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Syringe+PCA Service Manual

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1. Drivetrain Assembly 5A 10 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 9 Removing Drivetrain Assembly 1 Remove five 5 screws attaching Drivetrain Assembly to Front Case 2 Remove Drivetrain Assembly Front Case Drivetrain Assembly Alaris Syringe Module 8110 Series 5A 11 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 10 Removing Display Board Assembly 1 Disconnect harness flex cable from following locations on Display Board J1 keypad J4 backlight 2 Remove Display Board LED Backlight Harness Display Board Assembly Keypad Flex Cable A 5A 12 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY
2. Before adhering Linear Sensor Assembly to Extrusion Frame a Remove protective backing from Linear Sensor b Align hole in Linear Sensor Assembly with hole in Extrusion Frame Use a burnishing tool to ensure that Linear Sensor Assembly is securely adhered to Extrusion Frame Clean Linear Sensor Assembly surface using alcohol and lint free cloth such as Kimwipes or lint free tissue Linear Sensor Assembly Alignment Hole Alaris Syringe Module 8110 Series 5A 23 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 5 2 21 DISASSEMBLY REASSEMBLY Continued Removing Force Sensor and Actuator Knob Assemblies NOTE If the Force Sensor Assembly must be replaced on a Syringe Module with version 7 or earlier software the Force Sensor Assembly must be replaced at the depot See the note at the beginning of this chapter for more information Loosen four 4 screws attaching Upper Housing to Lower Housing just far enough to remove Upper Housing leaving O Rings attached to screws NOTE To avoid losing O Rings push each screw upward to grab and hold its O Ring before removing screws from Upper Housing Disconnect flex cable from Force Sensor Board J1 Lift Force Sensor Board off mounting posts Remove Actuator Knob Assembly Remove four 4 screws attaching Force Sensor Assembly to Lower
3. Alaris Syringe Module 8110 Series TA 23 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 16 IUI Interface Board Assembly NOTE This illustration is for board identification purposes only and does not represent the board s component layout J3 OOOOOOOOCOCOCOO O O Q 00000000 0000000 0000000 00000000 O 7A 24 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 17 Logic Board Assembly NOTE This illustration is for board identification purposes only and does not represent the board s component layout F1 E J12 Alaris Syringe Module 8110 Series TA 25 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module THIS PAGE INTENTIONALLY LEFT BLANK 7A 26 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 7B ILLUSTRATED PARTS BREAKDOWN PCA MODULE Chapter 7B ILLUSTRATED PARTS BREAKDOWN PCA Module 7 1 INTRODUCTION The
4. Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Table 7B 1 Parts List PCA Module Continued Item Part Number Description QTY 496 321035 Screw 4 40 x 3 4 PNH PHH 6 497 10012053 Screw 4 40 x 0 37 FLH PHH 3 498 10012051 Screw 4 40 x 1 4 BHD Torx Stainless Steel 15 499 e Silicone Grease Dow Corning Molykote 33 or equivalent As required use with item 410 645 148013 000 Label Patent 1 646 125569 Label Serial Number Replacement 1 800 148242 001 Bushing Latch Module 2 801 148245 001 Rod Latch Module 1 802 TC10003090 Bushing Latch Module Support Bushing 1 804 148299 100 Ground Strap Harness Assembly 1 805 148298 100 Handset Harness Assembly 1 806 148373 100 Dose Request Cord Strap 1 807 809061 Eyelet Stud 1 808 320761 Washer 4 Internal Locking 1 809 10013795 Handset Assembly 1 831 148287 000 Door Rear 1 832 148258 000 Lockplate Front Door 1 834 148282 000 Door Front 1 835 TC10003128 Hinge 1 836 TC10003331 Door Strike Plate 1 837 TC10003086 Strike Lockplate 1 838 148286 000 Lockplate Rear Door 1 844 TC10003130 Bushing Hinge 1 860 10010964 Key Kit 1 Includes 2 keys for Lock Assembly 2001 10013524 Lock Assembly 1 2003 147077 100 IUI Connector Kit Right 1 Includes Right Gasket Right IUI Connector Alaris Syringe Module 8110 Series 7B 5 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module
5. Display Board Keypad Flex Cable Handset Harness Alaris Syringe Module 8110 Series 5B 15 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 13 Removing Sensor Board Assembly 1 Remove Flag Leaf Spring and Barrel Position Flag as required 2 Remove one 1 screw attaching Sensor Board to Front Case 3 Remove Sensor Board Sensor Board Flag Leaf Spring Barrel Position Flag 5B 16 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 14 Removing Syringe Size Sensor Assembly 1 Remove one 1 screw attaching Syringe Size Sensor Assembly and Shaft Support to Front Case 2 Remove Syringe Size Sensor Assembly Potentiometer Extension Guide Syringe Size Sensor Assembly During Reassembly 1 Insert tab on Syringe Size Sensor Assembly into Potentiometer Extension Guide 2 Secure Syringe Size Sensor Assembly to Front Case Front Case Alaris Syringe Module 8110 Series 5B 17 Alaris PCA Module 8120 Series Te
6. Table 7B 1 Parts List PCA Module Continued Item Part Number Description QTY 2004 147078 100 IUI Connector Kit Left 1 Includes Left Seal Left IUI Connector 2006 10013532 Latch Kit 1 Includes Latch Support with washers attached Latch Bracket Compression Spring and item 422 Directions for Use 1 10010720 PCA Module V7 10010199 Syringe Module V7 Alaris System supports Guardrails Suite MX 10012555 Electronic Copy 10012398 Printed Copy 148444 000 Set Compatibility Card 1 CAES The Top disk Holder Internal Frame Shaft Support and various Syringe Barrel Clamp Assembly parts identified here are not backwards compatible with a Syringe Barrel Clamp Assembly having a Park Position Pin attached Prior to ordering any of these parts reference the Corrective Maintenance chapter for part identification and replacement instructions Newer versions of the Park Position Collar and Barrel Clamp are not interchangeable with earlier versions If either part requires replacement and the hex head bit 1 16 HX 115 16 length tool was used to remove the Park Position Collar 0 062 setscrew both parts must be replaced 9 Not sold by CareFusion 7B 6 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 1 Actuator Knob Assembly Actuator Knob Assembly items are available as an assembly Table 7B 1
7. e MITES The Top disk Holder Internal Frame Shaft Support and various Syringe Barrel Clamp Assembly parts identified here are not backwards compatible with a Syringe Barrel Clamp Assembly having a Park Position Pin attached Prior to ordering any of these parts reference the Corrective Maintenance chapter for part identification and replacement instructions Newer versions of the Park Position Collar and Barrel Clamp are not interchangeable with earlier versions If either part requires replacement and the hex head bit 1 16 HX 15 1 length tool was used to remove the Park Position Collar 0 062 setscrew both parts must be replaced e Order the Front Case Kit when replacing an old version Front Case Syringe Barrel Clamp Assembly or associated part or Top Disk Holder reference Figure 7A 7 amp Order the Front Case Assembly when replacing a new version Front Case Syringe Barrel Clamp Assembly or associated part or Top Disk Holder reference Figure 7A 7 e The Base Disk Holder can be relaced as an individual part only if it is used with a new version Front Case If an old version Front Case is in use order item 9 Front Case Kit reference Figure 7A 7 e Not sold by Carefusion TA 6 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 1 Actuator Knob Assembly Actuat
8. 5B 8 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 5 2 6 1 DISASSEMBLY REASSEMBLY Continued Removing Flex Cable Retainer Peel Flex Cable Retainer from Internal Frame Use a cotton swab or soft cloth lightly dampened with 70 Isopropyl Alcohol to remove adhesive debris from Internal Frame Retainer tucks into Front Case here Retainer adheres to Internal Frame here During Reassembly see Figure 7B 9 1 Ensure Internal Frame surface where retainer is adhered is clean and free of adhesive debris Remove protective backing from replacement retainer and adhere to Internal Frame If necessary bend retainer on each fold line at a 90 angle toward front of instrument Lay retainer over Flex Cable and tuck inside Front Case Flex Cable Retainer Alaris Syringe Module 8110 Series 5B 9 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 7 Removing IUl Board Assembly 5 Use small diagonal cutters to lift and 1 If present remove Retainer Clip from remove shap river trom IUI Board Dual Connector Cable IUI Board CAUTION connection Do not cut rivet 2 Disconnect Dual Connector Cable from IUI B 2 als 6 Remove IUI Board 3 Disconnect Syringe Size Sensor harness from IUI Board J4 Dur
9. Corrective Maintenance PCA Module 5 1 5 2 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 5 2 6 5 2 7 5 2 8 5 2 9 5 2 10 5 2 11 5 2 12 5 2 13 5 2 14 5 2 15 5 2 16 5 2 17 5 2 18 5 2 19 5 2 20 5 2 21 5 2 22 5 2 23 5 2 24 INTODUCHON EEUU 5B 1 Disassembly Reassembly ooo coco 5B 2 Removing Latch Assembly and Feet ooooooococccccccccccco occ 5B 3 Removing IUI Connector Assemblies sss 5B 4 Isemoving Hande erepto A DURER EERV AS Ad 5B 5 Removing Door Assembly ooo 5B 6 Removing Rear Case ssec t Eres laa dado 5B 8 Removing Flex Cable Retainer 1 0 2 0 00 rr rr 5B 9 Removing IUI Board Assembly 0 6 0 ccc crono rr 5B 10 Removing Logic Board Assembly 0 000 c cece t ttre eben ett e tee eeeees 5B 11 Removing Internal Frame Assembly 00 00 ccc cece eter es 5B 12 Removing Lock Assembly ooo occ rr 5B 13 Removing Latch Module and Drivetrain Assembly 0 00 0 c cece cece e eee 5B 14 Removing Display Board Assembly 0 00 0 eunana aneian erranaren arrra rnrn ren 5B 15 Removing Sensor Board Assembly 00 0 uuniin urrunaren t ttre tne eet tte rarae 5B 16 Removing Syringe Size Sensor Assembly 000 cece cette rreran rrarena 5B 17 Removing Syringe Barrel Clamp Assembly ssssssssssssssssss e 5B 18 Removing Status Indicator Lens 66 cece terre tenn nett ete eienen 5B 20 Removing Handset Harness 0 eee ns 5B 21 Remov
10. Retaining Rings Park Position Collar and Setscrew Syringe Barrel Clamp Assembly Shaft Seal Installation Step 1 Front Case Press around edges until seated in recess Shaft Seal l Recess Step 2 Front Case ir Bushing Shaft Seal fully seated Alaris Syringe Module 8110 Series 5B 19 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 16 Removing Status Indicator Lens 1 Remove two 2 screws attaching Status Indicator Lens to Front Case 2 Remove Status Indicator Lens Status Indicator Lens Front Case 5B 20 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 17 Removing Handset Harness During Reassembly 1 Install Handset Harness with red dot pointing to top of Front Case NOTE Use a e in deep well socket at least 4 in deep to remove and install the Handset Harness 2 Install Ground Harness then install first nut and tighten 1 Ensure that 9 e in socket is on top nut then remove top nut first of 2 nuts that 3 Install second nut and tighten ensuring secures Handset Harness to Front that socket
11. Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual PRINCIPLES OF OPERATION 4 8 4 9 FORCE SENSOR SUBSYSTEM Continued This mechanical advantage amplifies the input for a given force from a syringe which improves system resolution Improved resolution is particularly beneficial for smaller syringes with lower syringe forces A protrusion on the contact plate concentrates force from all syringe sizes to a specific location on the contact plate which minimizes the effect of variations in syringe loading and in the syringe push button geometry inherent in plastic syringes The protrusion also creates a longer moment arm for smaller size syringes because they contact the protrusion further from the contact plate pivot This increases the sensor force of small size syringes allowing better system resolution A silicone seal is also trapped between the force sensor and the lower housing PRESSURE SENSOR SUBSYSTEM SYRINGE MODULE ONLY The pressure sensor subsystem includes the Pressure Sensor Board Assembly disc detect system and related hardware The pressure sensor subsystem is only activated when an administration set with a pressure disc is used and the pressure disc is installed and enhances overall pressure detection in the patient line The Pressure Sensor Board includes a pressure sensing transducer that makes intimate contact with a flexible membrane pressure disc
12. aft Sea L_f Recess fully seated 1 5A 18 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 16 Removing Status Indicator Lens 1 Remove two 2 screws attaching Status Indicator Lens to Front Case 2 Remove Status Indicator Lens Status Indicator Lens Front Case Alaris Syringe Module 8110 Series 5A 19 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 17 Removing Housing Assembly and Guide Rod CAUTION Use EXTREME CAUTION when removing Housing Assembly If the Conductive Wiper is damaged replace the entire Lower Housing Carriage Assembly Linear Sensor Harness NOTE If the Housing Assembly must be replaced on a Syringe Module with version 7 or earlier software the Housing Assembly must be replaced at the depot See the note at the beginning of this chapter for more information Pull Linear Sensor Harness loose from clamps on Top Plate Remove two 2 screws attaching Top Plate to Extrusion Frame Knob gripper control Leadscrew Assembly Extrusion Frame 3 Gently place assembl
13. item 3 or separately Alaris Syringe Module 8110 Series TB 7 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 2 Housing Assembly CAUTION To avoid damaging Lower Housing part of item 4 use Nylok screws item 474 to install Force Sensor Assembly item 250 Install 6 Gasket item 281 around parameter and into undercut feature of Upper Housing item 285 Gasket is not to overlap into opening for Actuator Knob Assembly item 3 Nylok screws item 474 are provided as part of Lower Housing Carriage Assembly Kit item 4 and Force Sensor Assembly Kit item 250 7B 8 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 3 Drivetrain Assembly Linear Sensor Assembly item 15 needs to be properly aligned reference Corrective Maintenance chapter prior to being adhered to Extrusion Frame item 10 Harness is routed through harness clamps on Top Plate AR Clamp EV 2 PL 8PL L ld IL Ie B 1h PT lg amp UT d pts IN ff 3 A U r od 9r Alaris Syringe Module 8110 Series 7B 9 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module THIS PAGE INTENTIONALL
14. 1 Technical Troubleshooting Guide Follow the steps in order until the problem fault is corrected Before making a final diagnosis visually inspect the instrument for damage Following repair replacement use Maintenance Software to perform the required tests See Table 5A 3 Syringe Module or Table 5B 3 PCA Module Message Probable Cause Remedy Channel Disconnected Channel disconnected during operation Reconnect module to PC Unit Syringe Module only reprogram infusion setup 2 Channel communication problem 2 Visually inspect lUls on module and with Inter Unit Interface IUI PC Unit If necessary replace IUI Connector 3 Return to factory Channel Errors 1 Module error detected 1 Refer to Tables 6 2 6 3 and 6 4 to diagnose and correct problem 2 Perform applicable preventive maintenance calibration and verification 3 Return to factory Check Syringe 1 Syringe and or drivearm obstruction 1 Check drivearm and syringe travel 2 Plunger head not engaged 2 Lower plunger head onto syringe 3 Barrel Clamp not closed 3 Close Barrel Clamp over syringe 4 Flange detect sensor not engaged 4 Ensure flange detect sensor is engaged 5 Binary switches not working properly 5 Perform Binary Switches Test using or sensors defective Maintenance Software NOTE Open the module to perform the following steps 6 Force sensor harness disconnected 6 Check force sensor harness and or def
15. Alaris Syringe Module 8110 Series 5A 15 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 14 Removing Syringe Size Sensor During Reassembly Assembly 1 Insert tab on Syringe Size Sensor 1 Remove one 1 screw attaching Syringe Assembly into Potentiometer Extension Guide Size Sensor Assembly and Shaft Support to Front Case 2 Secure Syringe Size Sensor Assembly to Front Case 2 Remove Syringe Size Sensor Assembly Potentiometer Extension Guide Syringe Size Sensor Assembly DS S C A A el S P Bx NS ZB in AAN 5A 16 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 5 2 15 DISASSEMBLY REASSEMBLY Continued Removing Syringe Barrel Clamp Assembly CAUTION To replace a Syringe Barrel Clamp Assembly with a park position pin rather than a collar replace with Front Case Assembly Kit Table 7A 1 item 9 1 Loosen set screw securing park position collar to Barrel Clamp and remove oollar Remove Potentiometer Extension Guide Remove one 1 screw attaching Shaft Support to Front Case Remove Retaining Rings Compression Spring Bushing and Barrel Clamp
16. Continued 5 2 11 Removing Pressure Sensor Board During Reassembly Assembly When installing an old version of Base Disk 1 Disconnect Pressure Sensor Harness Holder use 4 40 x 5 16 screws item 486 in from Pressure Sensor Board upper mountings and 4 40 x 3 16 screws item 484 in lower mountings When installing a newer version of Base Disk Holder use 4 40 x 5 16 item 486 for all mountings Reference Figure 7A 4 2 Remove four 4 screws attaching Base Disk Holder to Top Disk Holder and Front Case 3 Remove Base Disk Holder and Pressure Sensor Board Assembly CAUTION To avoid damage to the Front Case when reinstalling the Base Disk Holder use correct size screws reference Figure 7A 4 Base Disk Holder new See CAUTION statement 4 40 x 5 16 4 E a M T L Oo oe e 4 40 x 5 16 m a upper mountings S RL j e M a nv E von Lana IET F E Pressure Sensor OF pore e Lu IF gt p Pressure Sensor Board Assembly Harness n 978 Ib o 4 lt e EN y dun No boss Z LE Base Disk Holder old See CAUTION statement 4 40 x 3 16 lower mountings Alaris Syringe Module 8110 Series 5A 13 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 12 Removing Top
17. Disk Holder NOTE When replacing the Top Disk Holder remove the Flag Disk Holder and Spring from CAUTION the old part and reuse To replace Older Version Top Disk Holder see below replace with Front Case During Reassembly Assembly Kit Table 7A 1 item 9 Set spring torque by inserting end of EE IEEE Spring in hole of Flag Disk Holder and 1 Remove two 2 screws attaching Top winding holder counterclockwise Disk Holder to Front Case Ensure Silicone Tubing and Gasket in 2 Remove Top Disk Holder Top Disk Holder mounting area on Front Case are in place and undamaged See Figure 7A 5 Top Disk Holder Older Version Top Disk Holder See CAUTION statement above Flag Disk Holder 5A 14 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 13 Removing Sensor Board Assembly 1 Remove Flag Leaf Spring and Barrel Position Flag as required 2 Remove one 1 screw attaching Sensor Board to Front Case 3 Remove Sensor Board Sensor Board Flag Leaf Spring Barrel Position Flag
18. PCA Module THIS PAGE INTENTIONALLY LEFT BLANK 7B 20 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 13 Handle Assembly Alaris Syringe Module 8110 Series 7B 21 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 14 Final Assembly TB 22 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 15 Key Kit and Handset Lock Assembly 860 reference MD E AS x Alaris Syringe Module 8110 Series TB 23 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 16 Display Board Assembly NOTE This illustration is for board identification purposes only and does not represent the board s component layout TB 24 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 17 IUI Interface Board Assembly NOTE This illustration is for board identification purposes only and does not represent the boa
19. Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Table 7B 1 Parts List PCA Module Continued Item Part Number Description QTY 200 TC10003887 Plate Force Sensor 1 203 147815 000 Force Sensor Seal 1 205 147814 000 Lock Plate Force Sensor 1 230 147799 001 Slide Plate 1 246 TC10003157 Flex Cable Retainer 1 250 10013882 Force Sensor Assembly Kit 1 Includes Force Sensor Assembly and item 474 255 TC10003065 Knob Actuator 1 265 147834 001 Flag Shaft Interrupter 1 271 321041 Spring Compression 0 3 x 0 236 x 0 032 1 275 147836 002 Cam Pull Rod 1 281 320763 Silicone Tubing 10 ft 1 pues T PCA Modules Figures 7B 1 and 7B 10 285 TC10002873 Housing Upper nu 1 295 147741 000 Status Indicator Lens 1 321 302513 Retaining Ring External 0 188 2 325 TC10004195 Barrel Clamp 1 326 321022 Spring Compression 1 327 10010642 Sensor Assembly Syringe Size 1 335 147810 001 Potentiometer Extension Guide 1 337 321155 Shaft Seal 1 340 147845 002 Shaft Support 1 342 147987 002 Bushing 1 345 147847 001 Flag Seal 1 350 TC10003235 Flag Barrel Position 1 355 147848 001 Leaf Flag Spring 1 360 TC10003211 Board Assembly Flange Detector Sensor 1 365 TC10003525 Board Assembly Display 1 370 147963 100 LED Backlight Assembly Keypad 1 Alaris Syringe Module 8110 Series 7B 3 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BR
20. Syringe Module includes a pressure sensing subsystem for use with administration sets that include pressure discs Up to four Syringe Modules can be attached to the PC unit Both modules can be used in conjunction with any combination of other Alaris Modules Both modules are appropriate for intermittent or continuous delivery of IV fluids Both modules can provide smooth delivery of small quantities of IV fluid within a very low contained volume Both modules include these advanced features bolus delivery drug library drug dose calculator loading dose titrate without stopping syringe size detector one handed syringe loading several modes of delivery multi channel coordinated infusion and dose limits Alaris Syringe Module 8110 Series 4 1 Alaris PCA Module 8120 Series Technical Service Manual PRINCIPLES OF OPERATION 4 2 4 3 4 3 1 GENERAL INFORMATION Continued Both the Syringe and PCA Modules include display logic drivetrain drive head plunger and force sensor subsystems NOTE All circuit boards in the Syringe and PCA Modules are not field repairable and must be returned to a CareFusion Service Center for repair DISPLAY BOARD ASSEMBLY The keypad sends signals to the microcontroller on the Display Board whose function is to manage displayed information The Logic Board provides 5V power to the Display Board through a 10 pin connector Microcontroller The Display Bo
21. Tip Width 3 Long Blade 5682A37 5A 2 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 1 Removing Latch Assembly and Feet During Reassembly 1 Remove two 2 screws attaching Latch Apply thin layer of Dow Corning Molykote 33 Assembly to bottom of Rear Case and or equivalent silicone grease to Feet remove Latch Assembly Components NOTE The Feet press fit into the module 2 Pull two 2 Feet from underside of module NOTE When reinstalling the Compression Spring be sure to orient as shown during reassembly Latch Screws 5 Rear Case J IL LP Feet Alaris Syringe Module 8110 Series 5A 3 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 2 Removing IUI Connector Assemblies Remove two 2 screws attaching each IUI left and right to module During Reassembly Do not mix gray old and black new IUI Connectors Ensure ground clips are still installed on both IUI connectors To install Right IUI Connector Gasket remove protective backing and adhere to IUI Connector IUI Connector Right o NA H 7 To install Left IUI Connector Seal position seal on one end of connector and stretch to other end to conf
22. a distance of 15 feet and provides a 45 viewing angle Channel Identification The display driver controls the 14 segment Channel ID display which can display letters A through H The Channel ID display is readable in normal hospital lighting conditions from a distance of 15 feet and provides a 45 viewing angle 4 3 3 Comparator Safety Monitor The comparator safety monitor circuit detects short or open failures of the Alarm LED or rate display and sends that information to the microcontroller This ensures correct alarm notification and prevents the module from displaying an invalid infusion rate 4 3 4 Status and Backlight LEDs A constant current drives and ensures consistent brightness levels for the three status LEDs Alarm Infusing Standby and the keypad backlight LED 4 2 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual PRINCIPLES OF OPERATION 4 4 LOGIC BOARD ASSEMBLY The Logic Board receives its power from the 8V supply on the PC Unit via the IUI connector The Logic Board contains DC to DC converters to convert the 8V supply to 3 3V 5V and 15V supplies and a variable voltage supply to the motor The Logic Board also contains an inverting circuit to produce a 5V supply The field programmable gate array FPGA on the Logic Board controls the supply voltages 5V 3 3V to the digital and analog sensors The Logic Board monitors the
23. drivetrain to The drivetrain is contained in the lower and drive the plunger in a controlled fashion upper housings The lower housing is also The drive head has claw like arms plunger attached to the drive tube that connects to grippers that capture the syringe plunger the drivetrain carriage at the opposite end The plunger grippers allow the drive head to A plastic sleeve over the drive tube provides capture a wide variety of syringes see the environmental and ESD protection to the flex Syringe or PCA Module section of the circuit routed up to the drive head Alaris System DFU and Set Compatibility Card for more information on suitable 4 7 PLUNGER HEAD BOARD ASSEMBLY syringes A strain gauge on the Plunger Head Board To load a syringe into the drive head the senses the force applied to the syringe gripper control drive head release lever plunger the greater the force the more rotates 90 clockwise This rotates an inner negative the amplifier output The resulting shaft which is connected to a slide plate signal is inverted and offset on the Logic Two holes in the slide plate interface with Board two pinion gears that make direct contact with the plunger grippers Once the slide The optical switches on the Plunger Head plate moves back the gears rotate and the Board detect whether a syringe is properly plunger grippers open to accept the syringe loaded and whether the plunger grippers are plunger flange position to capture
24. if applicable or returns display to System Config Syringe screen Pressing the PC Unit CANCEL key while in a System Configuration option screen leaves setting unchanged returns display to System Config Syringe screen To access System Configuration options 1 Hold OPTIONS key at power up System Config Module 1 of 2 Factory default No Shared Infusion Settings PC Unit Pump Module 3 Press Syringe Module soft key System Config Syringe 1 of 2 All Mode Disabled Auto Pressure Disabled Back Off Disabled Fast Start Disabled KVO Disabled gt Select an Option or EXIT PAGE EXIT DOWN 4 To view additional options press PAGE DOWN soft key System Config Syringe 2 of 2 Max rate 999 mL h Near End Disabled Pressure limit Disc 1000 mmHg Pressure limit NoDisc Med Priming Disabled gt Select an Option or EXIT PAGE UP EXIT SPO2 Module gt Select an Option or EXIT PAGE EXIT DOWN 2 Press PAGE DOWN soft key System Config Module 2 of 2 Syringe Module EtCO2 Module gt Select an Option or EXIT PAGE UP EXIT 2 4 1 All Mode Enabling All mode allows ALL to be selected as the volume to be infused VTBI to deliver the entire contents of the syringe CAUTION If KVO and ALL modes are both enabled the ALL mode will not deliver the entire syringe contents A small perc
25. illustrated parts breakdown for the PCA Module is divided according to its major assemblies 7 2 ILLUSTRATIONS Use the exploded views to identify the parts of each assembly Item numbers numbers in bubbles in the illustrations correspond to the item numbers in the parts list A part that does not have an item number is part of a higher assembly or kit NOTE Due to product changes over time illustrations in this chapter may differ from the instrument under service If there are questions contact CareFusion Technical Support 7 3 PARTS LIST The parts lists include the following information for replaceable parts e item This number corresponds to the item number in the illustration Part Number Use this number to order the part If a part number is not provided that part is not available for sale is part of a kit or higher assembly or can only be replaced repaired by CareFusion authorized service personnel Description Description of the part e QTY Total number of each item used Alaris Syringe Module 8110 Series 7B 1 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module 7 4 ORDERING PARTS Instrument software version Refer to Alaris System DFU for directions on how Parts can be ordered by writing or calling to view Software version CareFusion Customer Care refer to General Contract Information page at Part number beginning of thi
26. on the administration set The pressure of the fluid in the administration set is transmitted through the membrane and into the gel of the sensor where it is measured by a piezoresistive pressure transducer Circuitry on the Pressure Sensor Board amplifies pressure transducer output The board also includes an optical switch that detects the presence of an administration set pressure disc 4 10 PATIENT HANDSET CIRCUIT AND DOOR LOCK SENSOR CIRCUIT PCA MODULE ONLY The PCA Module Logic Board includes a patient handset circuit which senses whether a dose request cord is attached A button on the dose request cord allows a patient to request a dose of analgesia according to clinician programmed parameters The PCA Module Logic Board also includes a door lock sensor circuit that detects the position of the door lock UNLOCK PROGRAM or LOCK UNLOCK allows syringe loading or unloading or access to the latch that allows the PCA Module to be detached PROGRAM allows changes to programmed parameters without interrupting an infusion LOCKis the only position that allows an infusion to start Alaris Syringe Module 8110 Series 4 5 Alaris PCA Module 8120 Series Technical Service Manual PRINCIPLES OF OPERATION THIS PAGE INTENTIONALLY LEFT BLANK 4 6 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual PRINCIPLES OF OPERATION Figure 4 1 Block D
27. ond and harness can reach Logic NOTE Remove or install the Lock Assembly harness carefully to avoid damage to the harness Rear Case Lock Assembly Alaris Syringe Module 8110 Series 5B 13 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 11 Removing Latch Module and Drivetrain Assembly 1 Remove two 2 screws on Latch Bushings and remove Latch Module from underside of Drivetrain 2 Disassemble Latch Module parts Latch Bushing Supports Latch Bushings Latch Rod 3 Remove five 5 screws attaching Drivetrain Assembly to Front Case and remove Drivetrain Assembly During Reassembly Ensure both legs of Latch Bushings seat in the square cutouts on Drivetrain bottom plate Thread Latch Rod through Latch Lever Latch Module Underside of Drivetrain Assembly na Latch Rod Latch Lever Drivetrain Assembly Latch Bushing Support Latch Bushing Front Case 5B 14 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 12 Removing Display Board Assembly 1 Disconnect cables from these Display Board connectors J1 keypad J3 Handset Harness J4 backlight 2 Remove Display Board LED Backlight Harness
28. to module Right Handle Left Handle Rear Case 5A 6 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 5 2 5 1 DISASSEMBLY REASSEMBLY Continued Removing Flex Cable Retainer Peel Flex Cable Retainer from Internal Frame Use a cotton swab or soft cloth lightly dampened with 70 Isopropyl Alcohol to remove adhesive debris from Internal Frame Retainer tucks into Front Case here Retainer adheres to Internal Frame here During Reassembly see Figure 7A 11 1 Ensure Internal Frame surface where retainer is adhered is clean and free of adhesive debris Remove protective backing from replacement retainer and adhere retainer to Internal Frame If necessary bend retainer on each fold line at a 90 angle toward front of instrument Lay retainer over Flex Cable and tuck inside Front Case Flex Cable Retainer Alaris Syringe Module 8110 Series 5A 7 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 6 Removing IUI Board Assembly 1 If present remove Retainer Clip from Dual Connector Cable IUI Board connection 2 Disconnect Dual Connector Cable from IUI Board J2 3
29. x 5 6 PNH PHH Zinc Plated Steel 14 488 301708 Screw 6 32 x 5 16 PNH PHH 3 490 320855 Screw 6 32 x 7 16 PNH PHH Stainless Steel 7 491 320729 Washer 5 Stainless Steel 3 492 320851 Screw 4 40 x 5 16 PNH PHH Stainless Steel 3 494 320167 Washer 0 125 x 0 312 x 0 032 Stainless Steel 1 Alaris Syringe Module 8110 Series TA 5 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Table 7A 1 Parts List Syringe Module Continued Item Part Number Description QTY 496 321035 Screw 4 40 x 3 4 PNH PHH 6 499 Silicone Grease Dow Corning Molykote 33 or equivalent use with As required item 410 645 148013 000 Label Patent 1 646 125569 Label Serial Number Replacement 1 2003 147077 100 IUI Connector Kit Right 1 Includes Right Gasket Right IUI Connector 2004 147078 100 IUI Connector Kit Left 1 Includes Left Seal Left IUI Connector 2006 147080 100 Latch Kit 1 Includes Latch Compression Spring Leaf Spring Support Directions for Use 1 10010720 PCA Module V7 10010199 Syringe Module V7 Alaris System supports Guardrails Suite MX 10012555 Electronic Copy 10012398 Printed Copy 148089 001 Set Compatibility Card 1 Replacement of the Complete Housing Assembly Force Sensor Assembly or Logic Board Assembly in a Syringe Module with version 7 or earlier software must be performed at the depot Refer to the note in section 7 4 for further information
30. 0 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Table 7A 1 Parts List Syringe Module NOTE An assembly is a preassembled group of parts A kit is a group of unassembled parts Item Part Number Description QTY 2 10010997 Housing Assembly Complete _ 1 Includes items 3 4 200 203 205 250 281 285 461 3 148189 100 Actuator Knob Assembly 1 Includes items 230 255 265 271 275 482 4 148188 100 Lower Housing Carriage Assembly Kit 1 Includes Lower Housing all Lower Housing components Wiper Assembly Top Plate Carriage Assembly and item 474 5 148187 100 Leadscrew Assembly 1 Includes Leadscrew Bearing Cover Plate Pulley Retaining Ring 6 148186 100 Motor Pulley Assembly 1 8 10013671 Case Assembly Kit Rear 1 Includes Nameplate Label Rear Case and items 281 645 646 All items are attached except item 646 9 Case Assembly Front 1 10010996 Kit9 Assembled parts Front Case Base Disk Holder Flag Disk Detect Holder and Spring Keypad Status Indicator Lens and items 158 281 315 321 325 326 335 337 340 342 345 350 351 355 Loose parts items 246 380 10013911 Assembly 9 Includes Front Case Keypad and items 295 345 350 355 10 147539 101 Drive Train Extrusion Frame 1 15 147768 001 Linear Sensor Assembly 1 70 147726 002 Plate Bottom 1 85 147794 000 Bushing Motor Isolation 8 93 321050 Grommet Ru
31. 00 0000000060 o ooo oo Visual Instrument Inspection Status Indicator Lens Syringe Barrel Clamp assy Syringe Size Sensor Assy Continued Next Page Alaris Syringe Module 8110 Series 5A 27 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module Table 5A 3 Level of Testing Guidelines Syringe Module Continued Tests to Perform _ O Required X If verification fails Blank Not Applicable Repair Replacement of y Alarm Test Miscellaneous Barrel Size Accuracy Verification Barrel Size Calibration Binary Switches Test Channel ID IUI Connector Test Keypad Test Plunger Force Accuracy Verification Plunger Force Sensor Calibration Plunger Position Accuracy Verification Plunger Position Calibration Pressure Disc Accuracy Verification Pressure Disc Sensor Calibration Simultaneous Display Test Visual Instrument Inspection Instrument Dropped Instrument Software Flashed New Instrument Checkout No Fault Found instrument not opened No Fault Found instrument opened NOTES Use the Maintenance Software to perform testing and calibration After performing any calibration procedure always perform the associated verification t
32. 1 23 i AN 310 A 9 s A 873 44 PS ES to Display A S i Board J1 New See CAUTION statement No boss in lower 2 PL mountings Q Alaris Syringe Module 8110 Series 7A 11 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 5 Front Case Assembly Part 2 CAUTIONS When replacing any Syringe Barrel Clamp Assembly parts and a Park Position Pin versus a Collar is installed replace with Front Case Assembly Kit Table 7A 1 item 9 Figure 7A 8 Newer versions of the Park Position Collar and Barrel Clamp are not interchangeable with ERN earlier versions If either part requires J q replacement and the hex head bit 1 15 HX 115 16 length tool was used to remove the Park Position Collar 0 062 setscrew both parts must be replaced Y N Reference Corrective Maintenance chapter Removing Syringe Barrel Clamp Assembly section for Shaft Seal item 337 installation instructions NS Reference Figure 7A 4 TA 12 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 6 Top Disk Holder Front Case Assembly CAUTION N In
33. 10 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 13 Final Assembly Continued Do not mix gray old and black new IUI Connectors Alaris Syringe Module 8110 Series 7A 21 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 14 Rear Label Locations Labels items 645 and 646 are provided as separate items and as part of Rear Case Assembly Kit Reference Table 7A 1 item 8 for a list of parts included in Rear Case Assembly Kit EN Nameplate Label is available only as part of Rear Case Assembly Kit This label has a regulatory mark and any level of service that requires its replacement must be performed at the factory AN Before adhering Serial Number Label item 646 1 Print instrument model and serial number on label in permanent black ink 2 Apply clear overlay to completely cover label m Nameplate Label AN A a EX DIN o aaa TA 22 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 15 Display Board Assembly NOTE This illustration is for board identification purposes only and does not represent the board s component layout
34. 3 Screw Motor Pulley Assembly in place Motor Belt Alaris Syringe Module 8110 Series 5A 21 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 5 2 19 Removing Leadscrew Assembly and Bottom Plate 1 Remove two 2 screws attaching Leadscrew Assembly to Bottom Plate 2 Remove Leadscrew Assembly Remove remaining screw attaching Bottom Plate to Extrusion Frame 4 Remove Bottom Plate Bushing 8 PL Grommet 4 PL t A V RA hy 0 0 4 1 ES AA Bottom Plate DISASSEMBLY REASSEMBLY Continued i TN TA 3 3 i During Reassembly If replacing Bottom Plate remove bushings and grommets from old plate and install into new plate Extrusion Frame di se IN 9 LIB E PO ES Leadscrew Assembly 5A 22 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 20 Removing Linear Sensor Assembly CAUTION To avoid damaging the Linear Sensor Assembly do not touch with bare hands 1 Peel Linear Sensor Assembly off Extrusion Frame 2 Use alcohol to clean adhesive debris from Extrusion Frame During Reassembly 1 Ensure Extrusion Frame surface is clean Extrusion Frame
35. 32 x 5 16 12 in Ib Latch Cover Front Case 4 40 x 5 16 6 in Ib Logic Board 4 40 x 5 16 6 in Ib Park Position Collar setscrew no nylon patch 6 in Ib setscrew with nylon patch 10 in Ib Sensor Board 4 20 x 5 6 6 in Ib Status Indicator Lens 4 20 x 5 16 6 in Ib Syringe Barrel Clamp Assembly 4 40 x 5 16 6 in Ib Syringe Size Sensor Assembly 4 40 x 5 16 6 in Ib HOUSING CARRIAGE ASSEMBLY Actuator Knob Assembly 4 40 x 1 4 6 in Ib Force Sensor Assembly 2 56 x 3 16 6 in Ib Upper Lower Housing 4 20 x 1 8 in Ib Alaris Syringe Module 8110 Series 5B 29 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module Table 5B 3 Level of Testing Guidelines PCA Module Tests to Perform se O Required X If verification fails Blank Not Applicable Barrel Size Accuracy Verification Barrel Size Calibration Channel ID IUI Connector Test Plunger Force Accuracy Plunger Position Accuracy Verification Simultaneous Display Test Verification Plunger Force Sensor Keypad Test Calibration Alarm Test Repair Replacement of y 9 Binary Switches Test gt lt Plunger Position Calibration e x e Actuator Knob Assy Display Board Drivetrain Assy Force Sensor Assy e e e e e VisualInstrument Inspection Front Case Front and Rear Door Handle Assy Handset Harness Housing Carriage Assy Lower Housing Assy Compl
36. 9 Bushing 1 345 147847 001 Flag Seal 1 350 147846 000 Flag Barrel Position 1 351 147882 002 Gasket Mylar 1 355 147848 001 Leaf Flag Spring 1 360 TC10003211 Board Assembly Flange Detector Sensor 1 TA 4 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Table 7A 1 Parts List Syringe Module Continued Item Part Number Description QTY 365 TC10003525 Board Assembly Display 1 370 147963 100 LED Backlight Assembly Keypad 1 373 147851 101 Harness Assembly Display 1 375 147792 000 IUI Bracket Strap 1 380 147739 100 9 Frame Internal 1 385 TC10003125 IUI Bracket 1 390 TC10003918 Board Assembly Logic 1 395 147816 105 Board Assembly IUI Interface 1 396 806112 Snap Rivet Black Nylon 1 397 320999 Cable Assembly Dual End Connector 1 398 TC10003920 Retainer Clip 2 400 147791 002 IUI Support Bracket 1 410 142794 000 Foot Rubber use with item 499 2 450 147795 001 Handle Left 1 455 147796 001 Handle Right 1 460 321033 Screw 6 32 x 7 16 PNH PHH Zinc Plated Steel 5 461 321100 O Ring 0 07 x 0 07 40 Durometer 4 462 321060 Screw M2 5 x 12 PHH CHSE HD 4 474 10013293 Screw 2 56 x 3 16 Socket Head Cap Nylok 4 478 148225 000 Screw 4 20 x 1 Socket Cap Trifast 4 480 303655 Screw 4 20 x 5 16 Trilob PNH PHH 1 482 300345 Screw 4 40 x 1 4 PNH PHH Zinc Plated Steel 1 484 301711 Screw 4 40 x 9 15 PNH PHH 2 486 300926 Screw 4 40
37. Alaris PCA Module 8120 Series Technical Service Manual GENERAL INFORMATION Table 1 1 Abbreviations Acronyms Various abbreviations and acronyms are used throughout this manual The following are those that are not commonly known or easily recognized CHSE HD cheese head screw DBO database zero DFU Directions for Use IA intra arterial IUI inter unit interface NEOI near end of infusion TR HD truss head screw VDAC voltage DAC Alaris Syringe Module 8110 Series 1 3 Alaris PCA Module 8120 Series Technical Service Manual GENERAL INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK 1 4 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 2 CHECKOUT amp CONFIGURATION Chapter 2 CHECKOUT AND CONFIGURATION CAUTION Should an instrument be jarred severely or dropped remove it from use immediately It should be thoroughly tested and inspected by qualified service personnel to ensure proper function prior to reuse 2 1 2 2 INTRODUCTION This chapter describes initial setup and configuration for the Syringe and PCA Modules NOTE Due to product changes over time configurations described in this chapter may differ from the instrument under service If there are any questions contact CareFusion Technical Support NEW INSTRUMENT CHECKOUT Prior to placing a new instrument in use perform a check in procedure using the Maintenance Sof
38. Compression 1 Use a small pair of needle nose pliers to Spring onto Actuator Knob compress gently pull Interrupter Flag from Actuator Spring with Pullrod Cam then install Knob Assembly screw 2 Remove screw to remove Slide Plate Compression Spring and Pullrod Cam Screw Compression Spring N DEA Interrupter Flag S ES ES uw Sea ES AY Pullrod Cam Slide Plate Actuator Knob 5B 28 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module Table 5B 2 Torque Values PCA Module Functional Application Item Description Torque Value DRIVETRAIN ASSEMBLY Bottom Plate 6 32 x 7 16 12 in Ib Leadscrew Assembly 6 32 x 7 16 12 in Ib Motor Pulley Assembly M2 5 x 12 4 in Ib Top Plate 6 32 x lie 6 in Ib FINAL ASSEMBLY Handle Assembly 4 40 x 3 4 6 in Ib IUI Connectors 6 32 x he 12 in Ib Latch Assembly 4 40 x 3 s Torx Security 6 in Ib Lock Assembly Left Handle 4 40 x 516 6 in Ib Rear Case Front Case 4 40 x 5 16 6 in Ib Rear Case Internal Frame 6 32 x 7 16 12 in Ib Rear Door Front Case 4 40 x 1 4 Torx Security 6 in Ib Right and Left Door Hinge 4 40 x 1 4 Torx Security 6 in Ib FRONT CASE ASSEMBLY Drivetrain Assembly Front Case 4 40 x 5 16 6 in Ib Handset Harness Front Case Lemo Jam Nuts 40 in Ib Internal Frame Drivetrain Assembly 6 32 x 5he 12 in Ib Internal Frame Front Case 4 40 x 5 16 6 in Ib IUI Support Bracket 6
39. DUCTION E dada 2 1 22 New Instrument Checkout re MEAN 23 Configuration Options and Defaults Syringe Module 22 2 3 1 Factory Default Setting esses sse meme RR RR 4 d n RE iav ns 2 2 24 Configuration Setup Syringe Module mccocccooroccncccnncconononcnnnconcnnocnninnnno 22 2 4 1 AMM A ne ed ee e ia 2 3 2 4 2 AUO Pressure id tro ia agai aie UM DA Ett a TEAM IM as Ny 2 4 2 4 3 Back Off aio tica rs 2 4 2 4 4 Fasa ia o e A id bios 2 5 2 4 5 Mom UUERUUETMMM 2 5 2 4 6 DAKAR eec EET 2 6 A INE ETERNI NEM A 2 4 8 Pressure Limit Disc ooo 2 8 2 4 9 Pressure Limit No DISC i oor IIIa TUN RID EPEA E TENNIE RENES 2 8 2 4 10 PMI is Lead PEE lia bh easton dd Eb dd eB Ebbene 2 9 2 5 Configuration Setup Shared Infusion Pump and Syringe sss 2 9 2 6 Configuration Options and Defaults PCA Module o oocoocccccccccccccccccc occ 2 9 Chapter 3 Preventive Maintenance 3 1 Introduction nosci Ced eb me ceat Penes t edu E dda ER RUE LEE E CENE Rao Pu 3 1 3 2 Regular and Preventive Maintenance Inspections Calibration 5 3 1 3 3 Cleaning 1 222 se Iles uc ENEA bi hub big O d ded i desee aiidsdid eE 3 1 Chapter 4 Principles of Operation 4 1 Introduction MERE I 4 1 4 2 General Information 2 orc Ente bre T Meee eins aw RR ends das 4 1 4 3 Display Board Assembly ssssssssssssssssssssssss
40. Disconnect Syringe Size Sensor harness from IUI Board J4 4 Disconnect Flex Cable from IUI Board J3 Flex Cable IUI Board Assembly Snap Rivet iz B Sensor Retainer Clip Dual Connector Cable 5 Use small diagonal cutters to lift and remove snap rivet from IUI Board CAUTION Do not cut rivet 6 Remove IUI Board Assembly During Reassembly Route Dual Connector Cable and Syringe Size Sensor harness under IUI Support Bracket U IUI Support Bracket 5A 8 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 5 2 7 DISASSEMBLY REASSEMBLY Continued Removing Logic Board Assembly NOTE If the Logic Board must be replaced on a Syringe Module with version 7 or earlier software the Logic Board must be replaced at the depot See the note at the beginning of this chapter for more information If present remove Retainer Clip from Dual Connector Cable Logic Board connection Disconnect Dual Connector Cable from Logic Board J8 Disconnect Linear Sensor harness from Logic Board J12 Remove one 1 screw attaching Keypad ground wire and Logic Board to IUI Support Bracket Internal Frame Assembly Linear Sensor Harness Retainer Clip 5 Remove one 1 screw attachi
41. During Reassembly 1 If Shaft Seal has been removed a Reinstall with wide lip facing Front Case b Use a 2 flat bladed screwdriver to carefully push around edges of seal until it is fully seated into Front Case recess c Verify seal is completely seated by slowly pulling Barrel Clamp out 75 to 1 inch and then slowly pushing it back in ensuring seal does not move out of recess Potentiometer Extension Guide a Fully retract Barrel Clamp seat against Front Case b Insert Potentiometer Extension Guide through Shaft Support and snap into place on shaft Tighten park position collar setscrew against flat on end of shaft Barrel Clamp Assembly Partial View Park Position Collar Park Position Pin Continued on Next Page Alaris Syringe Module 8110 Series 5A 17 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 15 Removing Syringe Barrel Clamp Assembly Continued Syringe Barrel e Clamp Assembly I enc Shaft Seal see installation illustration Bushing Potentiometer Extension Guide Retaining Rings Park Position Collar and Setscrew Shaft Seal Installation Step 1 Step 2 Front Case 4 Front Case Press around edges ff n seated in recess Shaft Seal Sues Bushing
42. EAKDOWN PCA Module Table 7B 1 Parts List PCA Module Continued Item Part Number Description QTY 373 147851 101 Harness Assembly Display 1 375 147792 000 IUI Bracket Strap 1 380 147739 100 Frame Internal 1 385 TC10003125 IUI Bracket 1 390 TC10003919 Board Assembly Logic 1 395 147816 105 Board Assembly IUI Interface 1 396 806112 Snap Rivet Black Nylon 1 397 320999 Cable Assembly Dual End Connector 1 398 TC10003920 Retainer Clip 2 400 147791 002 IUI Support Bracket 1 410 142794 000 Foot Rubber use with item 499 2 416 148470 000 Latch Module Lever 1 417 148494 000 Latch Module Lever Cover 1 418 148495 000 Latch Module Seal 1 422 10010865 Screw 4 40 x e BHD Torx Security Stainless Steel 2 450 TC10003262 Handle Left 1 455 TC10003263 Handle Right 1 460 321033 Screw 6 32 x 7 16 PNH PHH Zinc Plated Steel 5 461 321100 O Ring 0 07 x 0 07 40 Durometer 4 462 321060 Screw M2 5 x 12 PHH CHSE HD 4 474 10013293 Screw 2 56 x 3 16 Socket Head Cap Nylok 4 478 148225 000 Screw 4 20 x 1 Socket Cap Trifast 4 480 303655 Screw 4 20 x 5 16 Trilob PNH PHH 3 486 300923 Screw 4 40 x 5 16 PNH PHH Zinc Plated Steel 16 488 301708 Screw 6 32 x 16 PNH PHH 3 490 320855 Screw 6 32 x 7 16 PNH PHH Stainless Steel 7 491 320729 Washer 5 Stainless Steel 3 492 320851 Screw 4 40 x 5 15 PNH PHH Stainless Steel 5 494 320167 Washer 0 125 x 0 312 x 0 032 Stainless Steel 1 TB 4 Alaris Syringe Module 8110 Series
43. Housing Remove Force Sensor Assembly Remove Force Sensor Lock Plate Force Sensor Plate Force Sensor Seal and Upper Housing During Reassembly see Figure 7A 1 Ensure Silicone Tubing gasket in Upper Housing is undamaged and is in place Ensure Plunger Flag part of Lower Housing Assembly and Force Sensor Assembly plunger are seated in Force Sensor Seal Ensure Force Sensor Assembly flex cable is tucked inside upper and lower housings CAUTION To avoid damaging Lower Housing use Nylok screws to install Force Sensor Assembly Upper Housing Silicone Tubing gt gasket not shown Actuator Knob Assembly Housing Carriage Assembly Kit O Rings 4 PL Force Sensor Board Assembly P O Force Sensor Assembly Kit Nylok Screws et PL P O Force Sensor Assembly Kit and Lower Housing Carriage Assembly Kit Wiper Assembly Top Plate and Carriage Assembly are not shown a Force Sensor Plate Force Sensor Lock Plate 5A 24 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 22 Removing Actuator Knob Assembly Parts 1 Use a small pair of needle nose pliers to gently pull Interrupter Flag from Actuator Knob Assembly 2 Remove screw to remove Slide Plate Compression Spring and Pullrod Cam Compressio
44. Technical Service Manual Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Supports Guardrails amp Suite v7 or Later November 2010 n General Contact Information CareFusion San Diego California http www carefusion com alaris Customer Advocacy North America Clinical and technical feedback Phone 888 876 4287 E Mail CustomerFeedback carefusion com Technical Support North America Maintenance and service information support troubleshooting United States Canada Phone Phone 888 876 4287 800 387 8309 Customer Care North America Instrument return service assistance and order placement United States Canada Phone 888 876 4287 Phone 800 387 8309 TABLE OF CONTENTS Chapter 1 General Information 1 1 io ucl E bL e deddddd b bbbe tete ieupust kaa E i ai Lbibbdeacto ens 1 1 1 2 Precaution Definitions isses e eres 1 2 LCENE 11 5 ecc TED 1 4 Operating Features Controls and Indicators sssse MA 4 5 Accessolies oes eevee e me aaaea eese camarada de 1 6 Alarms Errors Messages 0 00 ccc se e e e er lees eese 1 2 746 1 Silencing Alarms raices 12 1 7 Trumpet and Start Up Curves occ 1 2 Chapter 2 Checkout and Configuration 2 1 MINTO
45. Y LEFT BLANK 7B 10 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 4 Front Case Assembly Part 1 CAUTION Replace the Front Case with Front Case Assembly Kit Table 78 1 item 9 Figure 78 8 N A Flag Seal item 345 Barrel Position Flag item 350 and Flag Spring Leaf item 355 are provided separately and as assembled items in Front Case Assembly Kit Table 7B 1 item 9 Front Case is available only as part of Front Case Assembly Kit Table 7B 1 item 9 Status Indicator Lens item 295 is provided separately and is also an assembled item in Front Case Assembly Kit Table 7B 1 item 9 Front Case ZN see CAUTION statement A 480 2 PL 2 to Display Board J1 Alaris Syringe Module 8110 Series 7B 11 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 5 Front Case Assembly Part 2 CAUTION Newer versions of the Park Position Collar and Barrel Clamp are not interchangeable with earlier versions If either part requires replacement and the hex head bit 1 15 HX 119 16 length tool was used to remove the Park Position Collar 0 062 setscrew both parts must be replaced Jh Reference Corrective Maintenance chapter Removing Syringe Barrel Clamp Assem
46. a syringe plunger When either optical switch is unblocked current Once the syringe is loaded a plunger detect sensing circuitry on the Logic Board detects flag interfaces with an optical switch to a current from the switch indicate that a syringe is properly loaded into the plunger grippers The drive head 4 8 FORCE SENSOR SUBSYSTEM also includes a flag that indicates the drive l head position preventing an infusion from The force sensor subsystem includes a beginning prematurely force sensor mounted in the drive head rather than at the drivetrain as in other Several other components of the drive head designs control the opening and closing of the split nuts on the leadscrew A pull rod cam The cantilevered force sensor contact plate attached to the end of the rotating shaft in pivots on a lock plate mounted to the the drive head interfaces with a rod and underside of the lower housing The force head piece that can rotate to lift the rod sensor is positioned so that the cantilevered attached to the drivetrain carriage and cam contact plate acts as a moment arm from lock at the other end allowing the split nuts the pivot point providing mechanical to open Once the rotating shaft rotates advantage from the syringe force to the clockwise to load a syringe and then force sensor released a torsion spring returns the gripper control to its original position This torsion spring ensures that the gripper control 4 4 Alaris
47. ard s microcontroller provides four keypad functions Channel Select Pause Channel Off and Restart The microcontroller controls the keypad backlight and the Alarm Infusing and Standby LEDs The microcontroller controls the LED display driver for the Channel Identification Channel ID and 7 segment rate displays The microcontroller also drives the scrolling alphanumeric display that shows module status such as INFUSION COMPLETE or CHANNEL MALFUNCTION The microcontroller performs safety monitoring and generates alerts including the Alarm LED and applicable error messages if critical circuitry does not function properly 4 3 2 LED Display Driver The microcontroller communicates serially with the LED driver for the 8 digit 7 segment LED display The display driver uses a discrete resistor for brightness control Module software provides three brightness levels low 2796 of full brightness used when the PC Unit is operating on battery power medium 47 of full brightness used when the PC Unit is operating on AC power and high 10096 brightness is the maximum level possible Rate The display driver controls the five 7 segment displays used for the Rate display three 7 segment displays and two small 7 segment displays the smaller displays show fractional digits The five displays show infusion rates from 0 01 mL h to 999 mL h The Rate display is readable in normal hospital lighting conditions from
48. bber 4 112 321031 Timing Belt 1 120 147537 000 Guide Rod 1 158 TC10004194 Collar Park Position Barrel Clamp 1 200 TC10003887 Plate Force Sensor 1 203 147815 000 Force Sensor Seal 1 205 147814 000 Lock Plate Force Sensor 1 Alaris Syringe Module 8110 Series TA 3 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Table 7A 1 Parts List Syringe Module Continued Item Part Number Description QTY 230 147799 001 Slide Plate 1 246 TC10003157 Flex Cable Retainer 1 250 10013882 Force Sensor Assembly Kit O 1 Includes Force Sensor Assembly and item 474 255 TC10003065 Knob Actuator 1 265 147834 001 Flag Shaft Interrupter 1 271 321041 Spring Compression 0 3 x 0 236 x 0 032 1 275 147836 002 Cam Pull Rod 1 281 320763 Silicone Tubing 10 ft 1 NOTE A 10 foot length of Gasket tubing is enough for four Syringe Modules Figures 7A 2 7A 6 and 7A 13 285 TC10002873 Housing Upper EM 2i 1 295 147741 000 Status Indicator Lens 1 305 147482 104 Board Assembly Pressure Sensor 1 307 147975 102 Harness Pressure Sensor 1 310 147736 001 Disk Holder Base 1 315 147737 002 Disk Holder Top 1 321 302513 2 Retaining Ring External 0 188 2 325 TC10004195 Barrel Clamp 1 326 3210222 Compression Spring 1 327 10010642 Sensor Assembly Syringe Size 1 335 147810 001 2 Potentiometer Extension Guide 1 337 321155 Shaft Seal 1 340 147845 0022 Shaft Support 1 342 147987 002
49. bly section for Shaft Seal item 337 installation instructions 11999 p Reference Figure 78 see CAUTION statement 7B 12 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 6 Latch Module Assembly Alaris Syringe Module 8110 Series TB 13 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 7 Drivetrain Assembly Front Case Assembly B y Front Case Assembly Reference Figures 7B 4 and 7B 5 Drivetrain Assembly Reference Figure 7B 3 7B 14 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 8 Internal Frame Assembly Front Case Assembly Linear Sensor Harness part of Drivetrain Assembly is routed between IUI Bracket item 385 and Internal Frame item 380 and beneath IUI Support Bracket item 400 from left to right Drivetrain Assembly Front Case Assembly Reference Figure 7B 3 EN AN Linear Sensor Harness ig A ee i 3 PL Internal Frame to Front Case Assembly 2 PL Internal Frame to Drivetrain Assembly Alaris Syringe Module 8110 Series TB 15 Alaris PCA Module 8120 Series Te
50. ce Manual TABLE OF CONTENTS THIS PAGE INTENTIONALLY LEFT BLANK vi Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 1 GENERAL INFORMATION Chapter 1 GENERAL INFORMATION CAUTION 1 1 INTRODUCTION To avoid damaging the keypad do not use sharp This manual describes how to service the objects pens pencils etc to activate switches Alaris Syringe Module Syringe Module 8110 Series and Alaris PCA Module PCA Module 8120 Series Use this manual in conjunction with the following Alaris System documents and software Alaris Point of Care unit PC Unit 8000 Series Alaris Pump Module Pump Module 8100 Series Technical Service Manual e Alaris System Directions for Use DFU Maintenance Software and User Manual Software v7 x or later PRODUCT NAME NOTE The Alaris System was formerly known as the Medley System and is described in the Alaris System DFU This manual is intended for personnel experienced in analysis troubleshooting and repair of analog digital microprocessor based electronic equipment CAUTION If either module requires service while under warranty it must be serviced only by Any attempt to service this product by anyone CareFusion authorized service other than an authorized CareFusion Service Representative while the product is under warranty may invalidate the warranty personnel Refer t
51. chnical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 15 Removing Syringe Barrel Clamp During Reassembly Assembly 1 If Shaft Seal has been removed 1 Loosen set screw securing park position a Reinstall with wide lip facing Front collar to Barrel Clamp and remove collar Case 2 hemeve Potentiometer Extension b Use a 2 flat bladed screwdriver to cues carefully push around edges of seal 3 Remove one 1 screw attaching Shaft until it is fully seated into Front Case Support to Front Case recess 4 Remove Retaining Rings Compression c Verify seal is completely seated by Spring Bushing and Barrel Clamp slowly pulling Barrel Clamp out to 1 inch and then slowly pushing it back in ensuring seal does not move out of recess 2 Potentiometer Extension Guide a Fully retract Barrel Clamp seat against Front Case b Insert Potentiometer Extension Guide through Shaft Support and snap into place on shaft 3 Tighten park position collar setscrew against flat on end of shaft 5B 18 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 15 Removing Syringe Barrel Clamp Assembly Continued Shaft Seal see installation illustration Potentiometer Bushing Extension Guide P Compression ON Spring Shaft
52. chnical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 9 Logic Board and IUI Board Assemblies Internal Frame assembly Front Case Assembly Reference Figure 7B 8 to Logic Board J12 wt to Logic Board J11 Co La to Logic 93 Board J7 RE to Logic Board J4 to IUI J11 Board J3 NC Fr J4 to IUI Board J4 to IUI m 37 Board J2 u T Mu IT Es 2d at to Logic Ms a Board J8 a to Logic 398 Board J13 7B 16 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 10 Flex Cable Retainer Assembly If necessary bend Flex Cable Retainer on each fold line at a 90 angle toward front of instrument Lay retainer over Flex Cable and tuck inside edge of Front Case reference illustration to right Alaris Syringe Module 8110 Series 7B 17 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 11 Rear Case Front Case Assembly Install two Gasket item 281 pieces approximately 7 and 10 into channel on Rear Case Rear Case labels items 645 and 646 and Gasket item 281 are provided as separate items and as part of Rear Ca
53. ckout using Maintenance Software For information on replacement parts see the Illustrated Parts Breakdown chapter Following any level of maintenance perform the applicable tests refer to Level of Testing Guidelines table Alaris Syringe Module 8110 Series 5B 1 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Follow these procedures in order for the Before adhering gaskets and labels to the most efficient disassembly of PCA Module instrument clean the surface with a cotton subassemblies To reassemble the PCA swab or soft cloth lightly dampened with Module reverse the disassembly steps 70 Isopropyl Alcohol CAUTION CAUTION Disconnect the PCA Module from the Alaris To avoid the risk of electrical hazard or System before attempting disassembly damage to the instrument circuitry do not spray fluids directly onto the instrument or NOTE Perform all maintenance on an allow fluids to enter the instrument antistatic surface preferably a grounded antistatic mat Table 5B 1 Required Materials Supplies and Tools PCA Module NOTE Contact source information is subject to change Silicone grease Dow Corning Molykote 33 or equivalent http www dowcorning com 1 Phillips screwdriver an 2 Phillips screwdriver Small diagonal cutters Lint free cloth such as Kimwipes or lint free tissue The following items are a
54. e Door in Lock position and align Door edges front and back doors flush then tighten all screws Hinge ve AF US Rear Door d AN v d PT de ARE y e Y ev Ad li 1 Rear Door l HSS p ES Lockplate EN enn eee Front r P l ae Door HL Lockplate v o dd 7 V o PE Ts Front LAT Door 0 v A PN w j t E Front Y a Door 0 d bS trikeplat d Strikeplate Lockplate S V N i Front Door Alaris Syringe Module 8110 Series 5B 7 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 5 Removing Rear Case 1 Remove four 4 screws and associated washers attaching Rear Case to chassis assembly 2 Pull Rear Case away from chassis assembly During Reassembly Ensure that Silicone Tubing gasket in Rear Case is in place and undamaged see Figure 7B 10 Lock Assembly Harness Raise Drive Head to highest position before sliding Chassis Assembly into Rear Case Slide edges of Rear Case into Wiper Assembly flange Route Lock Assembly harness along flange on Rear Case Drive Head Slide edge of Rear Case into Wiper Assembly flange at reassembly Chassis Assembly Rear Case Assembly
55. ective connection to drive head If necessary reconnect harness or replace Force Sensor Assembly 2 7 Syringe Size Sensor Assembly 7 Check Syringe Size Sensor harness disconnected and or Assembly harness connection to J4 defective on IUI Board If necessary reconnect harness or replace Force Sensor Assembly 8 Linear Sensor harness disconnected 8 Check Linear Sensor harness and or defective connection to J12 on Logic Board If necessary reconnect harness or replace Force Sensor Assembly 9 9 Return to factory 6 2 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual TROUBLESHOOTING Table 6 1 Message Probable Cause Technical Troubleshooting Guide Continued Remedy Drive Not Engaged Force Sensor Assembly defective Plunger head rotates due to a dislodged or broken dowel pin and or tab in Carriage Assembly Cam Lock stripped or not engaged Use Maintenance Software to perform Binary Switch Test and calibrate if necessary If necessary replace Force Sensor Assembly 9 Replace Lower Housing Carriage Assembly Rotate Actuator Knob and slide plunger head up and down to check for full plunger head travel and Cam Lock engagement and disengagement Repair or replace Lower Housing Carriage Assembly if necessary Return to factory Occlusion Increased back pressure sensed while infusing Pressure Sensor Board and or Pressure Sensor Harness de
56. einstalling the Compression Spring be sure to orient as shown during reassembly Latch Screws Compression Spring Feet During Reassembly When reinstalling Latch Assembly press toward outer edge of module and screw into position Apply thin layer of Dow Corning Molykote 33 or equivalent silicone grease to Feet NOTE The Feet press fit into the module Rear Case Alaris Syringe Module 8110 Series 5B 3 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 2 Removing IUI Connector Assemblies Remove two 2 screws attaching each IUI left and right to module During Reassembly Ensure ground clips are still installed on both IUI connectors To install Right IUI Connector Gasket remove protective backing and adhere to IUI Connector IUI Connector Right IUI Connector Gasket Right CN Y LC S nn J To install Left IUI Connector Seal position seal on one end of connector and stretch to other end to conform to connector body Gently press on seal to seat completely Use lint free swab to apply alcohol to top sides and bottom of seal for lubrication while installing to Rear Case Do not apply alcohol to contacts or connector NN IUI Connector Seal Left IUI Connector Left Ground clip at each mounting hole on both IUI Connectors 5B 4 Alar
57. embly 2 From inside of Door align Front Door f Lockplate holes with through holes on Disassembling Door Assembly Door From outside of Door align holes 4 Remove four 4 screws attaching Front on hinge with those on Door and Front Door Rear Door Lockplate and Rear Door Lockplate Install but only loosely Door tighten seven 7 screws to attach hinge 5 Remove seven 7 screws attaching Hinge to Front Door and Lockplate Door Lock Assembly Assembly IN Harness ue Sg s T8 Torx Security Bt Screws and Hinge hy 118 ICI a AA Bushings x4 Jo r A y A 9 e ol e l Front Case hs 5B 6 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 4 Removing Door Assembly Continued 3 Align Rear Door Lockplate to inside of Rear Door Install but only loosely tighten four 4 screws on upper section of hinge L2 Reinstalling Door Assembly 4 Install four 4 Hinge Bushings into four 4 slots on lower section of hinge 5 Install but only loosely tighten four 4 T8 Torx Security screws 6 Clos
58. entage of the syringe contents will be left available for KVO operation Alaris Syringe Module 8110 Series 2 3 Alaris PCA Module 8120 Series Technical Service Manual CHECKOUT AND CONFIGURATION 2 4 2 4 1 1 2 To change option setting press soft key CONFIGURATION SETUP SYRINGE MODULE Continued All Mode Continued After accessing System Config Syringe options display press All Mode soft key System Configuration Syringe All mode Enable Disable Allows use of the All mode feature next to applicable option Enable or Disable Option setting changes and System Config Syringe page 1 displays 2 4 2 Auto Pressure Enabling Auto Pressure allows the Auto Pressure option to be displayed in the Pressure Limit screen when a pressure sensing disc is in use Auto Pressure automatically sets the alarm limit for a shorter time to alarm as follows If current pressure is 100 mmHg or less system adds 30 mmHg to current pressure to create a new alarm limit If current pressure is greater than 100 mmHg system adds 30 to current pressure to create a new alarm limit After accessing System Config Syringe options display press Auto Pressure soft key System Configuration Syringe Auto Pressure Fnable Disable Allows use of the auto pressure feature 2 To change option setting press soft key next to applicable op
59. er detect sensor nut engaged sensor and flange sensor On the Syringe Module only the Logic Board also reads signals from the SET IN sensor pressure sensor The motor drive circuitry on the Logic Board uses a variable voltage supply to drive a 5 phase stepper motor and save power depending on the torque loading A combination of software settings and motor feedback loop circuitry adjusts the motor supply voltage in response to detected motor loading The motor feedback loop starts with a nominal voltage based on pumping rate and adjusts motor voltage as needed to maintain constant peak motor current levels independent of torque load The motor feedback loop keeps the voltage range constant for any given pumping rate DRIVETRAIN ASSEMBLY The drivetrain is a linear positioning device The geared stepper motor powers the drivetrain and the linear motion of the drivetrain controls the drive head to push the syringe plunger accurately and with enough force to deliver medication from many different syringes Because system positioning is open loop the mechanical parts and assembly must maintain a high degree of accuracy Alaris Syringe Module 8110 Series 4 3 Alaris PCA Module 8120 Series Technical Service Manual PRINCIPLES OF OPERATION 4 6 DRIVE HEAD returns to its vertical closed position and The drive head captures the syringe by the confirms that the split nuts are closed syringe plunger and uses the
60. est 5A 28 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 5B CORRECTIVE MAINTENANCE PCA MODULE Chapter 5B CORRECTIVE MAINTENANCE PCA Module A 4 0 Disconnect the instrument from the Alaris System before performing maintenance Only qualified personnel using proper grounding techniques should open the instrument case CAUTION CMOS devices are sensitive to static electrical charges and may be damaged during repair if the repair activity is not performed in an electrostatic discharge ESD protected environment using approved ESD protective procedures including personnel grounding NOTE Due to product changes over time components assemblies illustrated in this chapter may differ from the disassembled instrument If there are any questions contact CareFusion Technical Support 5 1 INTRODUCTION This chapter describes how to disassemble and reassemble the PCA Module For more efficient repair read the Principles of Operation chapter for information on the mechanical and electrical functions of the PCA Module The surface mount devices on the circuit boards are not field repairable Return circuit boards to an authorized CareFusion Service Center for repair Attempting circuit board repairs voids all warranties Whenever the PCA Module is repaired perform the minimum tests required for new instrument che
61. ete Internal Frame Assy IUI Board IUI Connector Assy Latch Assy Latch Lever Leadscrew Assy Lock Assy Logic Board Rear Case Sensor Board Status Indicator Lens Continued Next Page 5B 30 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module Table 5B 3 Level of Testing Guidelines PCA Module Continued Tests to Perform O Required X If verification fails Blank Not Applicable Repair Replacement of y Syringe Barrel Clamp assy Alarm Test Barrel Size Accuracy Verification Channel ID IUI Connector Test Keypad Test Plunger Force Accuracy Verification Plunger Force Sensor Calibration Plunger Position Accuracy Plunger Position Calibration Simultaneous Display Test Visual Instrument Inspection Verification Syringe Size Sensor Assy eo Barrel Size Calibration e e Binary Switches Test Miscellaneous Instrument dropped Instrument software flashed New instrument checkout No fault found instrument not opened No fault found instrument opened NOTES Use the Maintenance Software to perform testing and calibration After performing any calibration p
62. f error is repeatable Replace Motor and or Logic Board If error is repeatable Replace Motor and or Logic Board If error is repeatable Replace Logic Board and or nut engagement sensor or engagement nut If error is repeatable Replace Logic Board and or nut engagement sensor or engagement nut Calibrate as required If error is repeatable Replace pressure sensing disc and or Logic Board If error is repeatable Replace Force Sensor Assembly 9_ Alaris Syringe Module 8110 Series 6 7 Alaris PCA Module 8120 Series Technical Service Manual TROUBLESHOOTING Table 6 4 Error Codes Continued Error Code 352 6700 353 6650 354 6670 354 6690 355 6620 356 6710 356 6780 Subsystem Logic Board Force Sensor Linear Position Sensor Pressure Sensing Disc Syringe Module only Logic Board Syringe Sizer Sensor Digital Sensor PCA Handset Explanation Force sensor circuit check failure Linear position sensor output is zero or is outside acceptable range Pressure sensor output is outside acceptable range Pressure Sensor current monitor current is outside acceptable range Syringe sizer output is outside acceptable range Digital sensor is outside acceptable range during no power test System detected PCA Handset Key stuck at power up Response If error is repeatable Replace Logic Board or Force Sensor Assembly O_ If error is repea
63. fective Syringe Module only Excessive downward pressure applied on drive head 2a 2b Check for proper set installation Check tubing to ensure there are no obstructions such as kinked or pinched tubing or a clogged filter Perform Binary Switches Test using Maintenance Software Using Maintenance Software perform Pressure Disc Verification calibrate if necessary If necessary replace Pressure Sensor Board and or Pressure Sensor Harness Use Maintenance Software to perform Plunger Force Accuracy Verification and if necessary calibrate Replace Force Sensor Assembly or Lower Housing Carriage Assembly if necessary Return to factory PCA Handset Stuck PCA Module only Handset is stuck or incorrectly connected Verify that handset is correctly connected to PCA Module Replace handset return original to factory Alaris Syringe Module 8110 Series 6 3 Alaris PCA Module 8120 Series Technical Service Manual TROUBLESHOOTING Table 6 1 Message Probable Cause Technical Troubleshooting Guide Continued Remedy Pressure Disc Installed Syringe Module only 1 Pressure sensing disc installed during an infusion 2 Sensor not sensing disc 1a 1b Press RESTART key Check for proper pressure sensing disc installation Disc must snap into holder If pressure sensing disc is not installed check binary sensor by inserting and removing disc Use Main
64. g Syringe page 1 displays 2 4 5 KVO Enabling KVO allows some infusions to automatically switch into KVO keep vein open mode upon completion The KVO option setting cannot be changed after the instrument is powered on and a profile selected CAUTION If KVO and ALL modes are both enabled the ALL mode does not deliver the entire syringe contents leaving a small percentage of the syringe contents available for KVO operation NOTE In the following procedure the KVO option is changed to Enable Changing the option setting to Disable disables the Change Rate and Change Volume soft keys as displayed in step 1 1 After accessing System Config Syringe options display press KVO soft key System Configuration Syringe 1 mL h KVO Enable Volume 2 Allows use of the KVO feature CONFIRM 2 To change option setting press soft key next to applicable option Enable or Disable System Configuration Syringe KVO Rate Disable 1 mL h Change Volume on 0j ange 2 Volume Allows use of the KVO feature CONFIRM Alaris Syringe Module 8110 Series 2 5 Alaris PCA Module 8120 Series Technical Service Manual CHECKOUT AND CONFIGURATION 2 4 CONFIGURATION SETUP SYRINGE MODULE Continued 2 4 5 KVO Continued 3 To change KVO rate press Change Rate soft key and enter new rate 0 01 to 2 5 mL h in 0 01 mL h
65. gs Pump Module and Syringe Module Syringe Module Settings Factory Default Setting To allow changes to System Configuration parameters 1 Hold OPTIONS key at power up 2 4 System Config Module 1 of 2 Factory default Yes Shared Infusion Settings PC Unit Pump Module SPO2 Module gt Select an Option or EXIT PAGE EXIT DOWN 2 Press Factory default soft key 3 Press No soft key System Configuration Factory Default Yes Settings Selection of Yes sets all System Configuration parameters to the factory default setting EXIT 4 To accept change press EXIT soft key Option setting changes and main System Config Module screen displays CONFIGURATION SETUP SYRINGE MODULE NOTES Pressing the EXIT soft key while in a System Config Module screen immediately powers the system down with no Powering Down display Pressing the EXIT soft key while in a System Config Syringe screen returns the display to the main System Config Module screen 2 2 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CHECKOUT AND CONFIGURATION 2 4 CONFIGURATION SETUP SYRINGE MODULE Continued NOTES Continued Pressing the CONFIRM soft key while in a System Configuration option screen accepts existing setting or setting change displays next option setting screen
66. iagram Syringe and PCA Modules INFUSE LED green STANDBY LED yellow ALARM LED red 7 Segment Displays T Scrolling HES AE EH pisos Channel g ID Display 5 D S z a o e 5 o 3 3 c Q c S 9 o 8 Transceiver Address Data Control Bus Logic board Flash Display board microcontroller 8 Bit DAC Variable 5 Phase parallel amp Motor Stepper Amp Voltage Drive Motor Driver 7 segment driver check circuit 12 Bit ADC 8 Channel Force Sensor Out Watchdog Plunger Sensor Position Address Latch System Reset FPGA Motor Drive Voltage Pressure Disc Sensor 8110 only Power On Reset Syringe Size Sensor LED driver check circuit Er der deb am um Ri LR EE TREE E l Unit Detect amp ID Circuit Patient Switch j gemaa L Patient Pa Plunger Detect Sensor ackli g Handset Us Sensors Signal Lever Detect Sensor Circuit Conditioning amp Flange Sensor Drive Circuit Split Nut Engaged Sensor l Set In Sensor 8110 onl Keypad Door Lock Sensor 8120 only ii Door Lock Select Sensor Circuit Amp Current l Sense amp Test P huse Circuit Cha Door Lock Sensor From IUI Connectors DC DC R sta Converter amp SJ 1 Model 8120 PCA Module Only R Channel Off 2 5V 2 5V Ref Reference Circuit Lever Detect Sensor Plunger Detect Drive Head Flange Sensor al Flex Cable Sensor Syringe Size Sen
67. in the illustration Part Number Use this number to order the part If a part number is not provided that part is not available for sale is part of a kit or higher assembly or can only be replaced repaired by CareFusion authorized service personnel Description Description of the part QTY Total number of each item used Alaris Syringe Module 8110 Series 7A 1 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module 7 4 ORDERING PARTS Parts can be ordered by writing or calling CareFusion Customer Care refer to General Contract Information page at beginning of this manual When requesting a part provide the following information Instrument name and model number for example Syringe Module Model 8110 Instrument software version Refer to Alaris System DFU for directions on how to view software version Part number Part description as provided in parts list Forlabels specify required language NOTE Replacing the Complete Housing Assembly Force Sensor Assembly or Logic Board Assembly in a Syringe Module with version 7 0 or earlier software requires special calibration equipment Until version 7 1 or later is installed in the Syringe Module these assemblies must be replaced at the depot Call CareFusion Technical Support 800 854 7128 ext 6003 for assistance and information 7A 2 Alaris Syringe Module 811
68. increments NOTE Flow rates less than 0 01 mL h are available only with a 1 cc syringe For larger syringes the lower limit adjusts to 0 1 mL h System Configuration Syringe KVO Enable Rate Disable Volume mid O ange 2 Volume Allows use of the KVO feature CONFIRM 4 To change KVO volume press Change Volume soft key and enter new volume level 0 5 to 5 System Configuration Syringe KVO Enable Rate Disable 2 mL h Change Volume pate O Change 5 Allows use of the KVO feature CONFIRM 5 To accept changes s press CONFIRM soft key Settings change and System Config Syringe page 1 displays 2 4 6 Maxrate The Maximum rate value identifies the maximum rate at which a bolus dose can be delivered When the Max Rate option is selected during bolus dose programming the bolus is delivered at the maximum rate for an automatically calculated duration 1 After accessing System Config Syringe options display page 2 press Max rate soft key System Configuration Syringe Maximum rate adjustment Maximum Change rate Value 999 mL h Confirm 2 To change maximum rate press Change Value soft key and enter new rate 0 1 to 99 9 mL h in 0 1 mL h increments 100 to 999 mL h in 1 mL h increments System Configuration Syringe Maximum rate adjustment Maximum Change
69. ing Latch Lever Assembly 0 000000 cece cece cece I n 5B 22 Removing Housing Assembly and Guide Rod 00 0 cece ete eee erennere 5B 23 Removing Motor Pulley Assembly ooooooccccccccccccccc occ e 5B 24 Removing Leadscrew Assembly and Bottom Plate 00 Lunnan eanan 5B 25 Removing Linear Sensor Assembly 0 0 0 c cect e 5B 26 Removing Force Sensor and Actuator Knob Assemblies 000 cece eee eee eee 5B 27 Removing Actuator Knob Assembly Parts sss 5B 28 Chapter 6 Troubleshooting 6 1 INTFOdUCION RERO nad NTE EEE Laa 6 1 Chapter 7A Illustrated Parts Breakdown Syringe Module 7 1 IrittodUctlon eie at ieee te YEG hades pit at did E REED as TA 1 7 2 WEStHATIONS en cee cece ao cnet mu mone boos oia TA 1 7 3 Pants LISO as tonta is to a a ta a is TA 1 7 4 Ordering Parts ss centre tmt e Rond eq Ed get Recette desint tati tae d s TA 2 Alaris Syringe Module 8110 Series iii Alaris PCA Module 8120 Series Technical Service Manual TABLE OF CONTENTS Chapter 7B Illustrated Parts Breakdown PCA Module 7 1 INTPOGUCTION 7B 1 7 2 MUST acosan aseos aid 7B 1 7 3 PAS aH I Pp tocan 7B 1 7 4 Ordering Parts e ii erre cenicero ARO List of Figures 4 1 Block Diagram Syringe and PCA Modules sssssssssssssss teen tee e teens 4 7 7A 1 Actuator Knob Assembly A IAT TA 2 Housing Assembly e e e e eene 7A 8 A Dr
70. ing Reassembly 4 Disconnect Flex Cable from IUI Board Route Dual Connector Cable and Syringe J3 Size Sensor harness under IUI Support Bracket Snap Rivet Syringe Size Sensor mE do not cut IUI Board Retainer Clip Dual Connector Cable IUI Support Bracket 5B 10 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 8 Removing Logic Board Assembly 1 If present remove Retainer Clip from Dual Connector Cable Logic Board connection 2 Disconnect Dual Connector Cable from Logic Board J8 3 Disconnect Linear Sensor Harness from Logic Board J12 4 Remove one 1 screw attaching Logic Board to IUI Support Bracket 5 Remove one 1 screw attaching Logic Board to Internal Frame Assembly 6 Disconnect harnesses from following locations on Logic Board J4 display J7 motor J11 flange detect J13 lock harness 7 Remove Logic Board During Reassembly Route Dual Connector Cable and Linear Sensor Harness under IUI Support Bracket N A Internal Frame Assembly gt Linear Sensor Harness bn Logic Board y J11 J4 IUI Support Bracket J12 ly Dual Connector Cable ia s J3 Ir J7 T k 413 Retainer Clip Alaris Syringe Module 8110 Series 5B 11 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Modu
71. is Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 3 Removing Handle During Reassembly 1 Remove six 6 screws attaching Left Assemble Left Handle over Lock Housing and Right Handles and ensure that Lock Harness is routed 2 Remove two 2 screws attaching Left Under LocK Housing boss Handle to Lock Housing Use two 2 screws to attach Left Handle 3 Detach Left and Right Handles from to Loek Housing each other and module Install Right Handle over Left Handle and secure with six 6 screws Right Handle ibm Lock Harness Left Handle Lock Housing Screws attach Left Handle to Lock Housing Rear Case Alaris Syringe Module 8110 Series 5B 5 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 4 Removing Door Assembly 6 Remove two 2 screws attaching 1 Remove four 4 T8 Torx Security screws Lockplate and Strikeplate Lockplate to Front Door and four 4 Hinge Bushings attaching Door Assembly to right side of Front During Reassembly Case 9 y Reassembling Door Assembly 2 Unlock Door and lift Lock Assembly away from Door Take care not to pull 1 Use two 2 screws to assemble Door on Lock Assembly harness Strikeplate to Front Door 3 Remove Door Ass
72. is on top nut second of2 Case nuts only 2 Use socket to remove second nut 4 Connect Handset Harness to Display Remove Ground Harness Board J3 4 Remove Handset Harness already disconnected from Display Board J3 Front Case Handset Harness Nut Nut Ground Harness Alaris Syringe Module 8110 Series 5B 21 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 18 Removing Latch Lever Assembly During Reassembly 1 Remove two 2 screws attaching Latch 1 Install Latch Seal onto shaft of Latch Cover to inside of Front Case Lever 2 Remove Ground Harness 2 Install Latch Lever into Front Case using a blunt instrument to seat seal into Remove Latch Lever and Latch Seal oval recess 3 Attach Latch Cover to Front Case Latch Seal n installs into Or oval recess 5B 22 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 19 Removing Housing Assembly and Guide Rod CAUTION Use EXTREME CAUTION when removing Housing Assembly If the Conductive Wiper is damaged replace the entire Lower Housing Carriage Assembly 1 Pull Linear Sensor Harness loose from clamps on Top Plate 2 Remove two 2 screws a
73. ivetrain Assembly A TAQ 7A A Front Case Assembly Part 1 oo 2000 0 DAA 7A 5 Front Case Assembly Part 2 l a ccc eee e ens 7A 12 7A 6 Top Disk Holder Front Case Assembly 0c TAM 7A 7 Front Case Syringe Barrel Clamp Assembly Top Disk Holder Interchangeability 74 14 7A 8 Front Case Assembly Ad tic A O 7A 9 Drivetrain Assembly Front Case Assembly nnno TAB 7A 10 Internal Frame Assembly Front Case Assembly 00 00 0000 c cece e eee TA 17 7A 11 Logic Board and IUI Board Assemblies ooo TAB 7A 12 Flex Cable Retainer Assembly 0000000 c cece nn TA 19 TA 13 Final Assembly aa III III III Ine I Ie I Ier eee eere PAM 1A 14 RearLabel Locations oio Uds des E CUR ESI VETERE EPTUEERRERES ARR RE Ed 7A 22 7A 15 Display Board Assembly ssssssssssssssssssss e e e e ens 7A 23 7A 16 IUl Interface Board Assembly sssssss see A24 JA T Logic Board Assembly csse es ues inpr RR JA25 7B 1 Actuator Knob Assembly ooooccccccccoocococcconocccn ccoo eee TBP 7B 2 Housing Assembly ssss RIRs TB 78 4 Front Case Assembly Part 1 ann TB 7B 5 Front Case Assembly Part2 isses IRI B 12 7B 6 Latch Module Assembly nnna TB 3 7B 7 Drivetrain Assembly Front Case Assembly ooo TB 7B 8 Internal Frame Assembly Front Case Assembly sss 7B 15 7B 9 Logic Board and IUI Board Assemblies 2 002 002 TB 78 10 Flex Cable Retainer Assembly TBAT 78 11 Rear Case Front Ca
74. l compatible admision Seis PISO operation the module s Administration Set Compatibility Card Insert provided 1 2 PRECAUTION DEFINITIONS separaten Refer to the Alaris System DFU 1 6 ALARMS ERRORS MESSAGES Alarm messages are displayed on the 1 3 SPECIFICATIONS scrolling Message Display bar Refer to the Refer to the product specific section of the product specific section of the Alaris Alaris System DFU System DFU for detailed information 1 4 OPERATING FEATURES CONTROLS 1 6 1 Silencing Alarms AND INDICATORS All alarms can be temporarily silenced by Refer to the product specific section of the pressing the SILENCE key on the PC Unit Alaris System DFU WARNING 1 5 ACCESSORIES If an alarm condition on the module occurs The Syringe Module uses standard single while the audio alarm is silenced the only use disposable syringes with luer lock alarm indications will be visual displays and connectors and administration sets symbols related to the alarm condition AOS O DURER 1 7 TRUMPET AND START UP CURVES Thie PEA Module aa tnde a ld Refer to the product specific section of the single use disposable syringes with luer Alaris System DFU lock connectors and non dedicated administration sets with integrated anti siphon valves designed for use on syringe type PCA devices For specific administration set instructions reference the directions for use provided with the set 1 2 Alaris Syringe Module 8110 Series
75. le 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 9 Removing Internal Frame Assembly 6 Remove two 2 screws attaching 1 Remove one 1 screw attaching three Internal Frame to Drivetrain Assembly 3 ground wires to IUI Support Bracket 7 Remove Internal Frame 2 Remove three 3 screws attaching During Reassembly Internal Frame to Front Case Assembly 8 y Route Linear Sensor Harness between Remove IUI Bracket Strap IUI Bracket and Internal Frame 4 Remove one 1 screw attaching IUI Route Lock Assembly harness through Support Bracket to IUI Bracket top of and under Internal Frame so that 5 Remove IUI Support Bracket and IUI Frame does not pinch harness when Bracket attached to Front Case and harness can reach Logic Board J13 Lock Assembly JN AMA LL Linear Sensor Harness IUI Bracket IUI Bracket Strap IUI Support Bracket N e Q Front Case N Drivetrain Assembly Ground wires Assembly Internal Frame 5B 12 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 10 Removing Lock Assembly During Reassembly 1 Already disassembled Handle Rear Route Lock Assembly harness through top Case IUI and Logic Boards and Internal of and under Internal Frame so that Frame Frame does not pinch harness when attached to 2 Remove Lock Assembly E
76. lt Motor Pulley Assembly and install other end of belt onto motor pulley Do not stretch belt to fit over pulley 3 Screw Motor Pulley Assembly into place Motor Pulley Assembly through Bottom Plate at a slight angle Motor Pulley Assembly Bottom Plate Motor Belt 5B 24 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 5 2 21 Removing Leadscrew Assembly and Bottom Plate DISASSEMBLY REASSEMBLY Continued During Reassembly If replacing Bottom Plate remove bushings 1 Remove two 2 screws attaching and grommets from old plate and install into Leadscrew Assembly to Bottom Plate new plate 2 Remove Leadscrew Assembly Remove remaining screw attaching Bottom Plate to Extrusion Frame 4 Remove Bottom Plate Extrusion Frame Bushing 8 PL Grommet 4 PL la a T I B e EU E l Ed Lorem i SET w 9 e 3 U m KC dE Leadscrew Assembly FT t CUCU N LU Ag 0 Vl E Alaris Syringe Module 8110 Series 5B 25 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 22 Removing Linear Sensor Assembly CAUTION To avoid damaging the Linear Sensor A
77. ly Flex Cable Retainer item 246 is provided as a separate item and as part of Front Case Assembly Kit Table 7A 1 item 9 Figure 7 8 If necessary bend Flex Cable Retainer on each fold line at a 90 angle toward front of instrument Lay retainer over Flex Cable and tuck inside edge of Front Case reference illustration to right Q Alaris Syringe Module 8110 Series 7A 19 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 13 Final Assembly Install two Gasket item 281 pieces approximately 7 and 10 into channel on Rear Case Rear Case and Silicone Tubing gasket item 281 are provided as separate items and as part of Rear Case Assembly Kit item 8 Reference Table 7A 1 item 8 for a list of parts included in Rear Case Assembly Kit 490 3 PL z e d i ONES E O INS LD V OF ah Rear Case ZA 7A 20 Alaris Syringe Module 81
78. n Spring Interrupter Flag Actuator Knob AN ie During Reassembly Install Slide Plate and Compression Spring onto Actuator Knob compress Spring with Pullrod Cam then install screw Screw N D OD Pullrod Cam Slide Plate Alaris Syringe Module 8110 Series 5A 25 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module Table 5A 2 Torque Values Syringe Module Functional Application DRIVETRAIN ASSEMBLY Item Description Torque Value Bottom Plate 6 32 x 7 16 12 in Ib Leadscrew Assembly 6 32 x 7 16 12 in Ib Motor Pulley Assembly M2 5 x 12 4 in lb Top Plate 6 32 x lie 6 in Ib FINAL ASSEMBLY Handle Assembly 4 40 x 3 4 6 in Ib IUI Connectors 6 32 x lie 12 in Ib Latch Assembly 4 40 x 5 16 6 in Ib Rear Case Front Case 4 40 x S16 6 in Ib Rear Case Internal Frame 6 32 x 7 16 12 in Ib FRONT CASE ASSEMBLY Disk Holder Base Disk Holder 4 40 x 5 16 6 in Ib Disk Holder Base Front Case 4 40 x 1 a 6 in Ib Disk Holder Top 4 40 x 3 16 6 in Ib Drivetrain Assembly Front Case 4 40 x 5 16 6 in Ib Internal Frame Drivetrain Assembly 6 32 x 5 16 12 in Ib Internal Frame Front Case 4 40 x 516 6 in Ib IUI Support Bracket 6 32 x 5 16 12 in Ib Logic Board Assembly 4 40 x 5 16 6 in Ib Park Position Collar setscrew no nylon patch 6 in Ib setscrew with nylon patch 10 in Ib Sensor Board Assembly 4 20 x 5 6 6 in Ib Status Indicator Lens 4 20 x 5 16 6 i
79. n Ib Syringe Barrel Clamp Assembly 4 40 x S16 6 in Ib Syringe Size Sensor Assembly 4 40 x 5 16 6 in Ib HOUSING CARRIAGE ASSEMBLY Actuator Knob Assembly 4 40 x 1 4 6 in Ib Force Sensor Assembly 2 56 x 3 16 6 in Ib Upper Lower Housing 4 20 x 1 8 in Ib 5A 26 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module Table 5A 3 Level of Testing Guidelines Syringe Module Tests to Perform se O Required X If verification fails Blank Not Applicable Barrel Size Accuracy Verification Barrel Size Calibration Channel ID IUI Connector Test Plunger Force Accuracy Plunger Position Accuracy Verification Simultaneous Display Test Verification Pressure Disc Accuracy Verification Pressure Disc Sensor Plunger Force Sensor Calibration Keypad Test Calibration Alarm Test Repair Replacement of y gt lt Plunger Position Calibration e x e Actuator Knob Assy e e Binary Switches Test Disc Holder Top Base Display Board Assy Drivetrain Assy Force Sensor Assy Front Case Handle Assy Housing Carriage Assy Lower Housing Assy Complete Internal Frame Assy IUI Board Assy IUI Connector Assy Latch Assy Leadscrew Assy Logic Board Assy Pressure Sensor Board Assy Rear Case Sensor Board Assy o o
80. nance chapter If a Flex Cable Retainer is not already installed install Flex Cable Retainer provided in kit reference Figure 7A 12 Flex Cable Retainer Front Case Assembly Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 7A 15 ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 9 Drivetrain Assembly Front Case Assembly Front Case Assembly Reference Figures 7A 4 and 7A 5 486 5 PL Drivetrain Assembly Reference Figure 7A 2 7A 16 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 10 Internal Frame Assembly Front Case Assembly Linear Sensor Harness part of Drivetrain Assembly is routed between IUI Bracket item Prior to replacing the Internal Frame reference 385 and Internal Frame item 380 and beneath the Corrective Maintenance chapter for IUI Support Bracket item 400 from left to right interchangeability information and replacement instructions Drivetrain Assembl
81. ng Logic Board to Internal Frame Assembly 6 Disconnect harnesses from following locations on Logic Board J4 display J7 motor J11 flange detect J14 pressure sensor 7 Remove Logic Board During Reassembly Route Dual Connector Cable and Linear Sensor Harness under IUI Support Bracket Logic Board Assembly Keypad Ground Wire Alaris Syringe Module 8110 Series 5A 9 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 8 Removing Internal Frame Assembly CAUTION To replace an Internal Frame whose Barrel Clamp Assembly has a park position pin rather than a collar replace with Front Case Assembly Kit Table 7A 1 item 9 1 Remove three 3 screws attaching Internal Frame to Front Case Assembly 2 Remove IUI Bracket Strap Barrel Clamp Assembly Partial View Park Position Collar Park Position Pin 3 Remove one 1 screw attaching IUI Support Bracket to IUI Bracket 4 Remove IUI Support Bracket and IUI Bracket 5 Remove two 2 screws attaching Internal Frame to Drivetrain Assembly 6 Remove Internal Frame During Reassembly Route Linear Sensor Harness between IUI Bracket and Internal Frame Linear Sensor Harness Front Case Assembly IUI Bracket IUI Bracket Internal Frame
82. no pressure sensing disc is in use 1 After accessing System Config Syringe options display page 2 press Pressure limit NoDisc soft key System Configuration Syringe Pressure Limit Selection no disc Low High CONFIRM 2 To change pressure limit occlusion pressure set point press applicable soft key Low Med High System Configuration Syringe Pressure Limit Selection no disc Low Med High CONFIRM 3 To accept change press CONFIRM soft key Setting changes and System Config Syringe page 2 displays 2 8 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CHECKOUT AND CONFIGURATION 2 4 CONFIGURATION SETUP SYRINGE MODULE Continued 2 6 2 4 10 Priming Enabling Priming mode allows a limited volume of fluid to be delivered to prime the administration set before connecting to a patient or following a syringe change When priming a single continuous press of the PRIME soft key delivers up to 2 mL of priming fluid 1 After accessing System Config Syringe options display page 2 press Priming soft key System Configuration Syringe Priming mode Enable Disable Allows use of the priming feature 2 To change option setting press soft key next to applicable option Enable or Disable Option setting changes and Sy
83. o the Warranty and Service Information sections of the Alaris System DFU The Alaris System is a modular infusion and monitoring system intended for use in adult pediatric and neonatal healthcare The Syringe Module is intended for facilities that use syringe pumps to deliver fluids medications blood and blood products using continuous or intermittent delivery through clinically acceptable routes of administration such as intravenous IV intra arterial IA subcutaneous epidural enteral or irrigation of fluid spaces Alaris Syringe Module 8110 Series 1 1 Alaris PCA Module 8120 Series Technical Service Manual GENERAL INFORMATION 1 1 INTRODUCTION Continued WARNING The PCA Module is intended for facilities Use only specified syringes and that use syringe pumps to deliver fluids or administration sets with the Syringe and medications using continuous or intermittent PCA Modules Using other syringes or delivery through clinically acceptable routes administration sets can cause improper of administration such as intravenous IV instrument operation inaccurate fluid subcutaneous or epidural delivery or pressure sensing or other Refer to the product specific Syringe potential hazards For a list of compatible Module or PCA Module section of the Sy Men reier to the produci specitic Alaris System DFU for a list of features and Po oe Aa Com cs aol Billet detailed information regarding setup and e
84. or Knob Assembly items are available as an assembly Table 7A 1 item 3 or separately Alaris Syringe Module 8110 Series 7A 7 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 2 Housing Assembly Install 6 Gasket item 281 around parameter and into undercut feature of Upper Housing item 285 Gasket is not to overlap into opening for Actuator Knob Assembly item 3 Replacement of the Force Sensor Assembly in a Syringe Module with version 7 or earlier software must be performed at the depot Refer to section 7 4 for further information Nylok screws item 474 are provided as part of Lower Housing Carriage Assembly Kit item 4 and Force Sensor Assembly item 250 CAUTION To avoid damaging Lower Housing part of item 4 use Nylok screws item 474 to install Force Sensor Assembly item 250 La AG 7A 8 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 3 Drivetrain Assembly Linear Sensor Assembly item 15 needs to be AN properly aligned reference Corrective Maintenance chapter prior to being adhered to Extrusion Frame item 10 Harness is routed through harness clamps on Top Plate S N Replacement of the Complete Housing Assembly in a Syringe Module with version 7 or earlier softwa
85. or not engaged Remove drivetrain blockage If necessary repair or replace Lower Housing Carriage Assembly Rotate Actuator Knob and slide plunger head up and down to check for full plunger head travel and Cam Lock engagement and disengagement If necessary repair or replace Lower Housing Carriage Assembly Return to factory Syringe Empty If syringe is not empty Force Sensor Board Assembly is defective Syringe plunger travel impeded Use Maintenance Software to perform Binary Switches Test Replace Force Sensor Assembly or Linear Sensor if necessary Rotate Actuator Knob and slide plunger head up and down to check for full plunger head travel and Cam Lock engagement and disengagement Repair or replace Lower Housing Carriage Assembly if necessary Return to factory Syringe Not Recognized Odd size or wrong brand syringe installed Syringe Size Sensor defective Logic Board software problem Replace syringe with a compatible syringe refer to Alaris System DFU Use Maintenance Software to perform Binary Switches Test Replace Syringe Size Sensor Assembly if necessary Replace Logic Board and flash with appropriate software version _ Return to factory Replacing the Force Sensor Assembly or Logic Board Assembly in a module with version 7 or earlier software must be performed at the depot Refer to the note at the beginning of this chapter for further information Alaris Sy
86. orm to connector body Gently press on seal to seat completely Use lint free swab to apply alcohol to top sides and bottom of seal for lubrication while installing to Rear Case Do not apply alcohol to contacts or connector IUI Connector Seal Left IUI Connector Left Ground clip at each mounting hole on both IUI Connectors 5A 4 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 3 Separating Rear Case from Chassis During Reassembly Assembly Ensure Silicone Tubing gasket in Rear 1 Remove four 4 screws and associated Case is in place and undamaged See washers attaching Rear Case to Figure 7A 12 chassis assembly Raise Drive Head to highest position 2 Separate Rear Case from Front Case by before sliding Chassis Assembly into pulling Rear Case away from chassis Rear Case assembly Ensure wiper assembly seals between cutout in rear case L Chassis Assembly 6 7 N Rear Case Assembly Alaris Syringe Module 8110 Series 5A 5 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 4 Removing Handle Remove six 6 screws attaching left and right handles to each other and
87. rate Value mL h Continued Next Page 2 6 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CHECKOUT AND CONFIGURATION 2 4 CONFIGURATION SETUP SYRINGE System Configuration Syringe MODULE Continued Enable 2 4 6 Max rate Continued Infusion s Alert Time Change 2 min Time System Configuration Syringe Allows use of the Near End of Infusion feature Maximum rate adjustment Maximum Change rate Value 99 9 mL h Confirm CONFIRM 2 To change option setting press soft key next to applicable option Enable or Disable System Configuration Syringe 3 To accept change press Confirm soft key Near End of Infusion Disable Setting changes and System Config Alert Time change 2 min Time Syringe page 2 displays Allows use of the Near End of Infusion feature 2 4 7 Near End Enabling Near End of Infusion NEO allows an alert to be set from 1 to coe 60 minutes before the infusion is complete The alert occurs at the configured time or 3 To change Alert Time press Change when 25 of the VTBI remains whichever Time soft key and enter new time occurs later 1 to 60 minutes System Configuration Syringe NOTE In the following procedure the Near End option is changed to Enable Changing Enable the option set
88. rce Sensor Assembly to Lower Housing Remove Force Sensor Assembly Remove Force Sensor Lock Plate Force Sensor Plate Force Sensor Seal and Upper Housing During Reassembly see Figure 7B 1 Ensure Silicone Tubing gasket in Upper Housing is undamaged and in place Ensure Plunger Flag part of Lower Housing Assembly and Force Sensor Assembly plunger are seated in Force Sensor Seal Ensure Force Sensor Assembly flex cable is tucked inside upper and lower housings CAUTION To avoid damaging Lower Housing use Nylok screws to install Force Sensor Assembly Upper Housing Silicone Tubing gasket not shown O Rings 4 PL r O T Actuator Knob 1 3i Force Sensor Board Assembly P O Force Sensor D Assembly Kit Force Ta Sensor Assembly Kit r Nylok Screws lo wt PL P O Force eU Sensor Assembly Ir jg Kit and Lower Plunger E Housing Carriage MER Assembly Kit Lower Housing Carriage Assembly Kit Force Sensor Seal ET vu zs dl y PA Y 1 i gt Wiper Assembly Top Plate and CERES Carriage Assembly not shown a Force Sensor Plate Force Sensor Lock Plate Alaris Syringe Module 8110 Series 5B 27 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 24 Removing Actuator Knob Assembly During Reassembly Parts Install Slide Plate and
89. rd s component layout J3 OOOOOOOOCOCOCOO O O Q 00000000 0000000 00000000 0000000 O Alaris Syringe Module 8110 Series 7B 25 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 18 Logic Board Assembly NOTE This illustration is for board identification purposes only and does not represent the board s component layout F1 E J12 7B 26 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 9 CareFusion Alaris and Guardrails are registered trademarks of CareFusion Corporation or one of its subsidiaries All other trademarks belong to their respective owners Part Number 12232252 2006 2010 CareFusion Corporation or one of its subsidiaries All rights reserved
90. re must be performed at the depot Refer to i H section 7 4 for further information N b d I N ae N ef 7 p Alaris Syringe Module 8110 Series 7A 9 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module THIS PAGE INTENTIONALLY LEFT BLANK 7A 10 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 4 Front Case Assembly Part 1 CAUTION To avoid damage to the Front Case when installing the Base Disk Holder ensure correct screws are used N Flag Seal item 345 Barrel Position Flag item 350 and Flag Spring Leaf item 355 are provided separately and also as assembled items in Front Case Assembly and Kit Table 7A 1 item 9 If Front Case or Base Disk Holder item 310 require replacement reference Table 7A 1 litem 9 or 310 and Figure 7A 7 for part replacement requirements A Status Indicator Lens item 295 is provided separately and is also an assembled item in Front Case Assembly and Kit Table 7A 1 litem 9 Front Case A N Ass A to Display Board J4 IN Old M See CAUTION statement
91. ringe Module 8110 Series 6 5 Alaris PCA Module 8120 Series Technical Service Manual TROUBLESHOOTING Table 6 2 Subsystem Codes Refer to the PC Unit Pump Module 8000 8100 Series Technical Service Manual for Alaris System codes 350 Safety System 351 Motor 352 Plunger Force 353 Plunger Position 354 Patient Pressure 355 Syringe Size 356 Digital Sensor 357 Keyboard 358 Keyboard Comm Table 6 3 Error Code Matrix Refer to the PC Unit Pump Module 8000 8100 Series Technical Service Manual for the Alaris System error code matrix 6600 Motor Watchdog Test Failure 6610 Motor Watchdog Failure 6620 Syringe Size Sensor Failure 6630 Plunger Force Not Tracking Pressure 6640 Plunger Force Sensor Failure 6650 Plunger Position Sensor Failure 6660 Plunger Position Failure 6670 Pressure Disc Sensor Failure Syringe Module only 6680 Timebases Out of Sync 6690 Pressure Sensor Current Monitor Failure 6700 Force Sensor Circuit Test Failure 6710 Digital Sensors lllegal State 6720 Motor Step Rate Failure 6730 Motor Step Sample Too Many Steps 6740 Nut Disengaged 6750 Nut Engage Failure 6760 Not Calibrated 6770 Pressure Sensor Circuit Test Failure 6780 PCA handset stuck PCA Module only 6 6 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual TROUBLESHOOTING Table 6 4 Error Codes Refer to the PC Unit Pump Module 8000 8100 Series Technical Ser
92. rocedure always perform the associated verification test Alaris Syringe Module 8110 Series 5B 31 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module THIS PAGE INTENTIONALLY LEFT BLANK 5B 32 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 6 TROUBLESHOOTING Chapter 6 TROUBLESHOOTING NOTE Replacing the Complete Housing 6 1 INTRODUCTION Assembly Force Sensor Assembly or Logic Board This chapter describes possible problems Assembly in a module with version 7 0 or earlier that can occur while using a Syringe or PCA software requires special calibration equipment Module Refer to this chapter before Until version 7 1 or later is installed in the module i f these assemblies must be replaced at the depot attempting to service the module Call CareFusion Technical Support 800 854 7128 ext 6003 for assistance and information To facilitate troubleshooting when an operating malfunction occurs the Syringe and PCA Modules alarm and display an error message and or error code The information in this chapter can help diagnose and correct technical problems Use Maintenance Software to perform applicable preventive maintenance calibration and verification procedures Alaris Syringe Module 8110 Series 6 1 Alaris PCA Module 8120 Series Technical Service Manual TROUBLESHOOTING Table 6
93. s I ee eee 4 2 Alaris Syringe Module 8110 Series i Alaris PCA Module 8120 Series Technical Service Manual TABLE OF CONTENTS Chapter 4 Principles of Operation Continued 4 3 1 Microcontroller coso e sortir iaa bec digas 4 2 43 2 LED Display Driver or M 4 3 3 Comparator Safety Monitor ssssssssssssssssssssssss e e e e s 4 2 434 Status and Backlight LEDs 2 4 4 Logic Board Assembly ssssssssssssssssssss e ee sse eres 4 3 4 5 Drivetrain Assembly ooo 4 3 4 6 Drive Head o ie RAM e b REPE M en TIDbH o Saas 4 4 4 7 Plunger Head Board Assembly ssssssssssssssssssssssss e eme ee 4 4 4 8 Force Sensor SubSySteml tees ores PEDIR PENUEPUMERP oie 4 4 4 9 Pressure Sensor Subsystem Syringe Module Only 0 4 5 4 10 Patient Handset Circuit and Door Lock Sensor Circuit PCA Module Only 4 5 Chapter 5A Corrective Maintenance Syringe Module 5 1 A E 5A 1 5 2 Disassembly Reassembly ooo cect e e e e ens 5A 2 5 2 1 Removing Latch Assembly and Feet oooooocccoccccccccccco ccoo e 5A 3 5 2 2 Removing IUI Connector Assemblies sss 5A 4 5 2 3 Separating Rear Case from Chassis Assembly 00 0000 c cece ccc cect e eee e eee 5A 5 5 2 4 Removing Handle eee reido 5A 6 5 2 5 Removing Flex Cable Retainer ooooococcccccccccccccccco conc cnc crr cnc 5A 7 5 2 6 Removing IUI Board Assembly ssssssssssssssss
94. s before each use Perform preventive maintenance inspections annually These requirements and guidelines are intended to complement the intent of Joint Commission on Accreditation of Healthcare Organizations JCAHO requirements 3 2 REGULAR AND PREVENTIVE MAINTENANCE INSPECTIONS CALIBRATION Use the Maintenance Software to perform calibration and preventive maintenance Contact CareFusion Technical Support for help obtaining or using Maintenance Software 3 3 CLEANING Refer to the Alaris System DFU Alaris Syringe Module 8110 Series 3 1 Alaris PCA Module 8120 Series Technical Service Manual PREVENTIVE MAINTENANCE THIS PAGE INTENTIONALLY LEFT BLANK 3 2 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 4 PRINCIPLES OF OPERATION Chapter 4 PRINCIPLES OF OPERATION 4 1 INTRODUCTION This chapter describes the principles of operation for the Syringe and PCA Modules Refer to the PC Unit Pump Module 8000 8100 Series Technical Service Manual for PC Unit information 4 2 GENERAL INFORMATION The Syringe and PCA Modules function as part of the Alaris System and function only when attached to a PC Unit PCA Module the PCA Module includes a locking security door and patient handset Only one PCA Module can be attached to the PC Unit and the PCA Module must be attached directly to the right of the PC Unit Syringe Module the
95. s manual When requesting e Part description as provided in parts list a part provide the following information nstrument name and model number for example Syringe Module Model 8110 Forlabels specify required language Table 7B 1 Parts List PCA Module NOTE An assembly is a preassembled group of parts A kit is a group of unassembled parts Item Part Number Description QTY 2 10010997 Housing Assembly Complete 1 Includes items 3 4 200 203 205 250 281 285 461 3 148189 100 Actuator Knob Assembly 1 Includes items 230 255 265 271 275 482 4 148188 100 Lower Housing Carriage Assembly Kit 1 Includes Lower Housing all Lower Housing components Wiper Assembly Top Plate Carriage Assembly and item 474 5 148187 100 Leadscrew Assembly 1 Includes Leadscrew Bearing Cover Plate Pulley Retaining Ring 6 148186 100 Motor Pulley Assembly 1 8 10013672 Case Assembly Kit Rear 1 Includes Rear Case Nameplate Label and items 281 645 646 All items are attached except item 646 9 10013531 Case Assembly Front 1 Includes Front Case Keypad and items 295 345 350 355 10 147539 101 Drive Train Extrusion Frame 1 15 147768 001 Linear Sensor Assembly 1 70 147726 002 Plate Bottom 1 85 147794 000 Bushing Motor Isolation 8 93 321050 Grommet Rubber 4 112 321031 Timing Belt 1 120 147537 000 Guide Rod 1 158 TC10004194 9 Collar Park Position Barrel Clamp 1 TB 2 Alaris
96. se Assembly sssssss eeu B 18 7B 12 Door Assembly sta clear CT CM 1B 19 Handle Assembly nrc MAD NPPPITPIM E Morelli FB 7B 14 Final Assembly a TB22 iv Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual TABLE OF CONTENTS List of Figures continued 18 15 Key Kit and Handset ebd erede OR RE HY RARE PER EVEERREId Mie Gees 7B 23 7B 16 Display Board Assembly rro 7B 24 78 17 IUI Interface Board Assembly ooo ccoo rr 7B 25 78 18 Logic Board Assembly ooo occ 7B 26 List of Tables 1 1 Abbreviations Acronyms ooo 1 3 5A 1 Required Materials Supplies and Tools Syringe Module n anana 5A 2 5A 2 Torque Values Syringe Module 0 0 cece eter ented bette teeter teens 5A 26 5A 3 Level of Testing Guidelines Syringe Module 0 e eee e ee 5A 27 5B 1 Required Materials Supplies and Tools PCA Module aanne 5B 2 5B 2 Torque Values PCA Module ooo 5B 29 5B 3 Level of Testing Guidelines PCA Module n 0 0 0 0 0c aaaeeeaa 5B 30 6 1 Technical Troubleshooting Guide 22 cece teen eet ttet ene e nes 6 2 G2 Subsystem Codes tte G6 6 3 Enor Code Matik seon ce doen deity sities arn beatae tutte e b EA 6 6 6 4 Error CodeS score 6 7 AS Parts List Syringe Module retta ei TAB 7B 1 Parts EisSt PCA Module socorro E r EREE E EE EEE ERE Up rans 7B 2 Alaris Syringe Module 8110 Series V Alaris PCA Module 8120 Series Technical Servi
97. se Assembly Kit item 8 Reference Table 7B 1 item 8 for a list of parts included in Rear Case Assembly Kit A Nameplate Label is available only as part of the Rear Case Assembly Kit This label has a regulatory mark and any level of service that requires its replacement must be performed at the factory Before adhering Serial Number Label item 646 1 Print instrument model and serial number on label in permanent black ink 2 Apply clear overlay to completely cover label 7B 18 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN PCA Module Figure 7B 12 Door Assembly B B q a i Sell T IS Seapine Po E NED H A e H 06 lhal C9 498 7 PL Alaris Syringe Module 8110 Series 7B 19 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN
98. se the disassembly damage to the instrument circuitry do not steps spray fluids directly onto the instrument or allow fluids to enter the instrument Before adhering gaskets and labels to the instrument clean the surface with a cotton swab or soft cloth lightly dampened with 70 Isopropyl Alcohol Table 5A 1 Required Materials Supplies and Tools Syringe Module NOTE Contact source information is subject to change Silicone Grease Dow Corning Molykote 33 or equivalent http www dowcorning com 1 Phillips Screwdriver 2 Phillips Screwdriver Small Diagonal Cutters Lint free cloth such as Kimwipes or lint free tissue The following items may be purchased from TECHNI TOOL 800 832 4866 http www techni tool com Hex Head Bit 1 6 HX 119 16 Length TT 758SC0172 used for 0 062 Park Position Collar Setscrew Power Bit Ball Hex 5 a HX 3 Length TT 758SC0172 Power Bit Ball Hex s2 HX 3 Length TT 758SC0173 Torque Screwdriver with a minimum range of 3 15 in lbs Recommend torque screwdriver Micro Adjustable TT 844SC5002 or TT 304T0034 Torx Bit Size T6 115 16 Length TT 758SC0301 The following items may be purchased from McMaster Carr 562 692 5911 http www mcmaster com Insert Bit Holder Hex Drive 6 Length 7225A42 Insert Bit 0 05 Hex Size 1 4 Hex Shank 1 Length 8526A46 used for 0 05 Park Position Collar Setscrew Slotted Screwdriver s
99. sor Plunger Force Sensor r Drivetrain Assembly x Syringe Barrel Gripper Carriage Flex Circuit Split Nut Engaged Sensor Motor Connection Flex Cable Connection 5 Phase Stepper Motor A A EA DANS Wb Plunger Position Sensor Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 4 7 PRINCIPLES OF OPERATION THIS PAGE INTENTIONALLY LEFT BLANK 4 8 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 5A CORRECTIVE MAINTENANCE SYRINGE MODULE Chapter 5A CORRECTIVE MAINTENANCE A Disconnect the instrument from the Alaris System before performing maintenance Only qualified personnel using proper grounding techniques should open the instrument case CAUTION CMOS devices are sensitive to static electrical charges and may be damaged during repair if the repair activity is not performed in an electrostatic discharge ESD protected environment using approved ESD protective procedures including personnel grounding NOTES Replacing the Complete Housing Assembly Force Sensor Assembly or Logic Board Assembly in a Syringe Module with version 7 0 or earlier software requires special calibration equipment Until version 7 1 or later is installed in the Syringe Module these assemblies must be replaced at the depot Call CareFusion Technical S
100. ssembly do not touch with bare hands 1 Peel Linear Sensor Assembly off Extrusion Frame 2 Use alcohol to clean adhesive debris from Extrusion Frame During Reassembly 1 Ensure Extrusion Frame surface is Before adhering Linear Sensor Assembly to Extrusion Frame a Remove protective backing from Linear Sensor b Align hole in Linear Sensor Assembly with hole in Extrusion Frame Use a burnishing tool to ensure that Linear Sensor Assembly is securely adhered to Extrusion Frame Clean Linear Sensor Assembly surface using alcohol and lint free cloth such as Kimwipes or lint free tissue clean Extrusion Frame Linear Sensor Assembly O 6 S Alignment Hole 5B 26 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 23 Removing Force Sensor and Actuator Knob Assemblies 1 Loosen four 4 screws attaching Upper Housing to Lower Housing just far enough to remove Upper Housing leaving O Rings attached to screws NOTE To avoid losing O Rings push each screw upward to grab and hold its O Ring before removing screws from Upper Housing 2 Disconnect flex cable from Force Sensor Board J1 3 Lift Force Sensor Board off mounting posts 4 Remove Actuator Knob Assembly Remove four 4 screws attaching Fo
101. sssssss t rete nb ee ete tte eeeeees 5A 8 5 2 7 Removing Logic Board Assembly 0 00 0 c cece etree ttn nett ete e terres 5A 9 5 2 8 Removing Internal Frame Assembly 0 0 00 c cece rr 5A 10 5 2 9 Removing Drivetrain Assembly sssssssssssssssssssss rr 5A 11 5 2 10 Removing Display Board Assembly sss 5A 12 5 2 14 Removing Pressure Sensor Board Assembly ooooocccccocccoocccccccccccc norris 5A 13 5 2 12 Removing Top Disk Holder 2 602 ccc ccc I es 5A 14 5 2 13 Removing Sensor Board Assembly ss sss 5A 15 5 2 14 Removing Syringe Size Sensor Assembly 6 sees 5A 16 5 2 15 Removing Syringe Barrel Clamp Assembly 0 000 c tte tenet ee 5A 17 9 2 16 Removing Status Indicator Lens coccion ias 5A 19 5 2 17 Removing Housing Assembly and Guide Rod 0 norris 5A 20 5 2 18 Removing Motor Pulley Assembly ssssssssssssssssssss rr rr 5A 21 5 2 19 Removing Leadscrew Assembly and Bottom Plate 000 0 0 5A 22 5 2 20 Removing Linear Sensor Assembly sssssssssssssssssssssss t tee rrarena raren 5A 23 5 2 21 Removing Force Sensor and Actuator Knob Assemblies 000 cece cece e es 5A 24 5 2 22 Removing Actuator Knob Assembly Parts ooooooocccccccccccooccccccccccco rr cnn 5A 25 ii Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual TABLE OF CONTENTS Chapter 5B
102. stall 4 Gasket item 281 into channel on Front Case The Top Disk Holder illustrated here is not backward compatible with older versions of the 2i Spring item 312 torque is set by inserting end of Front Case Assembly Prior to replacing this part spring in hole of Flag Disk Holder item 311 and reference the Corrective Maintenance chapter winding holder counterclockwise and Figure 7A 7 for replacement instructions and part identification NOTE All parts illustrated in this figure are provided separately and as assembled items in the Front Case Assembly Kit Table 7A 1 item 9 A see CAUTION statement A 82 Top Disk Holder Assembly see CAUTION statement Alaris Syringe Module 8110 Series TA 13 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 7 Front Case Syringe Barrel Clamp Assembly Top Disk Holder Interchangeability Old Versions These figures illustrate older versions of the Front Case New Version Syringe Barrel Clamp Assembly and Top Disk Holder This figure illustrates a newer version of the Front Case Syringe Barrel Clamp Assembly and Top Disk Holder These parts are not backwards compatible with older versions of parts reference figure to right The newer version of Top Disk Holder If the Front Case Syringe Barrel Clamp Assembly or an reference figure to lef
103. stem Config Syringe page 2 displays 2 5 CONFIGURATION SETUP SHARED INFUSION PUMP AND SYRINGE MODULES Refer to the 8000 8100 Series Technical Service Manual CONFIGURATION OPTIONS AND DEFAULTS PCA MODULE NOTE With the Profiles feature enabled the settings are configured independently for each profile A hospital defined best practice data set must be uploaded to enable the Profiles feature Date and Time is a System setting and is the same in all profiles System Settings Refer to the PC Unit section of the Alaris System DFU PCA Module Settings Refer to the PCA Module section of the Alaris System DFU PCA Module Configuration Parameters Select system configuration settings for the PCA Module during data set development then upload them as part of the data Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CHECKOUT AND CONFIGURATION THIS PAGE INTENTIONALLY LEFT BLANK 2 10 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 3 PREVENTIVE MAINTENANCE Chapter 3 PREVENTIVE MAINTENANCE WARNING 3 1 INTRODUCTION Failure to perform regular and preventive Perform regular and preventive maintenance inspections may result in improper maintenance inspections to ensure that the instrument operation Syringe and PCA Modules remain in good operating condition Perform regular inspection
104. supply voltages and analog sensor signals and sets up the nominal power level for any particular pumping rate Incoming analog sensor signals from the pressure sensor force sensor syringe sizer and plunger position sensor are filtered and buffered and then fed to the ADC as inputs The Logic Board includes a processor a 1M x 8 flash ROM 512K x 8 static RAM and a watchdog timer circuit The watchdog timer circuit has a 1 6 second timeout that can put the Syringe or PCA Module into a safe state if the Logic Board main processor fails The Logic Board reads and writes to the FPGA via I O address space The FPGA contains the digital logic for generating control signals for ADC DAC sensors motor feedback circuitry module detection and identification circuit interface and 10 phase step signals for the motor drive circuitry The FPGA also generates a master RESET signal for the module The Logic Board s main processor communicates with the Display Board s microcontroller via a serial channel The Logic Board provides the Power On Reset signal to the Display Board Upon keypad input to the Display Board the Logic Board 4 5 receives a Channel Off signal to stop the motor The Logic Board contains IUI interface circuitry that allows it to communicate with the PC Unit The digital sensor interface on the Logic Board contains current sense circuitry which reads output signals from the photointerrupters on the lev
105. t can be used with the associated part or Top Disk Holder illustrated below require If the Front replacement they must be replaced with the Front Case Front Case illustrated below Case requires replacement it must be Assembly Kit Table 7A 1 item 9 replaced with the Front Case Assembly Kit Table 7A 1 litem 9 y y ES md Le B TE 1 iS Ne is 3 mJ I AQ Er A O Syringe Barrel l Clamp Assembly Y 6 Hd U F gt L eL sa uL DA Top Disk Holder 9 p e o O oR re lle D lle Park Position Collar QD E P we e I gt Su s a VIP lo i FS PS Ii TA 14 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 8 Front Case Assembly Kit NOTES Reference Table 7A 1 item 9 for a list of parts that make up the Front Case Assembly as provided in Kit When installing the Front Case Assembly remove and reuse the existing Pressure Sensor Board Assembly reference Corrective Mainte
106. table Replace linear position sensor Replace pressure sensing disc If error is repeatable Replace Logic Board or Pressure Sensor If error is repeatable Replace syringe sizer sensor If error is repeatable Replace digital sensor If error is repeatable Replace PCA Handset Replacing the Force Sensor Assembly or Logic Board Assembly in a module with version 7 or earlier software must be performed at the depot Refer to the note at the beginning of this chapter for further information 6 8 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual 7A ILLUSTRATED PARTS BREAKDOWN SYRINGE MODULE Chapter 7A ILLUSTRATED PARTS BREAKDOWN 7 1 7 2 7 3 Syringe Module INTRODUCTION The illustrated parts breakdown for the Syringe Module is divided according to its major assemblies ILLUSTRATIONS Use the exploded views to identify the parts of each assembly Item numbers numbers in bubbles in illustrations correspond to the item numbers in the parts list A part that does not have an item number is part of a higher assembly or kit NOTE Due to product changes over time illustrations in this chapter may differ from the instrument under service If there are questions contact CareFusion Technical Support PARTS LIST The parts lists include the following information for replaceable parts e item This number corresponds to the item number
107. tenance Software to perform Binary Switches Test Replace Pressure Sensor Board Pressure Sensor Harness or Flag Disk Holder if necessary 3 Return to factory Pressure Disc Removed Syringe Module only 1 Pressure sensing disc removed during an infusion 2 Sensoris sensing disc 1a 1b Reinsert pressure sensing disc and press RESTART key Check for proper pressure sensing disc installation Disc must snap into holder If pressure sensing disc is installed check binary sensor by inserting and removing disc Use Maintenance Software to perform Binary Switches Test Replace Pressure Sensor Board Pressure Sensor Harness or Flag Disk Holder if necessary Return to factory Syringe Calibration 1 System detected Force Sensor Board pressure disc or Barrel Clamp requires calibration 2 Force Sensor Board pressure disc Syringe Size Sensor Assembly or Logic Board fails calibration Use Maintenance Software to perform applicable calibration s or a full calibration Replace part s failing calibration Perform applicable calibration and verification Return to factory 6 4 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual TROUBLESHOOTING Table 6 1 Message Technical Troubleshooting Guide Continued Probable Cause Remedy Syringe Drive Head Error 1 Syringe plunger travel impeded Cam Lock stripped
108. ting to Disable disables the hour n MM rn Change Time soft key as displayed in Alert Time step 1 TO min Allows use of the Near End of Infusion feature 1 After accessing System Config Syringe options display page 2 press Near End soft key CONFIRM 4 To accept changes s press CONFIRM soft key Settings change and System Config Syringe page 2 displays Alaris Syringe Module 8110 Series 2 7 Alaris PCA Module 8120 Series Technical Service Manual CHECKOUT AND CONFIGURATION 2 4 CONFIGURATION SETUP SYRINGE MODULE Continued 2 4 8 Pressure Limit Disc This option allows setting an occlusion pressure point when a pressure sensing disc is in use 1 After accessing System Config Syringe options display page 2 press Pressure limit Disc soft key System Configuration Syringe Pressure Limit Selection disc present Current limit 1000 mmHg Change Value CONFIRM 2 To change pressure limit press Change Value soft key and enter new limit 25 to 1000 mmHg in 1 mmHg increments System Configuration Syringe Pressure Limit Selection disc present Current limit 2 600 mmHg CONFIRM 3 To accept change press CONFIRM soft key Setting changes and System Config Syringe page 2 displays 2 4 9 Pressure limit No Disc This option allows setting an occlusion pressure point when
109. tion Enable or Disable Option setting changes and System Config Syringe page 1 displays 2 4 3 Back Off When Back Off mode is enabled and a pressure sensing disc is in use the motor reverses plunger movement during an occlusion until the pressure returns to preocclusion levels automatically reducing bolus flow 1 After accessing System Config Syringe options display press Back Off soft key System Configuration Syringe Back Off mode Enable Disable Allows use of the back off feature 2 To change option setting press soft key next to applicable option Enable or Disable Option setting changes and System Config Syringe page 1 displays 2 4 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CHECKOUT AND CONFIGURATION CONFIGURATION SETUP SYRINGE MODULE Continued 2 4 4 Fast Start When Fast Start mode is enabled and a pressure sensing disc is in use the instrument runs at an increased rate when an infusion starts taking up any slack in the drive mechanism 1 After accessing System Config Syringe options display press Fast Start soft key System Configuration Syringe Fast Start mode Enable Disable Allows use of the fast start feature 2 To change option setting press soft key next to applicable option Enable or Disable Option setting changes and System Confi
110. ttaching Top Plate to Extrusion Frame 3 Gently place assembly in a standing position and orient it with motor facing inward Knob gripper control Linear Sensor Harness Leadscrew Assembly CAUTION When performing the next step use care to avoid damaging the leadscrew pulley 4 Rotate knob gripper control to disengage plunger grippers and slowly raise Housing Assembly until Carriage Assembly nears top of Extrusion Frame 5 Angle Housing Assembly away from Linear Sensor Assembly so that Conductive Wiper does not contact Linear Sensor Gently remove Housing Assembly 7 Lift Guide Rod from Bottom Plate and remove nn Housing Assembly Wiper Assembly p A Clamp 2 PL m Plate T I I I I I I I I Conductive arriage Assembl Wiper 9 y Reference tel CAR If 1 l l l I I I 1 1 1 1 1 i I 1 f 1 l l l I I I n Alaris Syringe Module 8110 Series 5B 23 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 5 2 20 Removing Motor Pulley Assembly 1 Remove four 4 screws attaching DISASSEMBLY REASSEMBLY Continued 2 Install Motor Belt a Motor Pulley Assembly to Bottom Plate 2 Remove Motor Belt 3 Remove Motor Pulley Assembly During Reassembly 1 To prevent pinion damage install b Install wide end of belt onto leadscrew pulley Ti
111. tware When powering up the instrument verify the instrument beeps and all display LED segments flash This confirms that the instrument has performed its self test and is operating correctly During operation the instrument continually performs a self test and will alarm and display a message if it detects an internal malfunction Contact CareFusion authorized service personnel if the instrument has physical damage fails to satisfactorily pass the startup sequence fails a self test or continues to alarm Alaris Syringe Module 8110 Series 2 1 Alaris PCA Module 8120 Series Technical Service Manual CHECKOUT AND CONFIGURATION 2 3 2 3 1 CONFIGURATION OPTIONS AND DEFAULTS SYRINGE MODULE NOTES Changes to the factory default values are retained after a power cycle If Factory Default is Yes then all the configuration settings are set to their factory default lf Factory Default is No then one or more of the configuration settings has been changed Setting Factory Default to Yes sets all configuration settings to their factory default With the Profiles feature enabled the settings are configured independently for each profile A hospital defined best practice data set must be uploaded to enable the Profiles feature Date and Time is a system setting and is the same in all profiles Refer to the Alaris System DFU for the following System Settings Shared Infusion Settin
112. upport 800 854 7128 ext 6003 for assistance and information Due to product changes over time components assemblies illustrated in this chapter may differ from the disassembled instrument If there are any questions contact CareFusion Technical Support Syringe Module 5 1 INTRODUCTION This chapter describes how to disassemble and reassemble the Syringe Module For more efficient repair read the Principles of Operation chapter for information on the mechanical and electrical functions of the Syringe Module The surface mount devices on the circuit boards are not field repairable Return circuit boards to an authorized CareFusion Service Center for repair Attempting circuit board repairs voids all warranties Whenever the Syringe Module is repaired perform the minimum tests required for new instrument checkout using Maintenance Software For information on replacement parts see the Illustrated Parts Breakdown chapter Following any level of maintenance perform the applicable tests refer to Level of Testing Guidelines table Alaris Syringe Module 8110 Series 5A 1 Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Follow these procedures in order for the CAUTION most efficient disassembly of Syringe Module subassemblies To reassemble the To avoid the risk of electrical hazard or Syringe Module rever
113. vailable from TECHNI TOOL 800 832 4866 http www techni tool com Hex Head Bit 1 6 HX 11 16 Length TT 758SC0172 used for 0 062 Park Position Collar Setscrew Power bit ball hex 5 64 HX 3 length TT 758SC0172 Power bit ball hex 3 32 HX 3 length TT 758SC0173 Tamper resistant Torx bit size T8 115 16 length TT 758SC0321 Torque screwdriver with a minimum range of 3 15 in lbs Recommend torque screwdriver Micro Adjustable TT 844SC5002 or TT 4304TO034 Torque wrench with a minimum range of 40 in lbs Recommend Y torque wrench 1551E150 Torx Bit Size T6 115 16 Length TT 758SC0301 The following items may be purchased from McMaster Carr 562 692 5911 http www mcmaster com Insert bit holder Y hex drive 6 length 7225A42 Ya drive 9 16 deep well socket available at any hardware or tool store Slotted screwdriver s tip width 3 length blade 5682A37 Insert Bit 0 05 Hex Size 1 4 Hex Shank 1 Length 8526A46 used for 0 05 Park Position Collar Setscrew 5B 2 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE PCA Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 1 Removing Latch Assembly and Feet 1 Remove two 2 screws attaching Latch Assembly to bottom of Rear Case and remove Latch Assembly components 2 Pull two 2 Feet from underside of module NOTE When r
114. vice Manual for details on accessing the Maintenance Mode and viewing the Error Log Error Code 350 6600 350 6630 350 6680 351 6610 351 6660 351 6720 351 6730 351 6740 351 6750 351 6760 351 6770 352 6640 Subsystem Logic Board Force Sensor Logic Board Motor Watchdog Linear Position Sensor Motor Logic Board Motor Logic Board Engagement Nut Engagement Nut Module Pressure Sensing Disc Logic Board Syringe Module only Force Sensor Explanation Watchdog circuit failed power on self test Pressure not tracked by force sensor Timer bases clock frequency out of sync Unexpected countdown interrupt Movement error predicted change in linear position sensor inconsistent with expected position Motor steps accumulating too fast or too slow Too many steps in motor step sample Nut not engaged during infusion lever not opened Attempt to engage nut timed out before engaging Calibration flag not set Module not calibrated Pressure sensing disc circuit test failed during power on self test Force sensor output is zero or is outside acceptable range Response If error is repeatable Replace Logic Board If error is repeatable Replace Force Sensor Assembly 9 If error is repeatable Replace Logic Board If error is repeatable Replace Motor and or Logic Board If error is repeatable Replace linear position sensor I
115. y Front Case Assembly 5 Reference Figure 7A 9 400 3 PL Internal Frame to Front Case Assembly 2 PL Internal Frame to Drivetrain Assembly Alaris Syringe Module 8110 Series TA 17 Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 11 Logic Board and IUI Board Assemblies Replacement of the Logic Board Assembly in a Syringe Module with version 7 or earlier software must be performed at the depot Refer to section 7 4 for further information Internal Frame assembly Front Case Assembly Reference Figure 7A 10 lt to Logic to Logic Board J12 J Board J11 Co A 90 J4 J2 RCM Di res oss uem Gil to Logic TI 7759 Board J4 m f J12 T i J4 Jef Board J14 to Logic J7 Board J7 p to IUI Board J2 i p 914 ee to Logic Cb c a Board J8 a a ee 486 2 PL TA 18 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual ILLUSTRATED PARTS BREAKDOWN Syringe Module Figure 7A 12 Flex Cable Retainer Assemb
116. y in a standing position and orient it with motor facing inward CAUTION When performing the next step use care to avoid damaging the leadscrew pulley 4 Rotate knob gripper control to disengage plunger grippers and slowly raise Housing Assembly until Carriage Assembly nears top of Extrusion Frame Angle Housing Assembly away from Linear Sensor Assembly so that Conductive Wiper does not contact Linear Sensor Gently remove Housing Assembly Lift Guide Rod from Bottom Plate and remove ve Housing Assembly s e Wiper Assembly p Clamp 2 PL T m diis Plate Conductive Carriage Assembly Wiper Reference Bu A 5A 20 Alaris Syringe Module 8110 Series Alaris PCA Module 8120 Series Technical Service Manual CORRECTIVE MAINTENANCE Syringe Module 5 2 DISASSEMBLY REASSEMBLY Continued 5 2 18 Removing Motor Pulley Assembly 2 1 Remove four 4 screws attaching a Motor Pulley Assembly to Bottom Plate 2 Remove Motor Belt b 3 Remove Motor Pulley Assembly During Reassembly 1 To prevent pinion damage install Motor Pulley Assembly through Bottom Plate at a slight angle Motor Pulley Assembly Bottom Plate Install Motor Belt Install wide end of belt onto leadscrew pulley Tilt Motor Pulley Assembly and install other end of belt onto motor pulley Do not stretch belt to fit over pulley

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