation Such a program should include routine maintenance periodic maintenance inspection and the Performance Verification Test 51 ROUTINE MAINTENANCE Routine maintenance consists of basic inspection and cleaning procedures As a minimum requirement inspect and clean the infuser after each use In addition establish a regular cleaning schedule for the device 5 1 1 CLEANING AND SANITIZING Practice the cleaning and sanitizing guidelines in this section Follow hospital protocol for establishing the infuser cleaning schedule Before cleaning turn off the infuser and disconnect from AC power Clean the exposed surfaces of the infuser with a soft lint free cloth moistened with one of the cleaning solutions recommended in Table 5 1 or with a mild solution of soapy water Remove soap residue with clear water WARNING DISCONNECT THE INFUSER FROM AC POWER PRIOR TO CLEANING A THE DEVICE FAILURE TO COMPLY WITH THIS WARNING COULD RESULT IN ELECTRICAL SHOCK CAUTION To avoid mechanical or electronic damage do not immerse the infuser
148. ystem to AC power unless otherwise specified Connect the appropriate Hospira PCA set to a Hospira 30 mL PCA vial injector 4 Prime the vial and administration set Hold the vial vertically with the administration set extending from the top Slowly push down on the injector until all air is cleared from the vial and administration set CAUTION Confirm all caps on the vial and the administration set N are removed and all clamps are open when priming the syringe 5 2 4 SERVICE TEST MODE TESTS Table 5 2 and Table 5 3 provide a list of tests and options available in the service test mode Each test displays prompting information on the LCD screen to serve as a guide through the test Note The patient pendant must be connected to the infuser to complete the service test mode test To enter the service test mode proceed as follows l Confirm the AC power symbol on the front panel is lit 2 Turn off the infuser and enter the storage mode by opening the security door and pressing the OFF RECHG touchswitch for approximately six seconds The LCD screen should darken 3 Press and hold YES ENTER and ON simultaneously for approximately three seconds 4 The LCD screen displays INT RAM TEST until SERVICE TEST appears The LCD screen also displays the current software version and the total elapsed days since the infuser was placed in service Note Tests are self prompting giving the option of repeating the test or going to

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