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Hospira-Omni-Flow-400-Plus-Service-Manual

1. 615 6 3 2 2 PVT TROUBLESHOOTING 6 16 6 3 3 TROUBLESHOOTING WITH IV HISTORY 648 6 3 3 1 IV HISTORY ALARM STATUS CODES 6 19 6 3 4 TROUBLESHOOTING IN SPECIAL FUNCTION MODE 6 20 6 3 1 MONITORING CASSETTE PRESSURE AND SYSTEM VOLTAGES wd ee ae ox d a 6 3 4 2 BIOMED PASSWORD LEVEL 623 Section 7 REPLACEABLE PARTS AND REPAIRS 2 6 71 REPLACEABLE PARTS Rodeo a uo We 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES 78 7 231 SAFETY AND EQUIPMENT PRECAUTIONS 753 7 2 2 REQUIRED TOOLS AND MATERIALS deck owe MR 7 23 TRANSDUCER OFFSET ADJUSTMENT PROCEDURE 74 7 24 AC POWER CORD REPLACEMENT s 755 7 25 FUSEREPLACEMENT kt Bed oe 72 6 CASSETTE LOCKING KNOB REPLACEMENT 77 7 2 7 NURSE CALL CABLE REPLACEMENT 78 7 2 8 CLAMP KNOB REPLACEMENT Wd 729 PRINTER INTERFACE CABLE ASSEMBLY REPLACEMENT 79 7 210 SEPARATING THE TOP AND BOTTOM ENCLOSURES 7 10 7 2 11 BATTERY REPLACEMENT pe dde cu 11 7 212 CONTROL PWA AND TOP ENCLOSURE ASSEMBLY REPLACEMENT ee 743 7 2 13 LCD 45 7 2 14 KEYPAD REPLACEMENT vox xo ge PA 72 15 PUMP PWA REPLACEMENT SERIAL NUMBER SPECIFIC 7 19 7 2 16 POWER SUPPLY PWA REPLACEMENT 72
2. U12 WRITE 32 768 KHZ CRYSTAL TIME CLOCK CIRCUIT c puck TO U9 ONELVL1 INFUSIONA LED INFUSIONB LED U12 WRITE A1 A15 U34 U12 WRITE 00 07 1 0 ASCIA A1 D0 D7 vO U24 ASCIA ur TURN ON LITE INFUSIOND LED INFUSIONC LED ALARM ALARMCTL1 ALARMCTL2 U28 DATA SELECT AND DRIVER U26 svp OP AMP AND Q7 um U12 WRITE U9 CP1 INT 2 M U12 WRITE U12 WRITE 00 07 1 0 U31 RS 232 TRANSCEIVERS AND OPTO ISOLATORS Cun d COMM PORT U 1 0 DATAFROM PUMP J9 AND GATE DATATO PUMP TO PUMP DRIVER PWA 012 WRITE U9 PMPBDINT U32 DATA BUS LCD0 LCD7 AND CONTROL JS ee 9 17 LCD DISPLAY HOSPIRA Figure 9 7 Control PWA Block Diagram DRAWING NO Sheet 1 of 1 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 18 Omni Flow 4000 Plus 5V ADDRESS DATA 7 T INVERTERS DETECTORS POWERON 4 9152 MHZ SS US 0 us RESET CIRCUIT CRYSTAL U19 2 0 12 016 XTLIN XTLOUT m SAR
3. 9 25 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 26 Omni Flow 4000 Plus Section 10 INDEX A AC input rectification and filtering 4 13 AC line filter assembly replacement 7 32 AC power Cord replacement 7 5 Indicator 4 10 Interface 4 6 Acronyms and abbreviations 1 3 Air detection 4 17 Alarm Circuitry 4 9 Conditions 4 3 Alarm messages and service codes 6 1 Operator alarm messages 6 2 Pump service codes 6 6 Self test service codes 6 4 Software service codes 6 9 System service codes 6 10 Analog to digital converter 4 11 Artifacts 1 5 B Bag hanger replacement 7 34 Battery Operation overview 5 13 Replacement 7 11 Biomed password level 6 23 C Cassette Locking knob replacement 7 7 Pressure equalization 4 18 Test 4 3 5 9 Circuitry Alarm 4 9 Power on reset 4 9 Cleaning 5 1 Solutions 5 2 Clock Microprocessor and 4 8 4 10 Real time 1 6 4 8 Technical Service Manual Codes Pump service 6 6 Self test service 6 4 Software service 6 9 System service 6 10 Collection solenoid test 5 8 Component designators 1 3 Contrast control 4 9 Control PWA and top enclosure assembly replacement 7 13 Control PWA 4 7 AC power indicator 4 10 Alarm circuitry 4 9 EPROM and RAM 4 8 LCD backlight and contrast control 4 9 Microprocessor and clock 4 8 Peripheral access 4 8 Power on reset circuitry 4 9 Real
4. ON 10 11 12 Disconnect the device from AC power Separate the top and bottom enclosures as described in Section 7 2 10 Remove the battery as described in Section 7 2 11 Remove the Phillips pan head or slotted hex head screw that secures the ground strap to the top enclosure see Figure 7 7 Disconnect the three ribbon cables two 10 pin and one 8 pin connector from the control PWA see Figure 7 7 Separate the top enclosure from the bottom enclosure Using a Phillips screwdriver and a flat blade screwdriver remove the four screws that attach the pump assembly to the bottom enclosure see Figure 7 14 Note The pump assembly consists of the power supply PWA motor base mechanism and pump PWA Gently tilt the pump assembly away from the bottom enclosure so that the edge of the pump assembly is resting on the bottom enclosure and the power supply PWA is visible Disconnect the 6 pin switch panel connector and the 3 pin AC power connector from the power supply PWA Remove the pump assembly from the bottom enclosure and set the pump assembly on a padded surface so that the power supply PWA faces up Disconnect the two ribbon cables one 11 pin and one 10 pin connector from the power supply PWA Using the nutdriver remove the hex nut securing the top enclosure ground strap and motor base assembly ground strap to the pump assembly chassis Using the flat blade screwdriver re
5. 03K02012 Figure 7 3 Cassette Locking Knob 7 2 7 NURSE CALL CABLE REPLACEMENT No tools are required for this procedure The replacement parts for this procedure are Connector Phone Jack Long To replace the nurse call cable disconnect the defective nurse call cable from the jack and connect the replacement nurse call cable Replacement of the nurse call cable is a routine maintenance procedure and no additional verification procedure is normally required However if the device may have been damaged during this procedure perform the PVT in Section 5 2 430 06579 002 Rev 7 04 7 8 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES 7 2 8 POLE CLAMP KNOB REPLACEMENT No tools are required for this procedure The replacement parts for this procedure are Assembly Knob Pole Clamp Clamp Pole Black To replace the pole clamp knob remove the defective pole clamp knob by unscrewing it from the shaft counterclockwise Install the replacement pole clamp knob on the shaft Replacement of the pole clamp knob is a routine maintenance procedure and no verification procedure is normally required However if the device may have been damaged during this procedure perform the PVT in Section 5 2 7 2 9 PRINTER INTERFACE CABLE ASSEMBLY REPLACEMENT The recommended tool for this procedure is a small flat blade screwdriver The replacement part for this procedure is Omni Flow Printer Cable To replace the printe
6. 3 If no service code occurs but a malfunction exists see Section 6 3 Troubleshooting Procedures Descriptions Descriptions 11 Line A OFF with nonzero rate 39 Line C in KVO with zero rate 12 Line A ON with zero rate 41 Line D OFF with nonzero rate 13 Line A in PGM with nonzero rate 42 Line D ON with zero rate 14 Line A in DLY with nonzero rate 43 Line D in PGM with nonzero rate 15 Line A in HLD with nonzero rate 44 Line D in DLY with nonzero rate 16 Line A in FLS with zero rate 45 Line D in HLD with nonzero rate 18 Line A INF with zero rate 46 Line D in FLS with zero rate 19 Line A in KVO with zero rate 48 Line D INF with zero rate 21 Line B OFF with nonzero rate 49 Line D in KVO with zero rate 22 Line B ON with zero rate 52 Line A INF and another line is INF 23 Line B in PGM with nonzero rate 53 Line A is DIL no other line is INF 24 Line B in DLY with nonzero rate 54 Lines B C 430 06579 002 Rev 7 04 6 10 Omni Flow 4000 Plus 6 3 TROUBLESHOOTING PROCEDURES Table 6 5 System Service Codes Line B in HLD with nonzero rate 61 Line A Watchdog Timer Line B in FLS with zero rate 62 Line B Watchdog Timer Line B INF with zero rate 63 Line C Watchdog Timer Line B in KVO with zero rate 64 Line D Watchdog Timer Line C OFF with nonzero rate 65 Real Time Clock running fast Line C ON with zero rate 66 Real Time Clock running slowly Line C in PGM with nonzero rate 71 Line A pumping while in off state Line C in DLY w
7. HOSPIRA TECHNICAL SUPPORT OPERATIONS ELECTRONIC TECHNICAL SERVICE MANUAL Omni Flow 4000 Plus IV Medication Management System Hospira For use with the following list number 40051 04 Technical Service Manual 430 06579 002 REV 7 04 Hospira 2004 Hospira Inc This document and the subject matter disclosed herein are proprietary information Hospira retains all the exclusive rights of dissemination reproduction manufacture and sale Any party using this document accepts it in confidence and agrees not to duplicate it in whole or in part nor disclose it to others without the written consent of Hospira 430 06579 002 Rev 7 04 Omni Flow 4000 Plus Change History Remove and Insert Destroy Change Part Number Description of Change Pages Pages 430 06579 001 Original issue Rev 7 93 430 06579 A01 Updated cover and copyright page cover cover Rev 11 93 on reverse side Updated Change History and i to vi i to vi Contents Section 5 Updated equipment 5 3 to 5 6 5 3 to 5 6 requirements updated test setup Updated system tests 5 7 to 5 12 5 7 to 5 12 Section 6 Updated History Alarm table 6 23 6 24 6 23 6 24 Section 7 Updated required tools and 7 3 7 4 7 3 7 4 materials Updated top enclosure assembly 7 9 to 7 28 7 9 to 7 28 replacement and keypad replacement Back Cover Updated registered trademarks back cover back cover Note Change page manuals assembled by Hospira include a chan
8. Rate information User selected values Occlusion pressure limit KVO rate Callbacks Time and date Significant data is retained indefinitely unless one of the following occurs Complete battery discharge Battery disconnection Once significant data is lost the device reverts to the original factory settings 4 4 2 IV HISTORY The control PWA provides non volatile storage for IV history retention IV history includes programming IV totals purge count alarm codes and malfunctions and power information The storage area is maintained in a circular manner with newer information overwriting older Certain events require more storage than others so the amount of information that can be retrieved depends on the activities that have occurred The device retains a minimum of 48 hours of continuous event logging 4 5 SYSTEM INTERFACE DESCRIPTION The following sections describe the system interface For a graphic description of the interconnections refer to Figure 9 5 System Interconnect Block Diagram Technical Service Manual 4 5 430 06579 002 Rev 7 04 SECTION 4 THEORY OF OPERATION 4 5 1 AC POWER INTERFACE The device is connected to AC power via the power cord which connects to the AC power receptacle on the side of the rear enclosure The AC power is routed through two fuses contained in the AC power receptacle to the primary of transformer T1 of the power supply via connector P J19 Table 4 1 AC Pow
9. cams valve assemblies and solenoids is contained on the motor base assembly The retraction mechanism moves the motor base assembly back and forth engaging and disengaging it from the disposable cassette The retraction mechanism locks and activates a switch which signals when it is in the cassette locked position The two unipolar DC stepper motors have a cam and interrupter flag assembly attached that is used for valve lever movement piston movement and motor position verification using optical switches The valve motor assembly controls the opening and closing of the four input valves and the patient line output valve see Figure 4 1 Input Valves A cam assembly and an interrupter flag are attached to the stepper motor The upper cam is the input valve cam and consists of two parts a fixed cam and a movable blocking cam that is free to move back and forth within a limited range see Figure 4 2 Value Cam Assembly The input valve cam has a valley that allows each of the four input valves to open as the cam followers move into the valley The valve plungers connect to lever arms that ride on both the fixed and blocking cam The system positions the valve motor so that the cam follower attached to the selected valve lever arm is positioned over the valley of the blocking cam The system then reverses the motor direction and the follower drops into the valley of the fixed cam The selected input valve opens As the motor shaft rotates movin
10. 3 i PUMP ASSEMBLY TO CONTROL PWA AC POWER CONNECTOR 3 PIN SWITCH PANEL CONNECTOR 6 PIN 77 TO CONTROL PWA 03K02021 Figure 7 14 Pump Assembly and Rear Housing Technical Service Manual 7 23 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 6 32 x 1 SLOTTED HEX HEAD SCREW WITH WASHER 6 32 x 5 8 SLOTTED HEX HEAD TO CONTROL SCREW WITH WASHER 5 PWA AC POWER BN CONNECTOR gt E 1 i K COLORED STRIPE POWER SUPPLY PWA MOTOR BASE MECHANISM CHASSIS PIN 1 COLORED STRIPE 03K02022 Figure 7 15 Power Supply PWA and Motor Base Mechanism 72 17 REAR HOUSING ASSEMBLY REPLACEMENT Recommended tools for this procedure are as follows a 5 16 inch nutdriver flat blade screwdriver No 1 and No 2 Phillips screwdrivers and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Rear Housing Assembly Screw 6 32 x 5 16 Hex Head Slotted With Washer Screw 6 32 x 5 16 Pan Head Phillips With Washer To replace the rear housing assembly refer to Figure 7 14 Pump Assembly and Rear Housing and Figure 7 15 Power Supply PWA and Motor Base Mechanism then proceed as follows 1 Disconnect the device from AC power 2 Separate the top and bottom enclosures as described in Section 7 2 10 3 Remove the battery as described in Section 7 2 11 430 06579 002 Rev 7 04 7 24 Omni Flow 4000 Plus 7 2 R
11. 8 Tilt the device approximately 45 degrees clockwise towards the holster side 9 Lightly tap the pressure interface finger see Figure 5 1 Omni Flow Holster and verify that it moves freely Note Ifthe pressure interface finger does not move freely clean the holster area see Section 5 1 2 Cleaning If cleaning does not correct pressure interface finger binding return the device to Hospira PRESSURE e FINGER 03K02024 Figure 5 1 Omni Flow Holster 5 2 4 TEST SETUP WARNING A PATIENT SHOULD NEVER BE CONNECTED TO THE INFUSION PUMP DURING TESTING To set up the Omni Flow 4000 Plus for testing proceed as follows Note Assure that the specified universal primary set or an equivalent set is used for testing Using a set with PAV valves may cause the pump to fail some tests 1 Note the following hospital specific default settings for restoring programming of the device at the end of the PVT Time KVO Patient line occlusion alarm Units of temperature Callbacks 2 Confirm device and appropriate accessories i e printer are fully assembled 3 Mount the device on an IV stand if needed Technical Service Manual 5 5 430 06579 002 Rev 7 04 SECTION 5 MAINTENANCE AND SERVICE TESTS 4 Hang four containers of sterile water or tap water at a height of 24 to 32 inches 600 to 800 mm above the device see Figure 5 2 Test Setup 5 Connect the device to AC power Perform all tests with the
12. For final assemblies 850 06300 014 and higher refer to Section 7 2 12 Control PWA and Top Enclosure Assembly Replacement Recommended tools and materials for this procedure are as follows No 2 Phillips screwdriver electrical tape and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Assembly LCD Screw 4 40 x 1 4 Pan Head Phillips To replace the LCD refer to Figure 7 9 LCD Replacement then proceed as follows 1 Disconnect the device from AC power Technical Service Manual 7 15 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 2 Separate the top and bottom enclosures as described in Section 7 2 10 Remove the control PWA as described in Section 7 2 12 4 Using the Phillips screwdriver remove the pan head screws one from each corner of the LCD see Figure 7 9 5 Remove the defective LCD by gently pulling the LCD straight up off the control PWA connectors located on both sides of the display Install replacement Co 6 Reassemble the device in the exact reverse order of its disassembly Verify that no foreign material is trapped between the keypad and LCD Tighten the screws securing the control PWA to the top enclosure to 10 1 inch pounds Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify the ground strap lug remains parallel to the side of the top enclosure and faces away from the bottom enc
13. Procedures Adjustment 7 3 Instrument installation 1 5 Replacement 7 3 Troubleshooting 6 11 Proximal occlusion 4 17 Pump PWA 4 10 Analog to digital converter 4 11 EPROM and RAM 4 10 Microprocessor and clock 4 10 Motor and solenoid control 4 12 Optical switches 4 12 Peripheral access 4 11 Pressure transducer conditioning and power 4 11 Replacement 7 19 Watchdog timer 4 11 Pump service codes 6 6 Pumping mechanism pressure finger check 5 4 PVT troubleshooting 6 16 PWA functional description 4 7 Control PWA 4 7 Power supply PWA 4 13 Pump PWA 4 10 R RAM 4 8 4 10 Real time clock 1 6 4 8 Setting the real time clock at power up 1 7 Setting the real time clock using special function 1 7 Rear housing assembly replacement 7 24 Technical Service Manual Replaceable parts and repairs 7 1 Replacement and adjustment procedures 7 3 AC line filter assembly 7 32 AC power cord 7 5 Bag hanger 7 34 Battery 7 11 Cassette locking knob 7 7 Control PWA 7 13 Equipotential post 7 28 Fuse 7 6 Keypad 7 17 LCD 7 15 Nurse call cable 7 8 Pole clamp knob 7 9 Power connector plate assembly 7 29 Power supply PWA 7 22 Printer interface cable 7 9 Pump PWA 7 19 Rear housing assembly 7 24 Required tools and materials 7 3 Safety and equipment precautions 7 3 Serial RS 232 connector 7 26 Switch panel assembly 7 33 Top enclosure assembly 7 13 Transducer offset adjustment 7 4 Vent
14. Rev 7 04 SECTION 4 THEORY OF OPERATION The transducer output must be nulled for the A D input Op amp U3A with potentiometer R26 and the 5 Vy reference voltage are connected to the inverting input of op amp U3B and adjusted to null the transducer input of U3B Ambient pressure conditions produce an output between 0 2 and 0 6 The output of U3B connects to a voltage divider to limit the full scale input of the A D 4 6 2 7 MOTOR AND SOLENOID CONTROL The two stepper motors and two solenoids are controlled by MOSFET drivers that are controlled by the microprocessor via two memory mapped control registers The valve motor and patient solenoid share one control register U11 the piston motor and collection solenoid share control register U12 Each control register contains a bit which controls a P channel HEXFET Q15 or Q3 which functions as a common source Q15 and Q3 enable full current when conducting to allow motor stepping When Q15 or Q3 are off and motor stepping is not occurring a 150 ohm resistor R32 or R40 supplies sufficient current to hold the motors without slipping Each remaining bit of control registers U11 and U12 controls an N channel HEXFET Q4 Q5 Q9 010 and 911 for valve motor and patient solenoid and Q6 97 Q8 012 and Q13 for piston motor and collection solenoid Each N channel HEXFET sinks current from the motor phases or solenoid when switched on Several diodes and two zener diodes reduce inductive r
15. then on to reset device If condition does not clear contact Hospira With power on and cassette lever locked display lights and tone are working but no mechanical sound is heard no device valve motor initialization The continuous alarm tone may sound after power up Technical Service Manual Defective pump PWA Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING Table 6 6 Troubleshooting General Problems Symptoms With power on the device valve motors initialize but the continuous alarm tone sounds and LED lights Possible Causes Defective control PWA J9 to pump PWA J16 cable Defective control PWA Defective pump PWA Corrective Actions Replace cable Replace control PWA see Section 7 2 12 Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Keypad does not respond Defective keypad Defective control PWA Discharged battery Replace keypad see Section 7 2 14 Replace control PWA see Section 7 2 12 Verify AC power cord connected to AC power Verify AC POWER indicator lit Recharge battery for 24 hours with device powered off If problem persists replace battery see Section 7 2 11 Prime function does not work patient line and or collection bag 430 06579 002 Rev 7 04 Lines are clamped off collect
16. 12 Omni Flow 4000 Plus 4 6 PWA FUNCTIONAL DESCRIPTION 4 6 3 POWER SUPPLY PWA The power supply PWA see Figure 9 9 Power Supply PWA Block Diagram performs the following functions Rectifies AC voltage Supplies AC present indication Supplies regulated 14Vpc Supplies regulated 5 Charges and operates battery Senses battery fuse Controls audible alarm LoouvcuoccoLcru Monitors nurse call interface 4 6 3 1 AC INPUT RECTIFICATION AND FILTERING AC line voltage is applied to transformer T1 Tl secondary sends approximately 21 Vac through fuse F3 which protects the transformer in case of a short in the rectification circuit The secondary voltage is half wave rectified by CR1 and becomes the following separate signals 21 V BAT ENA provides early indication of AC power loss to switch the power supply to battery 21 V sent to pump PWA as input to the A D for software detection of AC power 21 V OUT supplied to control PWA to drive AC POWER indicator LED on keypad T1 secondary voltage is also supplied to a full wave rectifier consisting of CR2 CR3 CR4 and CR5 Full wave rectified DC is then filtered to produce 21 V BRIDGE that supplies the 14 volt regulator A linear regulator consisting of U1 UA723N and several discrete components provides regulation and current limiting for the 14 circuitry charges the 12 V lead acid battery and supplies the input to the 5 Vp regulator When the d
17. 21V 20 31 Vbatt 13 50 Note The fields following the line indicator are the pressures within the cassette during the stroke The values are A D readings in volts Note If the device is pumping the first character gt indicates the line that the last stroke delivered from If the device has just been powered up only the gt symbol appears This symbol is always there and has no significance Table 6 11 Cassette Pressure and System Voltages Definitions The null output of the pressure transducer The value may shift slightly with a cassette installed and during pumping Some amount of downward drift will occur A device at operating temperature and without a cassette installed in the holster has a P1 value of between 0 20 and 0 70 V A P1 value outside this range indicates a possible problem with the transducer or the pump PWA The pressure resulting from the intake of fluid from one of the input valves Various conditions affect this value Low head heights syringes or deliveries of viscous fluids produce a low P3 normal saline or water at high head heights produce a high P3 Monitoring the delivery of normal saline or water from a vented container or bag hung 700 mm 100 mm above the pump produces a P3 of 0 25 to 0 9 V A P3 value outside this range could indicate a problem with valve function Delivering from four lines with the same input characteristics should produce similar P3 values A line to line
18. 7 Messages Alarm 6 1 Operator alarm 6 2 Microprocessor and clock 4 8 4 10 Monitoring cassette pressure and system voltages 6 22 Motor and solenoid control 4 12 N Nurse call cable replacement 7 8 Nurse call test 5 12 O Occlusion Proximal 4 17 Test 5 10 Off status 4 1 On status 4 1 Cassette test 4 3 Main program software functions 4 2 Self test 4 2 Setup 4 2 Operator alarm messages 6 2 Optical switches 4 12 P Patient Occlusion detection 4 18 Solenoid test 5 8 Performance verification test 5 3 Cassette test 5 9 Collection solenoid test 5 8 End of PVT 5 13 Equipment required 5 3 High flow test 5 9 Inspection 5 4 Nurse call test 5 12 Occlusion test 5 10 Patient solenoid test 5 8 Printer pattern test 5 12 Pumping mechanism pressure finger check 5 4 Safety test 5 12 System tests 5 7 Test setup 5 5 10 2 Omni Flow 4000 Plus Volume accuracy test 5 10 Periodic maintenance inspection 5 13 Peripheral access 4 8 4 11 Pole clamp knob replacement 7 9 Power connector plate assembly replacement 7 29 Power on reset circuitry 4 9 Power supply PWA 4 13 AC input rectification and filtering 4 13 Replacement 7 22 Pressure monitoring 4 17 Air detection 4 17 Cassette pressure equalization 4 18 Patient occlusion detection 4 18 Proximal occlusion 4 17 Pressure transducer conditioning and power 4 11 Printer interface cable replacement 7 9 Printer pattern test 5 12
19. 7 Sequence of operation 4 1 System interface description 4 5 System malfunction detection 4 4 Timer Watchdog 4 11 Transducer offset adjustment procedure 7 4 Troubleshooting in special function mode 6 20 Biomed password level 6 23 Monitoring cassette pressure and system voltages 6 22 Troubleshooting 6 1 Alarm messages and service codes 6 1 General problems 6 12 In special function mode 6 20 430 06579 002 Rev 7 04 Procedures 6 11 System test 6 15 Technical assistance 6 1 With IV history 6 18 With the PVT 6 15 U Unpacking 1 5 User interface 4 6 User qualification 1 4 V Vent screen replacement 7 35 Volume accuracy test 5 10 W Warranty 2 1 Watchdog timer 4 11 10 4 Omni Flow 4000 Plus For technical assistance product return authorization and to order parts accessories or manuals within the United States contact Hospira Technical Support Operations 1 800 241 4002 For technical publications technical training courses and additional services visit the website at www hospira com Send all authorized prepaid returns within the United States to the following address Hospira Inc Technical Support Operations 755 Jarvis Drive Morgan Hill California 95037 For technical assistance and services outside the United States contact the local Hospira sales office CAUTION Federal USA law restricts this device to sale by or on the order of a physician or other licensed p
20. 7 through 9 for 8 psi Verify the OCCLUSION IN PATIENT LINE alarm activates at 8 0 1 5 psi on DPM 11 Repeat Steps 7 through 9 for 12 psi Verify the OCCLUSION IN PATIENT LINE alarm activates at 12 0 2 0 psi on DPM 12 Press STOP on line B and ENTER to stop pumping 13 Disconnect the distal tubing from the three way stopcock Place the tubing into a fluid collection container TO BAG OF WATER PATIENT DIGITAL PRESSURE METER DPM 0 00 0 TO 10 8 INCHES 0 TO 275 MM THREE WAY STOPCOCK 03K02010 Figure 5 3 Occlusion Test Setup Technical Service Manual 5 11 430 06579 002 Rev 7 04 SECTION 5 MAINTENANCE AND SERVICE TESTS 5 2 12 NURSE CALL TEST Note Bypass the following test if the nurse call function is not used or affected by repair To perform the nurse call test proceed as follows 1 Attach a phone jack test cable to the NURSE CALL jack on the device 2 Attach a DMM to the phone jack test cable 3 Enter the following infusion program Press CONTINUOUS INFUSION on line A Set the rate to 700 mL hr Press NEXT Set the volume to 1 0 mL Press ENTER 4 Verify that when the POSSIBLE EMPTY BOTTLE alarm activates the DMM reads less than 1 ohm 5 Press MUTE twice to silence alarm Press STOP on line A and ENTER to stop pumping 5 2 13 PRINTER PATTERN TEST Note Bypass the following test if the printer function is not used To perform the prin
21. CHARGE CASSETTE LOCK SWITCH FUSE BATTERY HOSPIRA Figure 9 6 System Block Diagram DRAWING NO Rev N A Sheet 1 of 1 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 16 Omni Flow 4000 Plus 5V 14V UPPER D8 D15 DATA BUS yo POWER ON RESET UPPER DATA BUS D8 D15 DIVIDERS U12 MPU ADDRESS A1 A19 BUS 1 0 LOWER M 12 288 MHz osc gt CLK WRITE RW IPLO 1 IPL2 CHIPS ONEL VL CP1 INT U 9 SEENE ONEL VL 8 03 INTERRUPT PMPBDINT ENCODER ONEL VL DISCRETE VOLTAGE U 1 0 RESET HALT ADDRESS AND GATE ______UPPER _y WITH STROBES RESISTOR pem d RA gt Ug gt OUT yo MEMORY SELECT EPROM ADS U12 U12 UDS MEM1U WRITE WRITE MEM2U MEM3U M3M3L MEM2L MEM1L ADDRESS BUS A1 A19 U17 EPROM E LOWER DATA BUS 00 07 KEYPAD U18 Kx EX PIA TO U9 ONELVL1 ALARM LED BATTERY LED U12 WRITE 12 WRITE SENSE CIRCUITS RTCAS RTCDS RESET WRITE U3 AND CONTROL CIRCUITS U21 DIVIDER L 12 288MHZ 3 072MHZ TO 07 768 HZ 03K02027 Technical Service Manual
22. Clamp Battery Section 7 2 11 Clamp Pole Black Section 7 2 8 Assembly Knob Pole Clamp Section 7 2 8 Knob Pole Clamp Section 7 2 8 Rod Threaded Section 7 2 8 Assembly Cable Internal Comm Printer Section 7 2 18 Cord AC Power Detachable Section 7 2 4 Assembly Cable Power Supply Control Section 7 2 16 Assembly Cable Pump PWA Power supply Section 7 2 16 Assembly Cable Control Pump PWA Bracket Power Cord Molded Section 7 2 16 Section 7 2 4 Plate Backup Data I O Section 7 2 18 Line Filter AC Section 7 2 21 Knob Cassette Locking Section 7 2 6 430 06579 002 Rev 7 04 Connector Phone Jack Long Section 7 2 7 Omni Flow 4000 Plus Table 9 2 IPB for the Omni Flow 4000 Plus Index Number Nomenclature Replacement Procedure 30 Drawer Fuse 2 Pole Section 7 2 5 31 Fuse 0 6 A 250 V Slo Blo Section 7 2 5 32 Hanger Bag Section 7 2 23 33 Terminal Equipotential Post Section 7 2 19 34 Tip Pole Clamp Shaft Section 7 2 8 35 Hardware Kit RS 232 Section 7 2 18 36 Screw Set Stepped Section 7 2 6 37 Screw 6 32 x 5 8 Hex Head Slotted with Where applicable Washer 38 Screw 6 32 x 5 16 Hex Head Slotted with Where applicable Washer 39 Screw 6 32 x 3 4 Pan Head Phillips SS Section 7 2 10 40 Screw 6 32 x 2 3 4
23. Error 02 Cassette Unlocked 21 34 Volt AC Error 03 Patient Line Occlusion 22 Xducer Pegged Low Error 04 Collection Bag Full 23 Piston Encoder Running Error 05 Piston Encoder Initial Error 24 Air In Line A 06 Xducer Pegged High Error 25 Air In Line B Technical Service Manual 6 19 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING Table 6 9 IV History Alarm Status Codes Descriptions Low Flow Rate Error Descriptions Air In Line C Valve Encoder Error Air In Line D Blown Battery Fuse Empty Source Line A ROM Test Failure Empty Source Line B RAM Test Failure Empty Source Line C Communications Fault Empty Source Line D Cassette Test Failure CPU RAM Fault Pump Timer Failure System RAM Fault Pump Logic Error CPU Err Program ROM Fault 5 Volt System Error Non volatile RAM Fault 5 Volt Reference Error Clock Default RAM Fault 8 Volt Reference Error 14 Volt Battery Error 6 3 4 History Buffer Range Error Communication Retry Failure TROUBLESHOOTING IN SPECIAL FUNCTION MODE The special functions assist in device troubleshooting by providing a variety of software tools and user controlled operations see Table 6 10 Special Function Keys For a detailed description of most of the user level special functions see the System Operating Manual Some of the functions require a special password and are described in
24. HR 7 Disconnect device from AC power and verify that the yellow BATTERY indicator lights 8 Connect the device to AC power Verify the green AC POWER indicator lights 9 Press SPECIAL FUNCTION 9 ENTER to initiate the system tests Follow the instructions displayed on the screen and perform the following tests Verify BATTERY ALARM and all LINE indicators and LCD backlight are flashing The green AC POWER indicator is lit but not flashing Press ENTER to continue Press all 48 keys as instructed Confirm that the nurse call relay is clicking on and off Press any key to continue Verify the alarm tone is turning off and on approximately every second Turn the volume control up and down to check for proper operation Verify alarm is still audible at minimum setting Press any key to continue Verify the display counts from 1 to O 10 in about 10 seconds a digit should be added every second Press any key to continue Technical Service Manual 5 7 430 06579 002 Rev 7 04 SECTION 5 MAINTENANCE AND SERVICE TESTS Verify alarm tone sounds continuously Press any key to stop the alarm then press any key to continue Turn the cassette lock lever to the CASSETTE UNLOCKED position Press any key to continue Turn the cassette lock lever to the CASSETTE LOCKED position Press any key to continue Verify the software revision displays 10 Press ESCAPE to return to base screen 5 2 6 COLLECTION SOLENOID
25. If no service code occurs during self test but a service code occurs during operation see one of the following sections Section 6 2 3 Pump Service Codes Section 6 2 4 Software Service Codes Section 6 2 5 System Service Codes If noservice code occurs but a malfunction exists see Section 6 3 Troubleshooting Procedures Note Ifan alarm persists after the corrective actions are performed contact Hospira 430 06579 002 Rev 7 04 6 4 Omni Flow 4000 Plus 6 2 ALARM MESSAGES AND SERVICE CODES Table 6 2 Self Test Service Codes and Corrective Actions Self Test Service Errors Possible Causes Corrective Actions 0001 Initial piston System unable to Verify proper seating of the cassette in encoder error detect home position the holster of piston motor Check for any piston binding from foreign Piston motor stalled material due to obstruction Replace pump PWA PWA replacement Defective optical is serial number specific see CAUTION switch on pump PWA in Section 7 2 15 0002 Transducer Binding of pressure Remove the cassette from the holster pegged high finger due to foreign Check for any foreign material on the above material pressure nose factory set Pange Defective transducer Replace pump PWA PWA replacement conditioning circuitry is serial number specific see CAUTION on pump PWA in Section 7 2 15 Damaged pressure Turn power off then on to reset dev
26. POWER CONNECTOR PLATE GROUND STRAP LUGS 2 THROUGH ENCLOSURE WALL TO SWITCH PANEL STUD AC LINE FILTER 03K02041 Figure 7 18 Power Connector Plate 430 06579 002 Rev 7 04 7 30 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES 6 32 HEX NUT 2 LOCK WASHER ee 58 FLATWASHER 2 v GROUND LUG FROM dl S ROUND LUGS FROM AC LINE FILTER WITCH PANEL 03K02039 Figure 7 19 AC Line Filter Ground Lug Placement Technical Service Manual 7 31 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 7221 AC LINE FILTER ASSEMBLY REPLACEMENT Note The AC line filter assembly is replaceable on pumps with final assemblies 850 06300 008 and higher For pumps with final assemblies 850 06300 007 and below refer to Section 7 2 20 Power Connector Plate Assembly Replacement Recommended tools for this procedure are as follows Phillips screwdriver 5 16 nutdriver The replacement parts for this procedure are Assembly AC Line Filter Assembly Ground Strap Switch Panel Comm Nut 6 32 Hex Steel Cad Zinc Plated Washer Flat 46 0 032 Thick Steel Washer Lock 6 0 018 Thick Internal Tooth Screw 4 40 x 3 16 Flat Head Phillips To replace the AC line filter refer to Figure 7 20 AC Line Filter and Figure 7 19 AC Line Filter Ground Lug Placement then proceed as follows Disconnect the device from AC power Separate the top and bottom e
27. PWA via Touchswitches connector P J12 LCD Module The LCD module mounts directly to the control PWA P J13 carries address and data information to and from the LCD P J14 supplies the AC power needed to power the display backlight Nurse Call The nurse call jack connects to the power supply PWA via P J5 Interface Rear Panel The rear panel contains the alarm volume potentiometer and the power Interface switch The rear panel connects to the power supply PWA via P J5 Serial Interface The DB 9 connector carries serial information from an asynchronous communication interface on the control PWA via a ribbon cable from P J10 430 06579 002 Rev 7 04 4 6 Omni Flow 4000 Plus 4 6 PWA FUNCTIONAL DESCRIPTION 4 5 3 MECHANISM INTERFACE The pump PWA interfaces with the pumping mechanism via a 20 pin connector P J18 and a 3 pin connector P J20 Table 4 3 Mechanism Interface describes each interface Table 4 3 Mechanism Interface Motor Connector The piston and valve motor drivers are contained on the pump PWA Each motor receives 14 Vpc and four excitation signals via P J20 Pressure The pump supplies 8 and ground to the pressure transducer Transducer and the transducer supplies an output of approximately 1 75 Vpc at 0 Connector backpressure to full scale output of 8 Vp to the pump PWA via P J20 Solenoid The collection line and patient line solenoid drivers are located on the pump Interface P
28. Pan Head Phillips SS Section 7 2 10 41 Screw 4 40 x 1 4 Pan Head Phillips SS Where applicable 42 Screw 6 32 x 5 16 Pan Head Phillips with Where applicable Washer 43 Screw 6 32 x 3 16 Hex Head with Washer Section 7 2 4 44 Screw 4 40 x 3 16 Flat Head Phillips Section 7 2 21 45 Screw 6 32 x 5 8 Pan Head Phillips with Where applicable Washer 46 Screw 4 40 x 1 8 Pan Head Slotted Section 7 2 14 47 Screw 6 32 x 1 Hex Head Slotted with Where applicable Washer 48 Screw 4 40 x 1 4 Hex Head Slotted with Where applicable Washer 49 Washer 124 x 206 x 015 Steel Section 7 2 14 50 Washer Lock 6 018 Thk Internal Tooth Where applicable 91 Washer Lock 4 015 Thk Internal Tooth Where applicable 52 Washer Flat 4 250 OD 125 ID 026 Thk Section 7 2 14 53 Washer Flat 6 032 Thk Steel Section 7 2 20 54 Washer Flat 0 25 OD 0 028 ID 0 036 Where applicable 55 Nut 6 32 Hex Steel Cad Zinc Plate Where applicable 56 Nut 4 40 Zinc Small Where applicable Technical Service Manual 9 3 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 4 Omni Flow 4000 Plus 36 38 39 40 41 22 47 48 HOSPIRA INC O C 2 Figure 9 1 Illustrated Parts Breakdown AS 4 A 7 e x Y R 9 BRAINS Rev N A
29. Universal primary set List 01169 01 Sterile water or tap water in four IV bags containers Three way stopcock latex free List 3233 01 or equivalent Digital pressure meter DPM Fluke Biomedical DPM3 Safety analyzer Fluke Biomedical 232D Digital multimeter DMM Fluke Biomedical 8012A Phone jack test cable cable fitted with 1 4 inch phone jack and banana plug IV stand Oooeovoeeoeo The optional printer pattern test requires the following equipment or equivalents Serial printer cable List 40518 23 Q Seiko Printer List 40517 11 Printer thermal paper List 40518 12 Technical Service Manual 5 8 430 06579 002 Rev 7 04 SECTION 5 MAINTENANCE AND SERVICE TESTS 523 INSPECTION Inspect the infusion system periodically for signs of defects such as worn accessories broken connections or damaged cables In addition inspect the system after repair or during cleaning Replace any damaged or defective external parts During device inspection note whether the pump contains a solid black or dark piston For devices not containing solid black or dark pistons confirm that a white silicone disk insert is present on the piston face If the white silicone disk insert is missing there will be approximately one eighth inch indentation on the face of the metal piston Ifthe silicone disk insert is missing remove the device from service immediately and contact Hospira Technical Support Operations Inspect the following
30. approximately six seconds during which time the screen displays the following message 4 Remove the shipping cassette from the device 1 8 4 REAL TIME CLOCK Therealtime clock maintains accurate time on battery power for approximately one month If the battery is not recharged during that time the real time clock settings may become invalid Pump operations such as programming an intermittent infusion require that the real time clock be operating properly Set the real time clock under the following circumstances Initial installation Time change 1 Following complete battery discharge Note The battery discharges any time the pump is disconnected from AC power Reconnecting the pump to AC power does not automatically reset the real time clock 430 06579 002 Rev 7 04 1 6 Omni Flow 4000 Plus 1 8 4 1 1 8 INSTRUMENT INSTALLATION PROCEDURE SETTING THE REAL TIME CLOCK AT POWER UP Upon completion of the pump self test the following screen appears INSERT CASSE y IN PLACE ESS ENTER 11 30 AM To set the real time clock proceed as follows 1 2 3 1 8 4 2 Change the time setting using the numeric keypad Press the numeric keys to enter the hour and minutes Press the NEXT key to change the AM PM designator then press the AM PM key Press the ENTER key the correct time displays SETTING THE REAL TIME CLOCK USING SPECIAL
31. areas for missing or damaged parts and for cosmetic defects Labels Keypad Accessories Quick Reference Guide Fuse retaining cover Pole clamp and knob Cassette holster valves pressure finger piston Collection bag hanger ON CHARGE switch LCD Top and bottom enclosures and screws All cords and plugs Nurse call jack Audible alarm knob Cassette locking knob L L DL D D DL D D D DL D D D LU 5 2 3 PUMPING MECHANISM PRESSURE FINGER CHECK To assure proper operation the pumping mechanism must fully engage the cassette and the pressure interface finger must move freely To verify proper mechanism engagement proceed as follows 1 Lift the cassette locking knob and rotate it counterclockwise to the CASSETTE UNLOCKED vertical position 2 Insert a cassette into the holster 3 Push the cassette locking knob clockwise to the CASSETTE LOCKED horizontal position let it engage without assistance 4 Verify the cassette locking knob fully engages with a snap Note If the cassette locking knob does not fully engage to the CASSETTE LOCKED position return the infusion system to Hospira 430 06579 002 Rev 7 04 5 4 Omni Flow 4000 Plus 5 2 PERFORMANCE VERIFICATION TEST 5 Lift the cassette locking knob and rotate it counterclockwise to the CASSETTE UNLOCKED position 6 Remove the cassette from the holster 7 Rotate the cassette locking knob clockwise until it seats in the CASSETTE LOCKED position
32. device connected to AC power unless otherwise specified FLUID LEVEL BAG OF WATER 4 24 TO 32 INCHES 600 TO 800 MM PATIENT LINE 03K02009 Figure 5 2 Test Setup 430 06579 002 Rev 7 04 5 6 Omni Flow 4000 Plus 5 2 PERFORMANCE VERIFICATION TEST 5 2 5 SYSTEM TESTS To perform the system tests proceed as follows 1 Turn the device on by setting the ON CHARGE switch to the ON position Verify the following screen displays gt gt gt gt gt gt gt gt SELF TEST IN PROGRESS lt lt lt lt lt lt lt lt ABBOTT 4000 PLUS 2 Verify the following screen displays indicating a successful completion of the self test ESTORE PREVIOUS PROGRAMMING Y N CLEAR IV HISTORY Y N NO 3 Press ENTER Verify the following screen displays ERT CASSETTE AND LOCK IN PLACE PRESS ENTER hh mm HR 4 Insert and lock cassette with collection bag and patient line into device Turn the cassette locking knob to the CASSETTE LOCKED position 5 Press ESCAPE Verify the following screen displays BYPASS CASSE ESS ENTER If the bypass cassette screen does not display verify the cassette locking knob is in the CASSETTE LOCKED position 6 Press YES NO to toggle display to YES Press ENTER Verify the following base screen displays A 0FF B OFF D OFF TOTAL hh mmHR 0 0 0 0 ML
33. ew d Fi PUMP PWA IO GROUND STRAP i ese CONTROL VIA wu PWA Sf SO eee i TOP STRAP RIBBON CABLES 03K02014 Figure 7 6 Battery Replacement 430 06579 002 Rev 7 04 7 12 Omni Flow 4000 Plus 7 2 12 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES CONTROL PWA AND TOP ENCLOSURE ASSEMBLY REPLACEMENT Recommended tools for this procedure are as follows a 1 16 Allen wrench a flat blade screwdriver a No 2 Phillips screwdriver and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Enclosure Top PWA Control Insulator Metal White Assembly Ground Strap Chassis Top Enclosure Screw 6 32 x 5 16 Hex Head Slotted with Washer Screw 6 32 x 5 16 Pan Head Phillips with Washer To replace the control PWA or top enclosure refer to Figure 7 7 Top Enclosure Connectors and Figure 7 8 Top Enclosure Assembly then proceed as follows 1 2 3 10 11 Disconnect the device from power Separate the top and bottom enclosures as described in Section 7 2 10 Using the flat head screwdriver remove the slotted hex head screw that secures the ground strap to the top enclosure see Figure 7 7 Disconnect the three ribbon cables two 10 pin and one 8 pin connector from the control PWA Separate the top enclosure from the bottom enclosure Remove the three slotted hex head screws that s
34. for inclusion of the system operating manual in Section 3 of this manual Note Figures are rendered as graphic representations to approximate actual product therefore figures may not exactly reflect the product Note This manual uses the terms infusion system and device interchangeably to refer to the Omni Flow 4000 Plus infusion system Technical Service Manual 1 1 430 06579 002 Rev 7 04 SECTION 1 INTRODUCTION 1 2 CONVENTIONS The following conventions are used throughout this manual Table 1 1 Conventions CONVENTION APPLICATION EXAMPLE Italic Reference to a section figure See Section 6 1 Technical table or publication Assistance START ALL CAPS In text references to keys and or touchswitches ALL CAPS Screen displays knobs LOW BATTERY Initial Caps with lowercase switches and device labels Cassette test in progress Bold Emphasis Caution Use proper ESD grounding techniques when handling components WARNING A WARNING CONTAINS SPECIAL SAFETY EMPHASIS AND MUST BE OBSERVED AT ALL TIMES FAILURE TO OBSERVE A WARNING MAY RESULT IN PATIENT INJURY AND BE LIFE THREATENING CAUTION A CAUTION usually appears in front of a procedure or statement It contains information that could prevent hardware failure irreversible damage to equipment or loss of data Note A note highlights information that helps explain a concept o
35. for troubleshooting procedure Enter the Special Function Mode See Section 6 3 4 Troubleshooting in Special Function Mode for troubleshooting procedure 5 If persistent errors occur or the problem can not be isolated contact Hospira Technical Service Manual 6 11 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING 6 3 1 TROUBLESHOOTING GENERAL PROBLEMS Table 6 6 Troubleshooting General Problems describes symptoms and corrective actions for general problems that can occur If the symptom is not found in Table 6 6 perform one of the troubleshooting procedures described in Section 6 3 2 through Section 6 3 4 Table 6 6 Troubleshooting General Problems Symptoms Device does not respond no display lights or alarm tone when the power switch is turned on AC POWER indicator not lit Possible Causes AC power cord not connected and battery fully discharged Blown AC fuse Defective AC power cord Defective AC panel assembly Defective power supply Corrective Actions Verify AC power cord connected to AC power Verify AC POWER indicator lit Recharge battery for 24 hours Replace AC fuse see Section 7 2 5 Replace AC power cord see Section 7 2 4 Replace AC panel assembly see Section 7 2 20 Replace power supply PWA see Section 7 2 16 Alarm sounds but no error message displays Discharged battery Verify AC power cord connected to AC power Verify AC POWER indicator lit Recharge
36. is connected Replace cable Verify black and red battery cables connected to battery Replace control PWA see Section 7 2 12 Replace battery see Section 7 2 11 Replace power supply PWA see Section 7 2 16 Serial number not retained BATTERY indicator not flashing or AC POWER indicator not lit Defective control PWA Power supply PWA J6 to control PWA J8 cable Defective control PWA Defective power supply PWA Replace control PWA see Section 7 2 12 Verify cable is connected Replace cable Replace control PWA see Section 7 2 12 Replace power supply PWA see Section 7 2 16 ALARM indicator any LINE indicator or LCD backlight not flashing Defective control PWA Defective LCD Replace control PWA see Section 7 2 12 Replace LCD see Section 7 2 13 Pressed key not responding Technical Service Manual Damaged or defective keypad Control PWA J12 to keypad cable Defective control PWA Replace keypad see Section 7 2 14 Verify cable is connected Replace keypad see Section 7 2 14 Replace control PWA see Section 7 2 12 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING Table 6 7 System Test Troubleshooting Symptoms Possible Causes Corrective Actions Nurse call relay not clicking Defective control PWA Defective power supply PWA Replace control PWA see Section 7 2 12 Replace power supply PWA see Section 7 2 16 Alar
37. screen 7 35 Required tools and materials 7 3 Routine maintenance 5 1 Cleaning 5 1 Inspection 5 1 Sanitizing 5 3 Safety and equipment precautions 7 3 Safety test 5 12 Sanitizing 5 3 Scope 1 1 Self test service codes 6 4 Self test 1 6 4 2 Separating the top and bottom enclosures 7 10 Sequence of operation 4 1 Off status 4 1 On status 4 1 Serial communications 4 9 Serial RS 232 connector replacement 7 26 Series specific information 1 4 Setting the real time clock At power up 1 7 Using special function 1 7 Setup 4 2 Significant data retention 4 5 3 430 06579 002 Rev 7 04 SECTION INDEX Software service codes 6 9 Specifications 8 1 Switch panel assembly replacement 7 33 System Malfunction detection 4 4 Service codes 6 10 Tests 5 7 System interface description 4 5 AC power interface 4 6 Mechanism interface 4 7 User interface 4 6 System operating manual 3 1 System test troubleshooting 6 15 System tests 5 7 T Technical assistance 6 1 Tests Cassette 5 9 Collection solenoid 5 8 High flow 5 9 Nurse call 5 12 Occlusion 5 10 Patient solenoid 5 8 Performance verification 5 3 Printer pattern 5 12 Safety 5 12 Self 1 6 Setup 5 5 System 5 7 Volume accuracy 5 10 Theory of operation 4 1 Alarm conditions 4 3 Data retention 4 4 Disposable cassette description 4 16 Mechanism functional description 4 14 Pressure monitoring 4 17 PWA functional description 4
38. tab and press towards the fuse drawer center The spring loaded fuse drawer will release and move outwards 430 06579 002 Rev 7 04 7 6 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES Remove the fuse drawer from the receptacle Remove the fuses replace with approved fuses only see Section 8 Specifications Do not use any other fuse types 4 Reassemble the device in the exact reverse order of its disassembly To verify successful replacement of fuses perform the PVT in Section 5 2 7 2 6 CASSETTE LOCKING KNOB REPLACEMENT The recommended tool for this procedure is a 1 16 inch Allen wrench The replacement parts for this procedure are Screw Set Stepped Knob Cassette Locking To replace the cassette locking knob refer to Figure 7 3 Cassette Locking Knob then proceed as follows 1 Using the Allen wrench remove the set screw securing the cassette locking knob to the shaft Remove the defective cassette locking knob 2 Secure the replacement cassette locking knob on the shaft by installing and tightening the set screw Replacement of the cassette locking knob is a routine maintenance procedure and no verification procedure is normally required However if the device may have been damaged during this procedure perform the PVT in Section 5 2 Technical Service Manual 7 7 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS CASSETTE LOCKING KNOB STEPPED SET SCREW
39. the piston interface in Figure 4 3 A fluid path connects the pumping chamber to a smaller chamber which is the pressure interface to the pump The fluid path divides into two paths from the pressure interface chamber One path leads to the patient valve which connects to the patient tubing The other path leads to the collection valve which has a line connecting it to a collection bag When the cassette is installed in a device the collection valve is the highest point on the cassette Any air in the fluid channel rises upward through the pumping chamber into the pressure chamber where it settles at the collection valve At that point the air can be vented into the collection bag when the device detects an excessive amount of air poc Y pa A Ts LD TO FRONT VIEW Eo d COLLECTION E AA Lo PRESSURE P n E Q INTERFACE gt A 421 PATIENT LINE 7 D Fe LINE E LINE A PISTON INTERFACE ALIGNMENT PIN HOLE REAR VIEW ALVE SEATS 6 03K02007 Figure 4 3 Disposable Cassette 430 06579 002 Rev 7 04 4 16 Omni Flow 4000 Plus 4 9 PRESSURE MONITORING ALIGNMENT PIN LINE B HOLSTER LINE C LINE D COLLECTION LINE PRESSURE INTERFACE NOSE PRESSURE INTERFACE FINGER PATIENT LINE 03K02008 Figure 4 4 Cassette Holster 4 9 PRESSURE MONITORING The pressure transducer in the mechanical assembly monitors cassette pressure at various points of the pump stroke
40. the switch panel to the bottom enclosure see Figure 7 17 Remove the defective switch panel and install the replacement panel Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Technical Service Manual 7 33 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS Note Verify all cables are freely extended and not pinched 9 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats 10 Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the switch panel assembly perform the PVT in Section 5 2 7 2 23 BAG HANGER REPLACEMENT Recommended tools for this procedure are as follows set of nutdrivers flat blade screwdriver No 1 and No 2 Phillips screwdrivers and torque driver with No 2 Phillips and flat blade heads The replacement part for this procedure is Hanger Bag Nut Hex 6 32 Steel Cad Zinc Plated To replace the bag hange
41. used for test Defective pump PWA Binding valve due to fluid spill accumulation Pressure interface binding due to fluid spill accumulation Damaged pump mechanism Use set listed in Section 5 2 1 Equipment Required If a set with PAV valves is used nuisance occlusion alarms may occur Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Clean holster Clean holster If test continues to fail contact Hospira Contact Hospira 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING Table 6 8 PVT Troubleshooting Test Failures Possible Causes Corrective Actions Nurse Call Test Defective control PWA Replace control PWA see Section 7 2 12 Defective power supply Replace power supply PWA see PWA Section 7 2 16 Foreign material in jack Clean jack Printer Pattern Test Defective control PWA Replace control PWA see Section 7 2 12 Serial printer cable Verify cable properly connected Verify connectors are clean Replace cable Safety Test Defective AC power cord Replace AC power cord see Section 7 2 4 Defective power supply Replace power supply PWA see PWA Section 7 2 16 6 3 3 TROUBLESHOOTING WITH IV HISTORY A continuously updated time date stamped history of all device events such as line mode changes transitions to battery power and all alarm events is maintained This information can be displayed or printed out Details on how to
42. wrap and unsolder the wires Remove the hex nut and lock washer attaching two ground wires to the switch panel stud see Figure 7 19 Technical Service Manual 7 29 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 9 Using a nutdriver remove the two 5 16 inch hex nuts attaching the plate to the bottom enclosure Remove the defective power connector plate assembly and install the replacement assembly see Figure 7 18 10 Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify all cables are freely extended and not pinched 11 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats 12 Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the power connector plate assembly perform the PVT in Section 5 2 4 40 HEX NUT 2 4 LOCK WASHER INTERNAL TOOTH 2 4 40 x 3 8 FLAT HEAD SOCKET SCREW 2 ENCLOSURE
43. 06579 002 Rev 7 04 CONTENTS 4 6 1 8 POWER ON RESET CIRCUITRY 49 4619 POWER INDICATOR 440 462 PUMPPWA ook 410 462 1 MICROPROCESSOR AND CLOCK 410 4 6 2 2 EPROMANDRAM s s 440 462 WATCHDOG TIMER 441 46 24 PERIPHERAL ACCESS WEE feu ox deos os AN 462 5 ANALOG TO DIGITAL CONVERTER 411 462 6 PRESSURE TRANSDUCER CONDITIONING AND POWER 4 11 4 6 2 7 MOTOR AND SOLENOID CONTROL 412 462 8 OPTICAL SWITCHES 412 4 6 3 POWER SUPPLYPWA E E 4 6 31 AC INPUT RECTIFICATION AND FILTERING 413 47 MECHANISM FUNCTIONAL DESCRIPTION 414 48 DISPOSABLE CASSETTE DESCRIPTION 4 16 49 PRESSURE 447 491 PROXIMAL OCCLUSION s 417 49 2 AIRDETECTION ceo ee 4 9 3 CASSETTE PRESSURE EQUALIZATION 448 4 9 4 PATIENT OCCLUSION DETECTION 418 Section 5 MAINTENANCE AND SERVICE TESTS ee ee ee 5 5 1 ROUTINE MAINTENANCE 511 B 512 CLEANING a 51 3 SANITIZING OX exu a e aw cedes UR 52 PERFORMANCE VERIFICATION TEST 2 2 ls 53 521 EQUIPMENT REQUIRED 53 522 INSPECTION ee eo Bl 5 23 PUMPING MECHANISM PRESSURE FIN
44. 2 7 2 17 REAR HOUSING ASSEMBLY REPLACEMENT 7 24 7 218 SERIAL RS 232 CONNECTOR REPLACEMENT 7 26 7 219 EQUIPOTENTIAL POST REPLACEMENT co 728 7 2 20 POWER CONNECTOR PLATE ASSEMBLY REPLACEMENT 729 7 2 21 AC LINE FILTER ASSEMBLY REPLACEMENT 7 32 7 222 SWITCH PANEL ASSEMBLY REPLACEMENT 7 33 7 2 23 BAG HANGER REPLACEMENT 1734 7 2 24 VENT SCREEN REPLACEMENT 5 735 Section 8 SPECIFICATIONS a 2 2 ll Section 9 DRAWINGS a 4 lll 9 Section 10 10 41 Technical Service Manual vii 430 06579 002 Rev 7 04 FIGURES Figures Figure 4 1 Input Valves Figure 4 2 Valve Cam Assembly Figure 4 3 Disposable Cassette Figure 4 4 Cassette Holster Figure 5 1 Omni Flow Holster Figure 5 2 Test Setup Figure 5 3 Occlusion Test Figure 7 1 Pump PWA R26 Trim Pot and Test Connector Jis Figure 7 2 Power Cord and Fuse Replacement Figure 7 3 Cassette Locking Knob Figure 7 4 Enclosure Screw Placement Figure 7 5 Top and Bottom Enclosure Separation Figure 7 6 Battery Replacement Figure 7 7 Top Enclosure Connectors Figure 7 8 Top Enclosure Assembly Figure 7 9 LCD Replacement Figure 7 10 Keypad ESD Grounding Strip Bottom View Figure 7 11 Keypad Replacement G Figure 7 12 Pump Figure 7 13 Pump PWA Conn
45. 3 ENTER to cancel flush Remove the needle from the patient line OCCLUSION TEST To perform the occlusion test refer to Figure 5 3 Occlusion Test Setup and proceed as follows Enter the following infusion program Press CONTINUOUS INFUSION on line B Set rate to 700 mL hr Press NEXT Set volume to 50 mL Press ENTER 2 Allow device to run for a few pump strokes and then clamp line B Verify device flushes with fluid from line A by observing dripping in line A sterile water container drip chamber and water flushing into collection bag Verify the AIR IN LINE OCCLUSION ON LINE B alarm activates 430 06579 002 Rev 7 04 5 10 Omni Flow 4000 Plus 5 2 PERFORMANCE VERIFICATION TEST 3 Press MUTE twice to silence alarm and return to base screen Unclamp line Press STOP line Press ENTER to stop pumping 5 Connect distal tubing to a DPM through a three way stopcock Open stopcock to air see Figure 5 3 6 Enter the following infusion program Press CONTINUOUS INFUSION on line B Set rate to 150 mL hr Press NEXT Set volume to 50 mL Press ENTER 7 Press SPECIAL FUNCTION 6 ENTER Press NEXT to move to MAX OCCLUSION field Enter 3 psi Press ENTER twice 8 Close the three way stopcock Verify the OCCLUSION IN PATIENT LINE alarm activates at 3 0 1 0 psi on DPM 9 Press MUTE to silence alarm Press RESUME Open the stopcock Press ENTER 10 Repeat Steps
46. ADJUSTMENT PROCEDURE CAUTION Use proper ESD grounding techniques when handling components Wear an antistatic wrist strap and use an ESD protected workstation Store PWAs in antistatic bags before placing them on any surface The transducer offset adjustment procedure should be performed when troubleshooting the device for nuisance alarms relating to occlusion pressure sensing or when replacing the pump PWA Recommended tools and equipment for this procedure are as follows a 1 16 inch Allen wrench No 2 Phillips screwdriver torque driver with No 2 Phillips and flat blade heads trim pot tool digital multimeter DMM with micro clip leads and GLPT To adjust the transducer offset refer to Figure 7 1 Pump PWA R26 Trim Pot and Test Connector J15 then proceed as follows 1 2 3 11 12 Disconnect the device from AC power Verify proper mechanism engagement as described in Section 5 2 3 Separate the top and bottom enclosures as described in Section 7 2 10 Separating the Top and Bottom Enclosures leaving the battery connections intact Locate test connector J15 on the pump PWA Connect the negative lead from the DMM to pin 3 analog ground then connect the positive lead to pin 1 transducer in Set the DMM to DC volts Power on the device using battery power Verify that the voltage is between 1 66 and 1 88 VDC Note If the voltage is out of range reassemble the device then contact Hospira to return
47. AM Al U11 EH 00 7 A DO 7 OCTAL s LATCH RESET D TYPE J18 CS1 AND DI RETE gc LATCH WRITE 5 L PATIENT SOL D7 A7 SOLENOID AS STROBE gb VALVE MOTOR DRIVERS gt y STROBE gt A8 AS A0 A14 mol Qu ADDRESS BUS 0 15 m 32K X 8 BIT EPROM CONTROL 5V INVERTERS DETECTORS 02 03 2 01 08 La CONTROL moe MPU 5 T PAL LATCH o4 R W WRITE y 17 AND J 1 8 5VREF 04 DISC RETE PATIENT SOL 4 288 MHZ DRIVERS et F i 4 16 05 SOLENOID NMI K 75HZ 15 START D0 7 AID0 7 06 AND MOTOR OUT ENA our INPUTS DRIVERS PUMP MOTOR END OF CONVERSION 07 4 08 CLK A0 A2 PORTS U13 NP U8 DIVIDER ANALOG DIGITAL CONVERT 614 4KHZ U1 DISCRETE 8V 14V 5VREF I 14V TO 14V TO J15 PIN 4 5VREF CHO gt J18 PIN 3 5VREF 5VREF PUMPALARM J16 PIN 4 BLOWN FUSE DISCRETE yen l 8v OUT SENSE1 J15 PIN 9 CONVERTER gt CONVERTER ENSE2 J15 PIN 10 Hin ycu2 LOCK N C J18 PIN 5 E 14V VOLTAGE 5VREF OUT TX2PMP J16 PIN 8 DIVIDERS CHA RXFRPMP J16 PIN 6 AND OP AMP TO CONTROL PWA T CIRCUITS 5VREF cHe HOSPIRA 03102031 TRANSDUCER Figure 9 8 Pump PWA Block Diagram DRAWING NO Rev N A Sheet 1 of 1 Technical Service Manual 9 19 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 20 Omni Flow 4000 Plus AC INP
48. BUFFER Error 11 Unassigned Autovector 42 POINT BUFFER Error 13 Spurious Interrupt 50 53 Update In Progress Timeout in RTC Self test 14 Unassigned Trap Codes 80 89 represent CPU Error Vector 15 Illegal Watchdog Counter 80 Bus Error value 16 BCR Command ACK Timeout 81 Address Error 17 BCR Release of Command 82 Illegal Instruction ACK Timeout 18 BCR Buffer Overflow 83 Zero Divide 19 BCR DATRDY Assert Timeout 84 CHK Instruction Technical Service Manual 6 9 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING Table 6 4 Software Service Codes BCR DATRDY Release 85 Instruction Timeout Attempt to Encode Morethan5 86 Privilege Violation Meds Code Error in IV History 87 Trace Undefined Screen 88 Line 1010 Emulator CLR_LINE_TIMER Error 89 Line 1111 Emulator Invalid Status in IV Status 98 Invalid IV History Pointers 6 2 5 SYSTEM SERVICE CODES Table 6 5 System Service Codes describes the alarm messages that occur when the system detects an unexpected line status condition while infusing If a system service code displays turn the power off then on Allow self test to complete and proceed as follows 1 If the system service code does not clear contact Hospira 2 If another type of service code occurs perform corrective action specified in one of the following sections Section 6 2 2 Self Test Service Codes Section 6 2 3 Pump Service Codes Section 6 2 4 Software Service Codes
49. Breakdown Exploded View Rear Exploded View Switch Panel Exploded View System Interconnect Block Diagram System Block Diagram Control PWA Block Diagram Pump PWA Block Diagram Power Supply PWA Block Diagram Power Supply Wiring Diagram Pump Chassis Wiring Diagram Table 9 2 IPB for the Omni Flow 4000 Plus Index Nomenclature Replacement Procedure Number 1 Enclosure Top Section 7 2 12 2 PWA Pump Therapist Section 7 2 15 3 Assembly Rear Housing Section 7 2 17 4 Power Supply Section 7 2 16 5 Assembly Keypad Section 7 2 14 6 Battery Section 7 2 11 Technical Service Manual 9 1 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS Table 9 2 IPB for the Omni Flow 4000 Plus Replacement Procedure Index Number Nomenclature Screen Vent Section 7 2 24 Assembly LCD Section 7 2 13 PWA Control Section 7 2 12 Insulator Metal White Section 7 2 12 Assembly Switch Panel Section 7 2 22 Switch Toggle 3 Position N A Cap Plastic N A Knob Plastic N A Resistor Potentiometer 10 K linear N A Switch Panel N A Assembly Line Filter AC Assembly Power Connector Plate Section 7 2 21 Section 7 2 20 Assembly Ground Strap Chassis Top Enclosure Section 7 2 12 Assembly Ground Strap Switch Panel Comm Section 7 2 20 Assembly Battery Clamp Section 7 2 11
50. CAUTION Do not spray cleaning solutions toward any openings in the device CAUTION Do not use sharp objects to clean the pump CAUTION Certain cleaning and sanitizing compounds may slowly degrade components made from some plastic materials Using abrasive cleaners or cleaning solutions not recommended by Hospira may result in product damage and potentially void the product warranty Do not use compounds containing combinations of isopropyl alcohol and dimethyl benzyl ammonium chloride CAUTION not use solvents that are harmful to plastic such as isopropyl alcohol or acetone Do not use abrasive cleaners CAUTION To avoid device damage cleaning solutions should be used only as directed in Table 5 1 Cleaning Solutions The disinfecting properties of cleaning solutions vary consult the manufacturer for specific information 1 Clean the exposed surfaces of the device with a soft lint free cloth dampened with one of the cleaning solutions listed in Table 5 1 or a mild solution of soapy water 2 Remove soap residue with clear water Table 5 1 Cleaning Solutions Cleaning Solution Manufacturer Preparation Coverage HBV Steris Corporation Per manufacturer s recommendation Dispatch Caltech Industries Per manufacturer s recommendation Formula C Johnson Diversey Per manufacturer s recommendation Manu Klenz Steris Corporation Per manufacturer s recommendation Precise Caltech Industries Per manufacture
51. EPLACEMENT AND ADJUSTMENT PROCEDURES 4 Remove the Phillips pan head or slotted hex head screw that secures the ground strap to the top enclosure see Figure 7 7 5 Disconnect the three ribbon cables two 10 pin and one 8 pin connector from the control PWA see Figure 7 7 Separate the top enclosure from the bottom enclosure 6 Using a Phillips screwdriver and a flat blade screwdriver remove the four screws that attach the pump assembly to the bottom enclosure see Figure 7 14 Note The pump assembly consists of the power supply PWA motor base mechanism and pump PWA 7 Gently tilt the pump assembly away from the bottom enclosure so that the edge of the pump assembly is resting on the bottom enclosure and the power supply PWA is visible 8 Disconnect the 6 pin switch panel connector and the 3 pin AC power connector from the power supply PWA Remove the pump assembly from the bottom enclosure and set the pump assembly on a padded surface so that the power supply PWA faces up 9 Replace the rear housing assembly 10 Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify that the ground strap lug remains parallel to the side of the top enclosure and faces away from the bottom enclosure Route the ribbon cables under the sheetmetal top strap and assure that the cables are not pinched between the pump PWA and the contr
52. FETY AND EQUIPMENT PRECAUTIONS Before opening the front enclosure take all necessary precautions for working on high voltage equipment WARNING UNLESS OTHERWISE INDICATED DISCONNECT THE DEVICE FROM AC POWER BEFORE PERFORMING ANY REPLACEMENT PROCEDURE WARNING POSSIBLE EXPLOSION HAZARD EXISTS IF THE DEVICE IS SERVICED OR REPAIRED IN THE PRESENCE OF FLAMMABLE ANESTHETICS CAUTION Use proper ESD grounding techniques when handling components Wear an antistatic wrist strap and use an ESD protected work station Store the PWAs in antistatic bags before placing them on any surface 722 REQUIRED TOOLS AND MATERIALS The following tools and materials or equivalents are required for the replacement procedures in this section In addition the beginning of each procedure lists tools and materials required for that specific procedure o Set of Phillips screwdrivers Set of flat blade screwdrivers X acto knife Set of Allen wrenches Set of nutdrivers Keypad application fixture P N 519 06312 001 Scissors Soldering gun Torque Limiting Screwdriver Mountz Torquemaster with Phillips and flat blade heads Trim pot tool Lint free cloth Technical Service Manual 7 3 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 7 2 3 Electrical tape Vibratite sealant Red GLPT insulating varnish A Digital multimeter DMM Fluke Model 8062A TRANSDUCER OFFSET
53. FUNCTION To set the real time clock using the special function feature proceed as follows Note Time can only be changed when all lines are OFF l ol Stop all lines from the pump status screen A OFF B OFF C OFF D OFF TOTAL 12 30 AM 0 0 0 0 0 Press the SPEC FUNC key then press the 1 key The following screen appears I CURRENT TIME 9 00 PM MILITARY TIME Y N NO ENTER Change the time setting using the numeric keypad Press the numeric keys to enter the hour and minutes Pressthe NEXT key to change the AM PM designator then press the AM PM key For military time press the NEXT key then press the YES key Press the ENTER key and verify the correct time displays Note Depending on software version Omni Flow 4000 Plus pumps default to either AM PM time or military time If military time is selected on a pump that is configured to AM PM time it defaults to AM PM when the pump is turned off Technical Service Manual 1 7 430 06579 002 Rev 7 04 SECTION 1 INTRODUCTION This page intentionally left blank 430 06579 002 Rev 7 04 1 8 Omni Flow 4000 Plus LL Section 2 WARRANTY Subject to the terms and conditions herein Hospira Inc herein referred to as Hospira warrants that a the product shall conform to Hospira s standard specifications and be free from defects in material and workmanship under normal use and service for a
54. G THE REAL TIME CLOCK AT POWERUP 17 1 8 4 2 SETTING THE REAL TIME CLOCK USING SPECIAL 17 Section 2 24 Section 3 SYSTEM OPERATING MANUAL 2 2 ee ee Section 4 THEORY OF OPERATION meu eese A 4 1 SEQUENCE OF OPERATION E x de mmm m meom eoe E 4 1 1 OFFSTATUS amp 6 s 6 wow 44444448 oco4 ox xoxo 441 412 5 6 4 1 2 1 SELFTEST how ox x4 xo UE 4122 MAIN PROGRAM SOFTWARE FUNCTIONS 42 4 1 2 3 42 4124 CASSETTETEST 2 eee 43 42 ALARM CONDITIONS are 43 SYSTEM MALFUNCTION DETECTION 2 ee 44 44 DATA RETENTION Laa a d 441 SIGNIFICANT DATA RETENTION 442 IV HISTORY Qc 45 SYSTEM INTERFACE DESCRIPTION 2 ls 45 451 AC POWER INTERFACE 46 452 USERINTERFACE 5 2 ee ee 46 4 5 3 MECHANISM INTERFACE 47 4 6 PWA FUNCTIONAL DESCRIPTION 47 4 6 1 CONTROLPWA aaa we m 4611 MICROPROCESSOR AND CLOCK 48 4612 EPROMANDRAM 48 4613 REAL TIME CLOCK 48 4614 PERIPHERAL ACCESS 2 4 8 4 6 1 5 SERIAL COMMUNICATIONS 2 2 2 49 4 6 1 6 LCD BACKLIGHT AND CONTRAST CONTROL 49 4617 ALARM CIRCUITRY 5 49 Technical Service Manual V 430
55. GER CHECK 54 524 TEST SETUP 5 5 5 25 SYSTEM TESTS oh ome ae oe ee 52 6 COLLECTION SOLENOID TEST 58 527 PATIENTSOLENOIDTEST 2 58 5 2 8 5 9 529 HIGH FLOW 5 9 5 2 10 VOLUME ACCURACY TEST 2 2 5 5 2 11 OCCLUSION TEST s 5 0 5 2 12 NURSE CALL TEST 2 2 ee ew ee s s 5 0 5 2 13 PRINTER PATTERN 5 0 5 214 SAFETY TEST 2 2o eee ew Re sw oe eee ee oe 512 5 2 15 END OF PVT E 5 3 PERIODIC MAINTENANCE INSPECTION 222222222222 54 BATTERY OPERATION OVERVIEW 513 Section 6 TROUBLESHOOTING ge ga Es Gs te ee 6 1 TECHNICAL ASSISTANCE 4 Miri de e on ae Gy gk Oe pce 62 ALARM MESSAGES AND SERVICE CODES 64 6 2 1 OPERATOR ALARM MESSAGES 2 4 62 622 SELF TEST SERVICE CODES 4 64 6 2 3 PUMP SERVICE CODES 2 66 624 SOFTWARE SERVICE CODES 2 2 4 4 69 6 2 5 SYSTEM SERVICE CODES 2 2 4 6 0 430 06579 002 Rev 7 04 vi Omni Flow 4000 Plus CONTENTS 63 TROUBLESHOOTING PROCEDURES one Be wae edd 63 1 TROUBLESHOOTING GENERAL PROBLEMS 612 6 3 2 TROUBLESHOOTING WITH 645 6 3 2 1 SYSTEM TEST TROUBLESHOOTING
56. MES WIRE COLORS SPADE LUGS FEED 14V RED GND 12 LEAD ACID BATTERY BLACK 03K02032 Technical Service Manual RIBBON CABLE TO POWER SUPPLY TO CONTROL PWA J6 PWA J8 P6 SIGNAL NAMES P8 LOGIC GND 1 10 p 83 R BLOWNFUSE NOT USED 7 LOGIC GND 5V 6 5 ALARM 7 8 KEEP ALIVE 14V a 14V SWITCHED 2 NURSE CALL m7 RIBBON CABLE TO POWER SUPPLY TO PUMP PWA J7 PWA J17 P7 SIGNAL NAMES P17 25 1 LOGIC GND 3 g BLOWNFUSE i LOGIC GND 14V ANALOG GND 14VMS 14VMS p ANALOG GND z y 2N m mo NIC NO wirE _SPARE m HOSPIRA Figure 9 10 Power Supply Wiring Diagram DRAWING NO NIA Sheet 1 of 1 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 24 Omni Flow 4000 Plus 03K02028 Technical Service Manual PUMP PWA TEST CONNECTOR J1 5 SIGNAL NAMES 1 XDUCER IN 2 XDUCER OUT 3 ANALOG GND 4 8V 5 5VREF 6 14V 7 5V 8 L
57. NOT APPLICABLE 03K02004 Technical Service Manual 9 5 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 6 Omni Flow 4000 Plus 03K02001 Technical Service Manual 9 7 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 8 Omni Flow 4000 Plus Technical Service Manual SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 10 Omni Flow 4000 Plus HOSPIRA Figure 9 4 Switch Panel Exploded View 03K02003 DRAWING NO Rev N A NOT APPLICABLE Technical Service Manual 9 11 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 12 Omni Flow 4000 Plus 03K02025 Technical Service Manual MODULAR LINE CORD MEMBRANE KEYPAD NO CONNECTION THESE CONNECT TO TRANSFORMER S PRIMARY POWER SUPPLY PWA LINE CORD RECEPTACLE LINE FILTER AND 2 FUSES BLACK 1 WHITE b 2 GREEN 3 P19 J19 POWER TOGGLE SWITCH ALARM VOLUME POT NURSE CALL JACK 14 WIRE RIBBON CHASSIS SCREW rm z 11 PIN 11 NOT USED LCD DISPLAY CONTROL PWA PINS 1 amp 2ARE
58. NOT USED 1 16 10 WIRE RIBBON WIRE RIBBON 6 INDIVIDUAL WIRES TWO WIRES PER FUNCTION na mu D SUB 5 WIRE RIBBON 3 INDIVIDUAL WIRES PUMP PWA PRESSURE TRANSDUCER MOTORS SOLENOIDS CASSETTE SW 16 INDIVIDUAL WIRES HOSPIRA Figure 9 5 System Interconnect Block Diagram DRAWING NO Rev NOT APPLICABLE Sheet 1 of 1 9 13 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 14 Omni Flow 4000 Plus LCD DISPLAY KEYPAD PRINTER CONTROL PWA 68HC000 MICROPROCESSOR NON VOLATILE SRAM 1 MEGABYTE EPROM 1 MEGABYTE REAL TIME CLOCK RTC PERIPHERAL INTERFACE ADAPTER PIA PRINTER RS 232 PORT LED DRIVERS 03K02026 Technical Service Manual SIGNAL ALARM KEYPAD MATRIX SERIAL INTERFACE TX AND RX SIGNALS TRANSDUCER ANALOG SIGNAL SENSE OPTO VALVE VALVE MOTOR SENSE 63A03 MICROPROCESSOR PUMP VOLATILE SRAM 64K BYTES gt MOTOR PUMP MOTOR EPROM 256K BYTES STEPPER MOTOR DRIVERS ANALOG TO DIGITAL CONVERTER A D COLLECTION VALVE OPTICAL ENCODER ELECTION 3 SOLENOID PISTON OPTICAL ENCODER PATIENT SOLENOID SOLENOID ALARM CIRCUITRY POWER SUPPLY NURSE CALL RELAY CIRCUITRY BATTERY
59. NT SCREEN REPLACEMENT Note Pumps with final assemblies 850 06300 008 and higher do not have vent screens Recommended tools for this procedure are as follows flat blade screwdriver No 2 Phillips screwdriver and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Screen Vent Screw 4 40 x 1 4 Hex Head Slotted with Washer Screw 4 40 x 1 4 Phillips Pan Head alternate Washer Flat 0 25 OD 0 028 ID 0 036 Thk Washer Flat 4 0 25 OD 0 125 ID 0 026 Thk alternate To replace the vent screen refer to Figure 7 16 Rear Housing Components then proceed as follows a PF OU Ne Disconnect the device from AC power Separate the top and bottom enclosures as described in Section 7 2 10 Remove the battery as described in Section 7 2 11 Remove the pump assembly as described in Section 7 2 16 Remove the four screws and washers attaching the vent screen and ground strap to the bottom enclosure see Figure 7 16 Remove the defective vent screen and install the replacement screen Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the vent screen to the bottom enclosure to 10 1 inch pounds Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify all cables are freely extended and not pinched Verify top enclosure alignment by placing a cassette in the holster Loc
60. OGIC GND SENSE1 der 11 12 MOTOR SOLENOID GND 13 PMPMTR COM VMTR COM 14 TO PUMP TO CONTROL PWA J16 RIBBON CABLE PWA J9 J1 6 SIGNAL NAMES J9 1 SPARE 3 23 SPARE LOGIC GND 3 6 4 PUMPALARM 5 5 LOGIC GND nl 67 RXFRPMP 3 7 LOGIC GND 2 8 2 1 PWA J18 SPARE NOT USED LEN SPARE NOT USED 2j i 3 SPARE NOT USED WIRE COLORS LOCKNO NOT USED 4 LOCKNC YELLOW LOGIC GND YELLOW h PMPMTR DRIVER A RED 113 9 9 PMPMTR DRIVER A BROWN 10 PMPMTR DRIVER WHT ORG 8 PMPMTR DRIVER GREEN H B PMPMTR COMMON BLACK WHITE 12 14VMS 3 PATIENT SOL WHITE 14VMS WHITE LA COLLECTION SOL WHITE 15 20 VMTR DRIVER RED 18 VMTR DRIVER A BROWN A 19 VMTR DRIVER B WHT ORG 17 VMTR DRIVER GREEN B BLACK 46 VMTR COMMON TO PUMP PWA J20 P20 SIGNAL NAMES WIRE COLORS XDUCER IN GREEN OUPUT ra ANALOG GND BLACK GND 3 INPUT CASSETTE LOCK SWITCH PUMP MOTOR PATIENT SOLENOID COLLECTION SOLENOID VALVE MOTOR FORCE TRANSDUCER HOSPIRA Figure 9 11 Pump Chassis Wiring Diagram DRAWING NO Sheet 1 of 1
61. PLUS 2 Verify that after successful completion of the cassette test the following base screen displays A OFF B OFF C OFF D OFF TOTAL hh mmHR 0 0 0 0 0 ML HR 5 2 9 HIGH FLOW TEST To perform the high flow test proceed as follows 1 Press SPECIAL FUNCTION 6 Press NEXT to move the cursor to the MAX OCCLUSION field Enter 8 psi Press ENTER twice 2 Enter the following infusion program Press CONTINUOUS INFUSION on line A Set rate to 150 mL hr Press NEXT Set volume to 50 mL Press ENTER Press CONTINUOUS INFUSION on line B Set rate to 150 mL hr Press NEXT Set volume to 50 mL Press ENTER Press CONTINUOUS INFUSION on line C Set rate to 150 mL hr Press NEXT Set volume to 50 mL Press ENTER Press CONTINUOUS INFUSION on line D Set rate to 150 mL hr Press NEXT Set volume to 50 mL Press ENTER 3 Verify the device operates without alarms until approximately 20 ml is delivered per the IV flow sheet 4 Press SPECIAL FUNCTION 4 ENTER to stop pumping 5 Press SPECIAL FUNCTION 6 Press NEXT to move the cursor to the MAX OCCLUSION field Enter 10 psi Press ENTER twice Technical Service Manual 5 9 430 06579 002 Rev 7 04 SECTION 5 MAINTENANCE AND SERVICE TESTS 5 2 10 VOLUME ACCURACY TEST To perform the volume accuracy test proceed as follows 1 2 3 4 5 6 7 8 9 10 5 2 11 Attach a 20 gauge need
62. Pump PWA Connections then proceed as follows 1 2 Disconnect the device from power Separate the top and bottom enclosures as described in Section 7 2 10 CAUTION Do not remove screws painted with red GLPT Using the Phillips screwdriver remove the five screws attaching the pump PWA to the motor base mechanism chassis see Figure 7 12 Lift the pump PWA away from the chassis and disconnect the 20 pin connector from J18 on the pump PWA see Figure 7 12 Disconnect the following connectors from the pump PWA see Figure 7 13 11 pin connector from J17 8 pin connector from J16 3 pin connector from J20 Remove the defective pump PWA and install the replacement PWA Reassemble the device in the exact reverse order of its disassembly Tighten the screws securing the top and bottom enclosures to 10 1 inch pounds Note When placing the pump PWA on the motor base mechanism chassis align the five clearance holes on the pump PWA to the standoffs before replacing the screws Note Route the ribbon cables under the sheetmetal top strap and assure that the cables are not pinched between the pump PWA and the control PWA Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob pr
63. R CONNECTOR SWITCH PANEL PLATE ASSEMBLY ASSEMBLY 7 9 PIN RS 232 CONNECTOR BAG HANGER ie S T 2 K p e O A 25 PIN RS 232 EQUIPOTENTIAL 4 40 x 1 4 SLOTTED CONNECTOR POST VENT FLAT WASHER HEX HEAD SCREW NOT ON NOT ON ALL DEVICES SCREEN 0 25 x 0 28 x 0 36 4 WITH WASHER 4 ALL DEVICES 03K02023 Figure 7 16 Rear Housing Components Technical Service Manual 7 27 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 7 2 19 POLE CLAMP SHAFT TIP POLE CLAMP KNOB SWITCH PANEL ASSEMBLY POLE CLAMP RS 232 HARDWARE KIT 9 6 32 x 5 8 SLOTTED HEX HEAD SCREW WITH WASHER 4 9 PIN RS 232 CONNECTOR 03K02036 Figure 7 17 Switch Panel RS 232 Connector and Bag Hanger EQUIPOTENTIAL POST REPLACEMENT Recommended tools for this procedure are as follows a 3 8 inch nutdriver a flat blade screwdriver No 1 and No 2 Phillips screwdrivers and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Terminal Equipotential Post Note Certain versions may not have an equipotential post To replace the equipotential post refer to Figure 7 16 Rear Housing Components then proceed as follows oa fF Disconnect the device from AC power Separate the top and b
64. Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Technical Service Manual 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING Table 6 3 Pump Service Codes and Corrective Actions Pump Service 4 Errors 14 volt system error Possible Causes Low or discharged battery 14 volt supply out of range Corrective Actions Recharge or replace battery Turn power off then on to reset device 21 volt AC error Line out of range Verify AC power source is correct voltage Turn power off then on to reset device Transducer pegged low error System detects low or no transducer output Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Check transducer to pump PWA J20 cable connection Piston encoder failure System unable to detect position of piston motor Verify proper seating of the cassette in holster Check for any binding of the piston from foreign material Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 IV History buffer range error Control PWA processor detected incorrect history buffer range value Replace control PWA see Section 7 2 12 Communication retry fault 430 06579 002 Rev 7 04 Data error in interboard communication Defective communication interface on control PWA or pump PWA Damage
65. Rev 7 04 SECTION 6 TROUBLESHOOTING This page intentionally left blank 430 06579 002 Rev 7 04 6 24 Omni Flow 4000 Plus pl Section 7 REPLACEABLE PARTS AND REPAIRS This section itemizes all parts and subassemblies of the Omni Flow 4000 Plus that are repairable within the scope of this manual In addition this section details replacement procedures for all listed parts 7 1 REPLACEABLE PARTS Replaceable parts for the Omni Flow 4000 Plus are itemized in the spare parts price list and are identified in Figure 9 1 Illustrated Parts Breakdown Table 9 2 IPB for the Omni Flow 4000 Plus identifies each part by an index number that correlates to Figure 9 1 To request a copy of the current spare parts price list contact Hospira see Section 6 1 Technical Assistance or to view the catalog online visit the website at www hospiraparts com For convenient reference insert a copy of the spare parts price list here Technical Service Manual 7 1 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS This page intentionally left blank 430 06579 002 Rev 7 04 7 2 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES 72 REPLACEMENT AND ADJUSTMENT PROCEDURES This section contains safety and equipment precautions required tools and materials and step by step procedures for replacing parts and subassemblies Unless otherwise stated always perform the PVT after a replacement procedure SA
66. Section 6 3 4 2 Biomed Password Level To access the following user level functions press SPECIAL FUNCTION the keys indicated and ENTER Table 6 10 Special Function Keys Function Record external procedure Description Allows certain external events to be added to IV history report Set date and time Sets or changes date and time all lines must be OFF Program flushes Programs a flush before or after intermittent infusions Cancel subsequent flushes 4 Stop all lines Cancels all flushes currently programmed Stops all lines at once 430 06579 002 Rev 7 04 Omni Flow 4000 Plus 6 3 TROUBLESHOOTING PROCEDURES Description Table 6 10 Special Function Keys Program callbacks Select or change preset values Selects or cancels intermittent mode callbacks Set parameters Manufacturer s settings KVO rate Maximum occlusion pressure Enable all callbacks Temperature units 7 Set print format mode IV History or Device Status Report Selects print mode 8 Selects preprogram function Allows lines to be programmed in advance 9 Clear IV Flow Sheet Records IV flow sheet information into the IV history and clears the IV flow sheet 0 Enter bio med password level see Section 6 3 4 2 Accesses password protected functions Software revision levels Displays software
67. Service Codes Table 6 5 System Service Codes Table 6 6 Troubleshooting General Problems Table 6 7 System Test Troubleshooting Table 6 8 PVT Troubleshooting n Table 6 9 IV History Alarm Status Codes Table 6 10 Special Function Keys Table 6 11 Cassette Pressure and System Voltages Table 9 1 Drawings Table 9 2 IPB for the Omni Flow 4000 Plus Technical Service Manual ix Tables TABLES 430 06579 002 Rev 7 04 TABLES This page intentionally left blank 430 06579 002 Rev 7 04 x Omni Flow 4000 Plus E AAA Section 1 INTRODUCTION The Omni Flow 4000 Plus is a programmable medication administration system designed to deliver up to four separate medications with a single infusion device and single administration set 1 1 SCOPE This manual is organized into 11 sections Section 1 Introduction Section 2 Warranty Section 3 System Operating Manual Section 4 Theory of Operation Section 5 Maintenance and Service Tests Section 6 Troubleshooting Section 7 Replaceable Parts and Repairs Section 8 Specifications Section 9 Drawings Section 10 Index Technical Service Bulletins If a problem in device operation cannot be resolved using the information in this manual contact Hospira see Section 6 1 Technical Assistance Specific instructions for operating the device are contained in the Omni Flow 4000 Plus System Operating Manual Provision is made
68. TEST To perform the collection solenoid test proceed as follows l 2 5 2 7 Prepare four sterile water containers and connect them to cassette lines A B C and D Press the PRIME CASSETTE key for line A Verify solution enters the drip chamber of line A and exits into the collection bag Priming continues until the cassette is fully primed power prime occurs only for line A and reverts to gravity prime after initial use Press and hold the PRIME CASSETTE key for line A Verify a steady flow of fluid enters into the drip chamber and into the collection bag Repeat priming verification test from Step 4 for lines B C and D Press ENTER PATIENT SOLENOID TEST To perform the patient solenoid test proceed as follows 1 Press and release PRIME PATIENT LINE for line A Verify solution enters the drip chamber of line A and exits through the patient line of the cassette Priming continues until the patient line is fully primed power prime occurs only for line A 2 Press and hold PRIME PATIENT LINE for line A Verify steady drops of fluid enter the drip chamber and exit out the patient line of the cassette 430 06579 002 Rev 7 04 5 8 Omni Flow 4000 Plus 5 2 PERFORMANCE VERIFICATION TEST 5 2 8 CASSETTE TEST To perform the cassette test proceed as follows 1 Press ENTER to initiate the cassette test Verify the following screen displays CASSETTE TEST IN PROGRESS ABBOTT 4000
69. UT 03K02030 Technical Service Manual HALF RECTIFIED 14 VDC LINEAR REGULATOR NURSECALL RELAY ALARM CIRCUITRY TO CONTROL PUMP PWA 21 VDC 14 VDC KAV 14 VDC SWITCHED 5 VDC SWITCHING FUSE REGULATOR P 5 VDC BATTERY BATTERY SENSE OUT TO A D FROM CONTROL PWA 1 FROM CONTROL PWA 1 HOSPIRA Figure 9 9 Power Supply PWA Block iagram Rev N A DRAWING NO N A 9 21 430 06579 002 Rev 7 04 SECTION 9 DRAWINGS This page intentionally left blank 430 06579 002 Rev 7 04 9 22 Omni Flow 4000 Plus POWER 18 AWG 18 AWG SUPPLY SIGNAL NAMES WIRE COLORS J19 P19 WIRES PWA T MODULAR HOT BLACK 1 BLACK AC LINE CORD LINE CORD HOT WHITE RECEPTACLE a AC RTN 2 WHITE earns CHE R AND 2 FUSES RIN E AC GND GRN YEL GREEN 5mm X 20mm R SCREW TO SUPPLY CHASSIS TO POWER SUPPLY FWA JS 22 AWG REAR PANEL P5 siGNAL NAMES WIRE COLORS ASSEMBLY POWER TOGGLE SWITCH ON 14V OUT BROWN O 1 2 o CHARGE 5 14V SWITCHED RED ALARM VOLUME POT 5 ALARM VOLUME ORANGE 10K COMMON YELLOW T FERRITE BEAD 5 NURSE CALL N O GREEN NURSE CALL COM BLUE GREEN 6 NURSE CALL PHONE JACK MONO CONNECTS PWA 18 AWG WITH FEMALE SIGNAL NA
70. WA Each solenoid receives 14 and ground via P J20 Connector Control PWA The control PWA and the pump PWA conduct serial communication via an Pump PWA 8 pin ribbon cable between P J9 of the control PWA and P J16 of the pump Connector PWA The cable also supplies the alarm signal from the pump PWA 4 6 PWA FUNCTIONAL DESCRIPTION The device electronics are contained on three printed wiring assemblies PWA control PWA pump PWA and power supply PWA The following sections provide a functional description of the device PWAs For circuit details refer to the schematic and block diagrams for each PWA in Section 9 4 6 1 CONTROL PWA The control PWA see Figure 9 7 Control PWA Block Diagram consists of the following o Microprocessor EPROMs Non volatile RAM Real time clock Status LEDs AC power alarm battery A B C and D line status display backlight LCD display control and intensity Keypad interface Keep alive voltage power Command transmission to pump PWA Status reception from pump PWA L DL DL D D DL D D D O Serial printer output Technical Service Manual 4 7 430 06579 002 Rev 7 04 SECTION 4 THEORY OF OPERATION 4 6 1 1 MICROPROCESSOR AND CLOCK The control PWA central processing element Ul2 consists of an MC68HC000 microprocessor operating at a clock frequency of 12 288 MHz The clock oscillator module OSC1 is also used for synchronous timing of various support ICs Timing for th
71. access and output the history are found in the System Operating Manual The various sections of a report can be used for debugging and analysis by verifying alarms and malfunctions Programming sequences can be verified and reproduced to help determine or recreate the cause of a problem Certain alarms or failure codes that can be attributed to operator error can be identified The following example shows a PUMP SERVICE CODE 0800 malfunction that occurs when the system is unable to detect the position of the piston motor PUMP SERVICE 9 MAR 93 CODE 0800 BATT 2 13PM B LOG C LOG D LOG TOTAL IV FLOW 0 0 0 0 0 ML SHEET 5V 5 00 8V 8 07 21V 0 00 Vbatt 12 38 CASSETTE 9 MAR 93 LOAD 2 13PM TRANSFER TO BATTERY 9 MAR 93 OPERATION BATT 2 13 PM ABBOTT 4000 PLUS INFUSION SYSTEM IV HISTORY RECORD SYSTEM POWER UP 430 06579 002 Rev 7 04 6 18 Omni Flow 4000 Plus 6 3 TROUBLESHOOTING PROCEDURES The events leading up to the service code include a system power up and a cassette load event indicating a cassette was being inserted or removed from the holster Since the device must retract the piston to allow the cassette to be removed or inserted the operator must wait before sliding a cassette in or out of the holster Removing or inserting the cassette too soon causes the cassette to stop the piston movement The device detects the obstruction and activates the alarm Removing the cassette and cycl
72. age can occur in a matter of hours and cause a permanent loss of battery capacity The amount of lost capacity depends on the degree of discharge the storage temperature and the length of time the battery was stored in a discharged state Note permanently damaged battery cannot be recharged to full capacity Technical Service Manual 5 13 430 06579 002 Rev 7 04 SECTION 5 MAINTENANCE AND SERVICE TESTS When the battery discharges below the acceptable level while the device is operating the audible alarm sounds and the LOW BATTERY message displays Although it is not recommended to continue operating the device on battery power at this point the battery will continue providing power until discharged At this point the device enters the battery discharged mode and operation ceases CAUTION As soon as the LOW BATTERY alarm occurs connect the device to AC power Recharging occurs any time the device is connected to AC power It is recommended that the device be connected to AC power whenever practicable to maximize available battery charge during transport or ambulation The power switch does not have to be on for the battery to recharge Recharging while operating the device is rate dependent 430 06579 002 Rev 7 04 5 14 Omni Flow 4000 Plus Section 6 TROUBLESHOOTING This section contains information on obtaining technical assistance from Hospira troubleshooting alarm messages and service codes and procedures for tr
73. alve encoder System unable to Verify proper seating of cassette in error detect position of holster valve motor Check for binding of valves from foreign material Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 0002 Blown battery Battery internally Replace battery fuse see fuse shorted from Section 7 2 5 sulfation due to age Replace battery see Defective on off Section 7 2 11 switch Replace on off switch Defective power Replace power supply PWA J7 to supply PWA pump PWA J17 cable Replace power supply PWA 0004 Device Data error in Replace control PWA J9 to pump communication interboard PWA J16 cable fault communication Defective Replace control PWA see communication Section 7 2 12 interface on control of pump PWA Damaged or Replace pump PWA PWA defective cable replacement is serial number specific see CAUTION in Section 7 2 15 0008 Device logic Processor status Replace pump PWA PWA error errordetected during replacement is serial number pump PWA specific see CAUTION in operation Section 7 2 15 0010 5 volt system 5 volt supply out of Turn power off then on to reset error range device 0020 5voltreference A D reference Replace pump PWA PWA error voltage out of range replacement is serial number specific see CAUTION in Section 7 2 15 0040 8 volt system Low or discharged Recharge or replace battery error battery 8 volt supply out of range
74. and editorial corrections Section 9 Added IPB drawings and Table 9 2 cover ito vi 4 11 4 12 5 1 to 5 12 6 1 to 6 6 7 1 to 7 26 cover ito vi 4 11 4 12 5 1 to 5 14 6 1 to 6 6 7 1 to 7 28 9 61 to 9 72 Omni Flow 4000 Plus Part Number 430 06579 002 Technical Service Manual Description of Change Section 10 Updated Index Back Cover Updated back cover Updated entire manual to reflect recent style Incorporated Hospira name change Remove and Destroy Pages I 1 to I 4 back cover all CHANGE HISTORY Insert Change Pages 10 1 to 10 4 back cover n a 430 06579 002 Rev 7 04 CHANGE HISTORY This page intentionally left blank 430 06579 002 Rev 7 04 iv Omni Flow 4000 Plus CONTENTS Contents Section 1 114 SCOPE 5 8 12 CONVENTIONS ee ee eee 13 COMPONENTDESIGNATORS 0 0007 18 14 ACRONYMS AND ABBREVIATIONS 5 5 13 15 SERIES SPECIFIC INFORMATION 14 16 USER 14 1 7 ARTIFACTS de cm esu de cec SR 18 INSTRUMENT INSTALLATION PROCEDURE 15 181 UNPACKING 2 2 2 25 2 2 2 2 5 2 2 2 2 15 182 INSPECTION 1 5 183 SELFTEST 2 0 ee ee 1 184 REALTIMECLOCK Logged L6 184 SETTIN
75. and top enclosure Place a two inch piece of electrical tape over the grounding strip and screw see Figure 7 10 Do not cover the viewing portion of the keypad display window CAUTION Failure to insulate the grounding strip will result in damage to the control PWA The strip must be covered to assure proper insulation between the control PWA and the top enclosure Reassemble the device in the exact reverse order of its disassembly Verify that no foreign material is trapped between the keypad and LCD Tighten the screws securing the control PWA to the top enclosure to 10 1 inch pounds Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify that the ground strap lug remains parallel to the side of the top enclosure and faces away from the bottom enclosure Route the ribbon cables under the sheetmetal top strap and assure that the cables are not pinched between the pump PWA and the control PWA Technical Service Manual 7 17 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 13 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats 14 Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON p
76. battery for 24 hours If alarm persists replace battery see Section 7 2 11 Device does not operate on battery power Battery not fully charged Power supply fault Verify AC power cord connected to AC power and verify AC POWER indicator lit Recharge battery for 24 hours If alarm persists replace battery see Section 7 2 11 Replace power supply PWA see Section 7 2 16 Device operates on battery power when plugged into AC power BATTERY indicator lit Blown AC fuse Defective AC power cord Defective AC panel assembly Power supply fault Replace AC fuse see Section 7 2 5 Replace AC power cord see Section 7 2 4 Replace AC panel assembly see Section 7 2 20 Replace power supply PWA see Section 7 2 16 Cassette cannot be inserted or removed from the holster 430 06579 002 Rev 7 04 Power is not on Cassette locking lever is in the LOCKED position Fluid spill accumulation Turn power on to insert or remove cassette Verify that cassette locking lever is in UNLOCKED position Clean holster Omni Flow 4000 Plus 6 3 TROUBLESHOOTING PROCEDURES Table 6 6 Troubleshooting General Problems Symptoms Failed Cassette Test Possible Causes Air in line Lines are clamped Collection bag is full Pressure sensor malfunctioning Container is empty Line A Binding valve due to fluid spill accumulation Pressure interface binding due to fluid spill accumu
77. cessor is initiated on an interrupt basis via U9 U24 supports the inter PWA serial interface and has a fixed 76 8 K baud transfer rate 010 an open collector Schmitt trigger carries the transmit and receive data signals between the two PWAs U34 provides the interface to the DB 9 connector of the device U34 has a selectable baud rate factory set to 9600 baud Transmit and receive data and ready to send signals are supplied to U31 MAX252 an isolated serial communications transceiver module with a low power shutdown mode When the device operates on battery power a signal from PIA U6 places U31 in standby to conserve power LCD BACKLIGHT AND CONTRAST CONTROL A signal from PIA UG activates a current driver consisting of U26A and Q7 The output turns on DC to AC converter that supplies the 85 potential required by the electroluminescent EL display light DC to DC converter Ul controls contrast by supplying 5 Vp to potentiometer the LCD contrast adjustment and then to the LCD module 4 6 1 7 ALARM CIRCUITRY A 9 6 KHz clock derived from the communications baud rate circuitry is supplied to divider U27 U27 supplies six frequencies to multiplexer U28 Three select signals from PIA U4 allow the software to select a frequency to modulate the power supply PWA alarm circuit for multi tone alarm capability 4 6 1 8 POWER ON RESET CIRCUITRY 010 an open collector Schmitt trigger uses a voltage divider and an RC networ
78. d or defective cable Replace control PWA J9 to pump PWA J16 cable Replace control PWA see Section 7 2 12 Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Omni Flow 4000 Plus 6 2 ALARM MESSAGES AND SERVICE CODES 6 2 4 SOFTWARE SERVICE CODES Table 6 4 Software Service Codes describes the alarm messages that occur when the system detects an unexpected condition in the main program sequence or process If a software service code displays turn the power off then on Allow self test to complete and proceed as follows 1 If the software service code does not clear contact Hospira 2 If another type of service code occurs perform corrective action specified in one of the following sections Section 6 2 2 Self Test Service Codes Section 6 2 3 Pump Service Codes Section 6 2 5 System Service Codes 3 Ifno service code occurs but a malfunction exists see Section 6 3 Troubleshooting Procedures Table 6 4 Software Service Codes Descriptions Descriptions 01 Full Worklist 27 Bad Executive Scheduler Duty Cycle 02 Illegal Sequencer Table Entry 28 Half Second Interrupt Failure 03 DO LINE HOLD Error 29 RTC Update in Progress Timeout 04 LINE STOP Error 30 Gross Timeout on Receive from pump PWA 05 START CONTINUOUS Error 31 Invalid Barcode Label Data Type 06 START INTERMITTENT 40 POINT GET BUFFER Error Error 09 Alarm Table Search Error 41 POINT SET
79. detecting air occlusion and flow problems 4 9 1 PROXIMAL OCCLUSION Cassette pressure is constantly monitored to evaluate input conditions If a line is pinched or clamped the pump will attempt to repeat the stroke If the device still detects an occlusion pumping from the occluded line stops and the device enters the input occlusion alarm state 4 9 2 AIR DETECTION The device continually monitors the system for air using the pressure in the cassette If the volume of air exceeds the threshold the device purges the air into the collection bag with fluid from line A After three unsuccessful attempts to clear the air the device enters the AIR IN LINE alarm state and pumping stops Technical Service Manual 4 17 430 06579 002 Rev 7 04 SECTION 4 THEORY OF OPERATION 4 9 3 CASSETTE PRESSURE EQUALIZATION Before opening the patient line the device equalizes the cassette pressure to that of the patient line 4 9 4 PATIENT OCCLUSION DETECTION The device continuously monitors the cassette pressure If the pressure reaches or exceeds the maximum occlusion pressure the device stops and enters the OCCLUSION IN PATIENT LINE alarm condition 430 06579 002 Rev 7 04 4 18 Omni Flow 4000 Plus NENNEN Section 5 MAINTENANCE AND SERVICE TESTS A complete maintenance program promotes device longevity and trouble free instrument operation Such a program should include routine maintenance periodic maintenance inspection and fol
80. difference could indicate a problem with the optical motor positioning components P4 is inversely proportional to the amount of air in the cassette Consistently low P4 values could indicate incomplete priming or low head height Patient pressure A very high P5 while pumping into atmosphere at a low rate could indicate a problem with the patient valve or the valve motor positioning components 430 06579 002 Rev 7 04 6 22 Omni Flow 4000 Plus 6 3 TROUBLESHOOTING PROCEDURES 6 3 4 2 BIOMED PASSWORD LEVEL Certain functions require a password to access The protected functions are as follows Verbose IV History Printing Default IV History does not list alarm voltage and pressure information Enabling Verbose IV History Printing provides these added values Dry Pumping Enabling dry pumping disables air in line detection circuitry so the pump can be run with or without fluid To enable or disable a biomed password function perform the following 1 Press SPECIAL FUNCTION 0 ENTER 2 Enter the password 3 6 8 4 and press ENTER 3 Enter one of the following codes and press ENTER 1 1 Verbose IV History 1 3 Dry Pumping 4 Press YES NO to enable or disable function Note Turning off the device disables dry pumping function and re enables air in line circuitry Verbose IV History must be reset using special function mode Technical Service Manual 6 23 430 06579 002
81. due to obstruction of Replace pump PWA PWA replacement valve is serial number specific see CAUTION Defective optical in Section 7 2 15 switch on pump PWA 6 2 3 PUMP SERVICE CODES Table 6 3 Pump Service Codes and Corrective Actions describes alarm messages that may occur during operation Before troubleshooting any of the codes in Table 6 3 turn the power off then on Allow the self test to complete then proceed as follows 1 If a service code occurs during self test see Section 6 2 2 2 Ifno service code occurs during the self test review IV History to verify code events and conditions If a service code has occurred carefully inspect the device for damage as described in Section 5 1 1 If no exterior damage is noted perform the PVT If a service code occurs during operation perform the corrective action specified in one of the following Table 6 3 Pump Service Codes and Corrective Actions Section 6 2 4 Software Service Codes Section 6 2 5 System Service Codes 3 Ifno service code occurs but a malfunction exists see Section 6 3 Troubleshooting Procedures Note Ifanalarm persists after the corrective actions are performed contact Hospira 430 06579 002 Rev 7 04 6 6 Omni Flow 4000 Plus Service 4 Errors 6 2 ALARM MESSAGES AND SERVICE CODES Table 6 3 Pump Service Codes and Corrective Actions Pump Possible Causes Corrective Actions 0001 V
82. e real time clock RTC and memory access is derived from OSC1 by two dividers U19 and U14 in conjunction with address decode logic U15 U13 U20 and U16 4 6 1 2 EPROM AND RAM Program memory resides in two EPROMs AT27C512R U8 and U17 Each device contains 512 K bits 64 K bytes of nonvolatile read only storage The pair form 64 K words of storage for the MC68HCOOO RAM consists of two RAMS DS1235YWL U5 and U23 Each device contains 256 K bits 32 K bytes of random access storage configured to 32 K words Each device contains a lithium power source for nonvolatile storage PAL U16 along with the clock divider U14 perform memory accessing and address decoding 4 6 1 3 REAL TIME CLOCK RTC U3 MC146818A contains the real time clock Several internal registers contain minute hour day month and year information Access is controlled by decoder U20 and divider Ul9 The timing element consists of a Pierce oscillator formed by crystal Y1 and several discrete components Adjustable capacitor CV1 fine tunes the circuit Q2 and Q5 circuitry monitor the state of the switched 14 Vpc and 5 power supplies Since 5 is derived from 14 Vpc the activation or deactivation of the 5 power supply will lag the 14 Vpc power supply If the circuit detects 14 dropping indicating the system has been switched off Q2 turns off Q2 turning off inhibits chip enable of U3 preventing the microprocessor fro
83. eactance generated by switching inductive loads To activate a solenoid the pump PWA microprocessor writes a one in the solenoid bit of the appropriate control register U11 or U12 The N channel HEXFET conducts sinking current from the solenoid which activates the solenoid The solenoid remains activated until the control register is written with that solenoid bit off Motor stepping requires activation of the P channel HEXFET Q15 or Q3 common and activation and deactivation of the four motor phase N channel HEXFETs in proper sequence The pump PWA microprocessor does this sequence under program control Correct phase sequencing allows the motors to start stop and step in either direction at a rate determined by the speed at which the microprocessor changes the control register patterns 4 6 2 8 OPTICAL SWITCHES Both the piston motor and valve motor have a set of two optical switch detectors that send position information through a sense line to the I O port of the pump PWA microprocessor Due to the narrow beam width optical switch beam position relative to the motor shaft must be precisely set Detector outputs for both motors are multiplexed allowing only one set of optical switches to be enabled and therefore the state of only one of the motors to be read When no status information is being read both sets of optical switches are disabled to eliminate the emitter current drain and increase battery life 430 06579 002 Rev 7 04 4
84. ections Figure 7 14 Pump Assembly and Rear Housing Figure 7 15 Power Supply PWA and Motor Base Mechanism Figure 7 16 Rear Housing Components Figure 7 17 Switch Panel RS 232 Connector and Bag Hanger Figure 7 18 Power Connector Plate Figure 7 19 AC Line Filter Ground Lug Placement Figure 7 20 AC Line Filter Figure 9 1 Illustrated Parts Breakdown Figure 9 2 Exploded View er Figure 9 3 Rear Exploded View Figure 9 4 Switch Panel Exploded View ee Figure 9 5 System Interconnect Block Diagram Figure 9 6 System Block Diagram Figure 9 7 Control PWA Block Diagram Figure 9 8 Pump PWA Block Diagram Figure 9 9 Power Supply PWA Block Diagram Figure 9 10 Power Supply Wiring Diagram Figure 9 11 Pump Chassis Wiring Diagram 430 06579 002 Rev 7 04 viii 4 15 4 15 4 16 4 17 5 5 5 6 5 11 7 5 7 6 7 8 7 10 7 11 7 12 7 14 7 15 7 16 7 18 7 19 7 21 7 21 7 23 7 24 7 27 7 28 7 30 7 31 7 33 9 5 9 7 9 11 9 13 9 15 9 17 9 19 9 21 9 23 9 25 Omni Flow 4000 Plus Table 1 1 Conventions Table 4 1 AC Power Interface Table 4 2 User Interface Table 4 3 Mechanism Interface Table 5 1 Cleaning Solutions Table 6 1 Operator Alarm Messages and Corrective Actions Table 6 2 Self Test Service Codes and Corrective Actions Table 6 3 Pump Service Codes and Corrective Actions Table 6 4 Software
85. ecure the white insulation layer to the control PWA see Figure 7 8 Remove the insulation and replace if necessary Remove the Phillips pan head screw that secures the control PWA to the top enclosure Lean the control PWA on its edge and disconnect the 14 pin connector from the underside of the control PWA Do not scratch the liquid crystal display Remove the defective control PWA or top enclosure assembly and install the replacement part s Verify the grounding strip from the keypad is installed between the top enclosure and control PWA to allow a screw to secure the grounding strip Tighten the screws attaching the control PWA to the top enclosure to 10 1 inch pounds Reassemble the device in the exact reverse order of its disassembly Verify that no foreign material is trapped between the keypad and the LCD Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify that the ground strap lug remains parallel to the side of the top enclosure and faces away from the bottom enclosure Route the ribbon cables under the sheetmetal top strap and assure that the cables are not pinched between the pump PWA and the control PWA Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat loosen the screws on the bottom enclosure and readjust the top encl
86. eel Screw 4 40 x 1 8 Pan Head Slotted To replace the keypad refer to Figure 7 10 Keypad ESD Grounding Strip Bottom View and Figure 7 11 Keypad Replacement then proceed as follows Disconnect the device from AC power Separate the top and bottom enclosures as described in Section 7 2 10 Remove the control PWA as described in Section 7 2 12 Remove the electrical tape covering the keypad ESD grounding strip and remove the slotted screw and washer see Figure 7 10 Using a nutdriver remove the five nuts with washers holding the keypad assembly to top enclosure Remove the defective keypad assembly 6 Remove the paper backing from the replacement keypad assembly 10 11 12 Place the new keypad assembly on the top enclosure while inserting the keypad connector and ESD ground strip through the slot in the top enclosure see Figure 7 11 Lay the keypad assembly onto mounting holes of the top enclosure Place a drop of Vibratite sealant on each of the studs from the keypad assembly protruding through the back of the top enclosure Secure the keypad assembly in place by reinstalling the five nuts with washers Fold the keypad ESD grounding strip so that the rough surface is on the outside Install the grounding strip onto the top enclosure with the screw and washer that were removed in Step Four Bend the keypad ESD grounding strip so that it is flat against the display window
87. eplace cable Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Clean holster Omni Flow 4000 Plus 6 3 TROUBLESHOOTING PROCEDURES Table 6 8 PVT Troubleshooting Test Failures Cassette Test Possible Causes Air in line Lines are clamped Collection bag is full Pressure sensor malfunctioning Container is empty Line A Binding valve due to fluid spill accumulation Pressure interface binding due to fluid spill accumulation Damaged pressure interface Corrective Actions Reprime cassette to clear any air out of cassette Unclamp all input lines and the collection bag line Empty collection bag Clean the holster and inspect the pressure interface nose area Replace cassette and perform cassette test again Clean holster Clean holster If test continues to fail contact Hospira Contact Hospira Maximum Rate Test Defective pump PWA Binding valve due to fluid spill accumulation Damaged pump mechanism Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Clean holster Contact Hospira Volume Accuracy Test IV flow sheet not cleared Pressure interface or valve binding due to fluid spill accumulation Clear IV flow sheet prior to testing Clean holster Proximal Occlusion Test Distal Occlusion Test or Maximum Occlusion Test Technical Service Manual Incorrect set
88. er Interface describes the internal power interface Table 4 1 AC Power Interface Switch Panel The switch panel connects to the power supply PWA via connector P J5 Interface This connector carries 14 to and from the power switch alarm volume signals to the potentiometer and the nurse call output to the phone jack Control PWA The control PWA connects to the power supply via a ribbon cable from Power Interface P J8 to P J6 of the power supply PWA This interface supplies the control PWA with 5 unswitched 14 and unregulated 21 Vpc The power supply PWA receives the nurse call signal and the alarm signal from the control PWA via this cable Pump PWA The pump PWA connects to the power supply PWA via a ribbon cable from Power Interface P J17 to P J7 of the power supply PWA This cable supplies the pump PWA with 5 14 unregulated 21 and the blown battery fuse sense signal Battery Interface The battery connects to the power supply PWA via two color coded wires which attach to the battery Charge and discharge current flows through fuse F4 of the power supply PWA 4 5 2 USER INTERFACE The user interface consists of keypad touchswitches LCD module nurse call jack alarm volume potentiometer power switch and 9 pin serial interface Table 4 2 User Interface describes each interface Table 4 2 User Interface Keypad The 48 touchswitches of the keypad connect to the control
89. evice LOW BATTERY WARNING Technical Service Manual Verify AC power cord connected to AC power Verify AC POWER indicator lit Recharge battery for 24 hours If alarm persists replace battery see Section 7 2 11 Replace power supply PWA see Section 7 2 16 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING Table 6 1 Operator Alarm Messages and Corrective Actions Alarm Messages Corrective Actions MUTE HOLD TIME Press RESUME or STOP for all lines on HOLD EXCEEDED WARNING Perform system test to verify keypad functionality see Section 5 2 5 If test fails replace keypad Turn power off then on to reset device POSSIBLE FAULTY Replace cassette and repeat cassette test CASSETTE Clean the holster and inspect the pressure interface nose area Turn power off then on to reset device CASSETTE TEST Press ENTER to repeat test TIMEOUT Press ESCAPE to abort test Turn power off then on to reset device 6 2 2 SELF TEST SERVICE CODES Table 6 2 Self Test Service Codes and Corrective Actions describes the alarm messages that may occur during self test Before troubleshooting any of the codes in Table 6 2 turn the power off then on Allow self test to complete and proceed as follows l If a service code occurs during self test carefully inspect the device for damage as described in Section 5 2 2 Inspection If no exterior damage is noted perform corrective action specified in Table 6 2 2
90. evice is plugged into AC power and switched off the 14 regulator supplies the battery with charge current If the device is unplugged the regulator shuts off A switching regulator consisting of U2 L2 and several discrete components produces 5 from the output of the 14 regulator The 14 regulator output is also routed to the switch on the rear of the device to become 14 V SWITCHED If the device is unplugged from AC power the battery supplies the voltage for the 5 Vp regulator The control PWA sends the alarm signal to alarm circuitry DS1 Q7 and Q6 which produces audio tones modulated at the frequency selected by the software The potentiometer on the rear of the device controls alarm volume A 5 overload detection circuit consists of an SCR U3 a zener CR11 and transistor Q8 If 5 drops due to an overload U3 turns on switching Q8 on and sounding the alarm Technical Service Manual 4 13 430 06579 002 Rev 7 04 SECTION 4 THEORY OF OPERATION The nurse call relay K1 activates when the control PWA activates the NURSE CALL IN signal turning on FET Q9 4 7 MECHANISM FUNCTIONAL DESCRIPTION The delivery mechanism is actuated by stepper motors that allow precise control over pumping action The device microprocessor constantly monitors delivery mechanism activity to ensure accurate fluid delivery The majority of the functional hardware such as the pressure transducer stepper motors
91. evice to service Note If any tests fail refer to Section 6 Troubleshooting contact Hospira Technical Support Operations 5 3 PERIODIC MAINTENANCE INSPECTION Periodic maintenance inspections should be performed per hospital procedures for compliance to accreditation requirements It is recommended that JCAHO and or hospital protocol be followed for establishing a periodic maintenance inspection schedule Product specifications for this inspection are listed in Section 8 Specifications To perform the periodic maintenance inspection complete the performance verification test in Section 5 2 5 4 BATTERY OPERATION OVERVIEW The Omni Flow 4000 Plus is intended to operate on battery power on an exception basis only as follows Emergency backup i e AC power failure inadvertent disconnect of AC power cord Temporary portable operation i e patient moved from one location to another The device should be plugged into AC power whenever possible to ensure the battery remains fully charged The yellow BATTERY indicator lights when the device is operating on battery power Factors that most commonly affect battery life are the depth and frequency of discharge and the length of the recharge period As a general rule the more often the battery is discharged and recharged the sooner it will need replacement A primary cause of damage is leaving the battery in a less than fully charged state for any period of time Battery dam
92. g the cam from one input valve position to another the movable blocking cam lags behind the fixed cam This action prevents the followers of unselected input valves from falling into the fixed cam valley as the cam travels past them The patient line outlet cam is at the bottom of the assembly and controls the opening and closing of the patient line only The input and patient cams are positioned so that it is impossible to open an input and output valve simultaneously Since an input and an output valve cannot be opened simultaneously two solenoids are employed for the cassette priming process When priming the cassette the valve cam opens the desired input line and a solenoid opens the collection bag valve Likewise when priming the patient line the valve cam opens the input line and the second solenoid opens the patient line The pressure transducer monitors the pressure inside the cassette during the pumping cycle Data from this transducer is used to assure pumping accuracy detect air in line and sense occlusions The stroke sequence is performed by microprocessor controlled pumping algorithms which are executed by the pump PWA The piston s connecting rod follows the cam attached to the pump stepper motor The connecting rod action provides the back and forth motion of the piston against the disposable cassette diaphragm used to pump fluid Each piston stroke delivers an approximate volume of 0 22 mL 430 06579 002 Rev 7 04 4 14 O
93. ge page identifier in the part number on the cover page This change page manual is identified on the cover page as 430 06579 A01 430 06579 BO1 Updated cover and copyright page cover cover Rev 4 95 Updated Change History and i to vi i to vi Contents Section 1 Added acronyms and 1 1 to 1 4 1 1 to 1 6 abbreviations revised section numbering Section 4 Added Section 4 11 Battery Operation Overview 4 19 4 20 4 19 4 20 Technical Service Manual i 430 06579 002 Rev 7 04 CHANGE HISTORY Part Number Description of Change Section 5 Revised sections 5 1 2 5 2 1 4 and Table 5 1 moved Section 5 3 to Section 4 11 Section 6 Updated address Index Added index Updated registered trademarks Remove and Destroy Pages 5 1 to 5 12 6 1 6 2 back cover Insert Change Pages 5 1 to 5 12 6 1 6 2 1 1 to 1 4 back cover Note Stand alone change pages are identified as part number 450 06579 01 Hospira assembled manuals which contain change pages are identified on the cover page as part number 430 06579 01 430 06579 CO1 Rev 8 96 430 06579 002 Rev 7 04 Updated cover and copyright page Updated Change History and Contents Section 4 Updated Section 4 7 2 3 Watchdog Timer Section 5 Added Section 5 1 2 Pumping Mechanism Pressure Finger Check and reformatted entire section Section 6 Added new address and note in Table 6 1 Section 7 Updated torque settings
94. ice transducer If code does not clear contact Hospira 0004 Pump PWA Checksum error in ROM test pump PWA ROM failure 0008 Pump PWA Pattern error in pump Replace pump PWA PWA replacement RAM test PWA RAM test is serial number specific see CAUTION failure in Section 7 2 15 0010 Pump PWA Pump PWA watchdog timer failure timer error 0016 Invalid RTC Pump battery needs Verify AC power cord connected to AC setting recharging power Verify AC POWER indicator lit Recharge battery for 24 hours with device powered off then set RTC see Section 1 8 4 If problem persists replace battery see Section 7 2 11 0020 Control CPU Pattern errorin control Replace control PWA see RAM failure PWA CPU RAM test Section 7 2 12 0040 System RAM Patternerrorin control failure PWA program RAM test 0080 Program Checksum error in ROM failure control PWA ROM 0100 Non volatile Pattern error control RAM failure PWA non volatile RAM test 0200 Clock default Control PWA RAM failure detected incorrect clock status Technical Service Manual 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING Table 6 2 Self Test Service Codes and Corrective Actions Self Test Service Errors Possible Causes Corrective Actions Valve System unable to Verify proper seating of the cassette in encoder detect home position holster initial error of valve motor Check for any binding of the valves from Valve motor stalled foreign material
95. ine A clamped or pinched or collection bag full or clamped L1 AIR IN LINE The device has made three unsuccessful attempts to purge air from the cassette The device reverts to KVO mode until the cause of the alarm condition is corrected and the line restarted UNABLE TO PUMP AT PROGRAMMED RATE The software has determined that due to proximal and distal conditions the desired programmed rate cannot be maintained The device reverts to KVO mode POSSIBLE EMPTY CONTAINER Occurs when the volume programmed for a continuous delivery has decremented to zero The device continues to pump LOW BATTERY WARNING Battery voltage is low while operating device on battery power To clear the alarm condition connect device to AC power HOLD TIME EXCEEDED WARNING Line s placed on hold for more than two minutes MUTE TIME EXCEEDED WARNING Alarm muted for more than two minutes CALLBACK Callbacks may be programmed to alarm at the start and end of an intermittent delivery When the device detects certain alarm conditions the following occurs The device enters the Keep Vein Open KVO state or pumping stops depending on the alarm state The LCD displays the appropriate alarm message The alarm LED lights The nurse call circuit signals all alarm conditions DL D D L The IV History registers the alarm event Pressing MUTE silences the alarm for approximately two minutes If lines are placed on hold pressing RESUME restart
96. ing the power could clear the alarm The IV history also records system voltages for determining if the recommended battery maintenance in regards to charging and discharging has been followed Recorded events indicate the amount of time the device operated on battery power and the amount of time the device charged on AC power The following example shows a PUMP SERVICE CODE 0080 malfunction on power up indicating a 14 volt system error Vbatt Examination of the history shows the device was not plugged into AC power when the system was turned on The voltage event shows the battery voltage Vbatt to be 9 87 VDC This could indicate the battery was not recharged after battery operation Allowing the pump to recharge could clear the service code Review of programming and operation will indicate how long the device operated on battery PUMP SERVICE 5 FEB 93 CODE 0080 BATT 4 25PM A LOG B LOG C LOG D LOG TOTAL IV FLOW 0 0 0 0 0 ML SHEET 5V 5 00 8V 7 98 21V 0 00 Vbatt 9 87 CASSETTE 5 FEB 93 LOAD BATT 4 25 PM ABBOTT 4000 PLUS INFUSION SYSTEM IV HISTORY RECORD SYSTEM POWER UP 6 3 3 1 IV HISTORY ALARM STATUS CODES Table 6 9 IV History Alarm Status Codes describes the alarm messages that can appear in the IV History Alarm messages and service codes are described in Section 6 2 Table 6 9 IV History Alarm Status Codes Descriptions Descriptions 01 Low Battery Voltage 20 14 Volt System
97. ion bag full or container is empty Defective pump PWA Keypad not working 6 14 Unclamp all lines Verify that collection bag line and patient line are unclamped or that collection bag not full Verify container not empty Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Verify that keystrokes prime keys activate keystroke acknowledgment tones If the tones do not activate replace keypad see Section 7 2 14 Omni Flow 4000 Plus 6 3 2 6 3 TROUBLESHOOTING PROCEDURES TROUBLESHOOTING WITH THE PVT Note If an alarm code displays see Section 6 2 Alarm Messages and Service Codes The PVT can be used as a troubleshooting tool to isolate problems Table 6 7 System Test Troubleshooting describes device failures that can occur during system tests Table 6 8 PVT Troubleshooting describes device failures that can occur during other PVT tests 6 3 2 1 SYSTEM TEST TROUBLESHOOTING Table 6 7 System Test Troubleshooting describes the failures that can occur during system tests as described in Section 5 2 5 If an alarm code displays see Section 6 2 Alarm Messages and Service Codes Table 6 7 System Test Troubleshooting Symptoms Date Time information not retained Possible Causes Power supply PWA J6 to control PWA J8 cable Battery disconnected Defective control PWA Defective battery Defective power supply PWA Corrective Actions Verify cable
98. ith nonzero rate 72 Line B pumping while in off state Line C in HLD with nonzero rate 73 Line C pumping while in off state Line C in FLS with zero rate 74 Line D pumping while in off state Line C INF with zero rate 6 3 TROUBLESHOOTING PROCEDURES This section describes troubleshooting procedures for problems not associated with alarm messages A description of service codes is given in Section 6 2 Alarm Messages and Service Codes Before performing any troubleshooting procedure turn the power off then on Allow the self test to complete then proceed as follows 1 Ifa service code occurs perform the corrective action specified in one ofthe following sections Section 6 2 2 Self Test Service Codes Section 6 2 3 Pump Service Codes Section 6 2 4 Software Service Codes Section 6 2 5 System Service Codes 2 If no service code occurs but a malfunction exists carefully inspect the device for damage as described in Section 5 1 1 3 Refer to Table 6 6 Troubleshooting General Problems for symptoms and perform specified corrective action If the symptom is not found go to Step 4 4 If no service code occurs but a malfunction exists perform the following troubleshooting procedures and corrective actions specified Perform the PVT If an error occurs see Section 6 3 2 Troubleshooting with the PVT Print out or display the IV History See Section 6 3 3 Troubleshooting with IV History
99. k then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the vent screen perform the PVT in Section 5 2 Technical Service Manual 7 35 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS This page intentionally left blank 430 06579 002 Rev 7 04 7 36 Omni Flow 4000 Plus sy Section 8 SPECIFICATIONS PHYSICAL Pumping Mechanism Dimensions Weight Casing ELECTRICAL Power Requirements Fuses AC Line Leakage Power Cord Plug Battery Battery Life Battery Recharge Time Nurse Call Jack External Communications DELIVERY RATE RANGE Delivery Rate Ranges VTBI KVO Fluid Types ALARMS AND LIMITS Occlusion Pressure Air in Line Technical Service Manual Piston Diaphragm 11 25 H x 12 Wx 7 5 D inches Approximately 14 5 Ibs High density polyurethane structural foam 120 Vac 50 60 Hz 50 W Slo Blo 0 6 A 250 Vac Less than 20 microamperes Hospital grade 3 pin 12 volt sealed lead acid rechargeable Approximately fi
100. k to hold the control PWA circuitry reset which allows system voltages to stabilize and satisfies the MC68HC00O0 initialization requirements Technical Service Manual 4 9 430 06579 002 Rev 7 04 SECTION 4 THEORY OF OPERATION 4 6 1 9 AC POWER INDICATOR The power supply PWA supplies 21 Vpc signal ACAVAIL to the control PWA via P J8 ACAVAIL is the half wave rectified output of the AC transformer and activates the green AC POWER LED when present 4 6 2 PUMP PWA The pump PWA see Figure 9 8 Pump PWA Block Diagram performs the following functions o Monitors system critical voltage Generates motor drive voltage Primes solenoid control Monitors pressure transducer Senses valve and pump motor shaft position Provides mechanical alignment of optical switches Senses cassette locked unlocked Processes commands from the control PWA Forwards status information to the control PWA 4 6 2 1 MICROPROCESSOR AND CLOCK The pump PWA central processing element U14 HD63A03R is an eight bit microprocessing unit with 128 bytes of internal RAM a serial communications interface parallel I O ports and a multi function timer Since the data byte and low order address byte are multiplexed a latch U19 holds the low order byte for microprocessor operations The microprocessor uses a 4 9152 MHz crystal Y1 and internal circuitry to provide timing functions The microprocessor generates a 1 2288 MHz clock for
101. lation Damaged pressure interface Corrective Actions Reprime cassette to clear any air out of cassette Unclamp all input lines and the collection bag line Empty collection bag Clean the holster and inspect the pressure interface nose area Replace container Replace cassette and perform cassette test again Clean holster Clean holster If test continues to fail contact Hospira Contact Hospira When an infusion is attempted the device frequently clears air and or sounds an air in line occlusion alarm Empty container clamped lines or full collection bag Defective cassette Foreign material in pressure interface area Defective pressure sensor Check for empty container clamped lines or a full collection bag Perform cassette test to determine if cassette is defective see Table 6 8 Clean foreign material from pressure interface area Turn power off then on to reset device If condition does not clear contact Hospira Alarm message on the display reads CASSETTE UNLOCKED POSSIBLE FREE FLOW LOCK RESUME OR CLAMP LINES STOP Cassette lever is sticking Cassette lock switch circuit is open Verify that cassette locking lever is in the LOCKED position and is fully seated Turn power off then on to reset device If condition does not clear contact Hospira With power on no display or lights appear continuous alarm sounds 5 volt supply not working Turn power off
102. le to distal end of patient line Press PRIME PATIENT LINE for line A to prime patient line and needle Press ESCAPE to return to base screen Press SPECIAL FUNCTION 9 ENTER to clear the IV flow sheet Place the needle into a 25 mL graduated cylinder Enter the following program Press SPECIAL FUNCTION 8 Press YES NO to toggle YES for PREPROGRAM FUNCTION SELECTION Press ENTER Press INTERMITTENT INFUSION on line B Set EACH DOSE field to 4 mL Press NEXT Set for 2 minutes Press ENTER Press YES NO to toggle NO for CALLBACK SYRINGE and DILUTION fields Press ENTER Press ENTER at the start time screen The base screen displays and line B status indicates DLY Enter the same program for lines C and D Status for lines B C and D indicate DLY on the base screen Enter the following infusion program for line A Press SPECIAL FUNCTION 2 Press LINE STATUS for line D to enter D in FLUSH AFTER field Press ENTER Set FLUSH VOLUME field to 8 mL Press NEXT Set for 2 minutes Press ENTER The base screen displays and line A status indicates OFF Press RESUME ENTER to begin delivery Line B begins pumping followed by line C then line D and completes with a flush from line A Measure the collected volume Press V FLOW SHEET and compare the collected volume to IV flow sheet value Collected volume should be within 1 2 mL of the IV flow sheet Press ENTER Press SPECIAL FUNCTION
103. losure Route the ribbon cables under the sheetmetal top strap and assure that the cables are not pinched between the pump PWA and the control PWA 7 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats 8 Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the LCD perform the PVT in Section 5 2 F LIQUID CRYSTAL i DISPLAY hg 4 40 x 1 4 PHILLIPS PAN HEAD SCREW 4 2 PIN CONNECTOR 14 PIN CONNECTOR CONTROL PWA 03K02017 Figure 7 9 LCD Replacement 430 06579 002 Rev 7 04 7 16 Omni Flow 4000 Plus 7 2 14 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES KEYPAD REPLACEMENT Recommended tools for this procedure are as follows set of nutdrivers No 2 Phillips screwdriver electrical tape lint free cloth and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Assembly Keypad Nut 4 40 Zinc Small Washer Flat 4 250 OD 125 026 Thk Washer 124 x 206 x 015 St
104. lower right corner of the base screen display indicate changes from the factory default settings Clean holster Turn power off then on to reset device FULL COLLECTION BAG OR OCCLUSION ON LINE A Check all lines for closed clamps or kinks Check capacity of collection bag Verify that IV bags are a minimum of 17 inches above the device Clean holster Perform the Transducer Offset Adjustment procedure see Section 7 2 3 Turn power off then on to reset device AIR IN LINE OR OCCLUSION LINE A Check for air in cassette Check line A for closed clamp or kinks Check IV container volume on line A Verify that IV bags are a minimum of 17 inches above the device Turn power off then on to reset device AIR IN LINE OR OCCLUSION Lines B C D Check for air in cassette Check alarm line for closed clamp or kinks Check IV container volume on alarm line Verify that IV bags are a minimum of 17 inches above the device Turn power off then on to reset device UNABLE TO PUMP AT PROGRAMMED RATE Check patient line for closed clamp or kinks Check all lines for closed clamps or kinks Verify that IV bags are a minimum of 17 inches above the device Note Pending alarms must be cleared before reprogramming over line A if an error or alarm causes line A to revert to KVO Turn power off then on to reset device POSSIBLE EMPTY CONTAINER Check programmed container volume Turn power off then on to reset d
105. lowing any repair procedure performance verification testing 5 1 ROUTINE MAINTENANCE Routine maintenance consists of basic inspection and cleaning procedures As a minimum requirement inspect and clean the device after each use In addition establish a regular cleaning schedule for the device Note It is recommended that the device be returned to Hospira for service at a maximum five year interval or immediately following significant spillage which could have entered the device 5 1 1 INSPECTION Inspect the device periodically for signs of defects such as worn accessories broken instrument connections or damaged cables In addition inspect the device after repair or during cleaning Replace any damaged or defective external parts See Section 5 2 2 Inspection for a detailed list of areas to be inspected 5 1 2 CLEANING The following procedures are designed to maintain the device sustain system longevity and promote trouble free instrument operation Follow hospital protocol for establishing the device cleaning schedule WARNING DISCONNECT THE DEVICE FROM AC POWER PRIOR TO CLEANING THE INSTRUMENT FAILURE TO COMPLY WITH THIS WARNING COULD RESULT IN ELECTRICAL SHOCK CAUTION Do not immerse the device in liquids Immersion could damage the device Do not allow liquids to enter the device electronics compartment Technical Service Manual 5 1 430 06579 002 Rev 7 04 SECTION 5 MAINTENANCE AND SERVICE TESTS
106. m for a maximum of two minutes The red alarm light remains on After two minutes the audible alarm is reactivated Technical Service Manual 6 1 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING Note In CALLBACK mode or if a faulty cassette alarm occurs press MUTE twice to completely cancel the alarm In all other alarm conditions press MUTE twice to display the base screen 2 Observe the display and determine the cause of the alarm using the information in the tables in this section Note It is possible to have multiple alarms Each alarm type is prioritized based on severity and chronology The current alarm visual display is overwritten but not lost if a subsequent higher priority alarm occurs The preceding alarm is placed on the alarm stack based on priority and time of occurrence If multiple alarms of the same priority exist such as multiple upstream occlusions the alarms are displayed in reverse chronological order the most recent alarm first 3 Correct the identified problem and press RESUME ENTER to resume all infusions If there are more alarm messages display stacked alarms by priority As each stacked alarm displays an audible alarm tone of two seconds duration sounds This tone calls attention to the alarm condition but does not require pressing MUTE to silence the tone CAUTION If excessive alarms continue contact Hospira 6 2 1 OPERATOR ALARM MESSAGES Operator alarm messages are co
107. m accessing the IC and altering time date data during the power transition The circuit performs similarly during the system off to on transition 4 6 1 4 PERIPHERAL ACCESS Microprocessor I O is performed through several peripheral interface adapters PIA Each PIA contains two bi directional data busses and four control lines The microprocessor programs the functional configuration of each PIA during system initialization PIA U4 supplies the nurse call signal that enables the power supply PWA to drive the nurse call relay U4 provides three signals used by the alarm control circuitry to effect alarm tone U4 also controls the status LEDs for lines C and D 430 06579 002 Rev 7 04 4 8 Omni Flow 4000 Plus 4 6 PWA FUNCTIONAL DESCRIPTION PIA UG interfaces the microprocessor to the LCD module by supplying the enable register select read write strobe 8 data bits and the LCD backlight control signal U6 also controls the status LEDs for lines A and B One output of U6 controls the activation of the serial communications driver IC PIA U18 provides keypad interface and controls battery and alarm status LEDs SERIAL COMMUNICATIONS The control PWA has two HD63A50 asynchronous communication interface adapters ACIA U24 and U34 Both ACIAs are accessed via the address decoder U20 The clock for both ACIAs is supplied by the microprocessor signal ECLK the main processor clock divided by 10 Dialog between the two ACIAs and the micropro
108. m tone not cycling on and off properly or responding to volume control Defective control PWA Defective power supply PWA Replace control PWA see Section 7 2 12 Replace power supply PWA see Section 7 2 16 Display does not count Defective Real Time Replace control PWA see correctly Clock Section 7 2 12 Alarm tone not sounding Pump PWA J16to control Verify cable connected Replace cable continuously or PWA J9 cable responding to the pressing of a key Defective control PWA Defective pump PWA Replace control PWA see Section 7 2 12 Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Cassette lock lever not responding properly 6 3 2 2 Defective pump PWA Cassette lock lever not seating PVT TROUBLESHOOTING Replace pump PWA PWA replacement is serial number specific see CAUTION in Section 7 2 15 Verify cassette lock leveris in the position and is fully seated Table 6 8 PVT Troubleshooting describes failures that can occur during other PVT tests If an alarm code displays see Section 6 2 Alarm Messages and Service Codes Table 6 8 PVT Troubleshooting Test Failures Collection Solenoid Test or Patient Solenoid Test 430 06579 002 Rev 7 04 Possible Causes Pump PWA J18 to pump mechanism cable Defective pump PWA Binding valve due to fluid spill accumulation Corrective Actions Verify cable connected R
109. machine is not operating correctly or has loose or defective connections to its sensing electrodes these artifacts may be accentuated so as to simulate actual physiological signals To determine if the abnormality in the monitoring equipment is caused by the device instead of some other source in the environment set the device so that it is temporarily not delivering fluid Disappearance of the abnormality indicates that it was probably caused by electronic noise generated by the device Proper setup and maintenance of the monitoring equipment should eliminate the artifact Refer to the appropriate monitoring system documentation for setup and maintenance instructions 1 8 INSTRUMENT INSTALLATION PROCEDURE CAUTION Product damage may occur unless proper care is exercised during unpacking and installation The battery may not be fully charged upon receipt Do not place the device in service if it fails the self test CAUTION Infusion pump performance may be degraded by electromagnetic interference EMI from devices such as electrosurgical units cellular phones pagers and 2 way radios Operations of the infusion pump in such conditions should be avoided The instrument installation procedure consists of unpacking inspection and self test 1 8 1 UNPACKING Inspect the infusion pump shipping container as detailed in Section 1 8 2 Inspection Use care when unpacking the Omni Flow 4000 Plus Retain the packing slip and save all packing ma
110. ment then proceed as follows 1 Disconnect the device from AC power 2 Separate the top and bottom enclosures as described in Section 7 2 10 3 Using the nutdriver remove the two hex head screws that mount the battery clamp assembly to the pump assembly Remove the battery clamp assembly 4 Remove the defective battery Dispose of the battery in accordance with local battery disposal practices Technical Service Manual 7 11 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 5 Install the replacement battery into the bottom enclosure Verify that the red positive lead is oriented towards the upper left corner of the bottom enclosure 6 Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Route the ribbon cables under the sheetmetal top strap and assure that the cables are not pinched between the pump PWA and the control PWA 7 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not self seat loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats To verify successful replacement of the battery perform the PVT in Section 5 2 RED WIRE 6 32 x 5 16 HEAD SCREW 2 BATTERY BATTERY CLAMP ASSEMBLY BLACK WIRE lt
111. mni Flow 4000 Plus 4 7 MECHANISM FUNCTIONAL DESCRIPTION PATIENT LINE FOLLOWER PATIENT VALVE INPUT VALVES A 03K02005 Figure 4 1 Input Valves E a a BLOCKING CAM aa OUTPUT CAM EUN 4 03K02006 Figure 4 2 Valve Cam Assembly Technical Service Manual 4 15 430 06579 002 Rev 7 04 SECTION 4 THEORY OF OPERATION 4 8 DISPOSABLE CASSETTE DESCRIPTION The pump operates on a fluid displacement principle to deliver fluid volumetrically Major elements of the cassette are shown in Figure 4 3 Disposable Cassette The valve seats are normally open The mechanism seals the valve seats of the cassette as the cassette is locked into place Each valve is opened or closed by valve pins which are pushed into or pulled out of the valve seats of the flexible diaphragm enclosed in the cassette The position of the cassette in the holster is determined and maintained by the pressure interface nose and the alignment pin of the mechanism see Figure 4 4 Cassette Holster The alignment pin positions and holds the cassette for proper engagement of the pressure interface as the cassette is being locked into place The pressure interface finger contacts the pressure interface diaphragm and transmits cassette pressure to the pressure transducer in the mechanical assembly In normal pump operation only one of the four inputs can be opened at a given time The fluid travels along a common fluid channel to the pumping chamber shown as
112. move the six slotted screws that mount the power supply PWA to the motor base mechanism chassis see Figure 7 15 Remove the power supply PWA and install the replacement PWA Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify that the ground strap lug remains parallel to the side of the top enclosure and faces away from the bottom enclosure Route the ribbon cables under the sheetmetal top strap and assure that the cables are not pinched between the pump PWA and the control PWA 430 06579 002 Rev 7 04 7 22 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES 13 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats 14 Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the power supply PWA perform the PVT in Section 5 2 6 32 x 5 16 i 6 32 x 5 16 PHILLIPS HEX HEAD SCREW PAN HEAD SCREW WITH WASHER SLOTTED WITH WASHER
113. nclosures as described in Section 7 2 10 Remove the battery as described in Section 7 2 11 Remove the pump assembly as described in Section 7 2 16 oa AeA ON Label wires and connectors on the RS 232 connector then cut the shrink wrap and unsolder the wires Oo Using the nutdriver remove the two hex nuts and the two standoffs attaching the RS 232 connector to the bottom enclosure see Figure 7 17 Remove the defective connector and install the replacement connector 7 Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify all cables are freely extended and not pinched 8 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats 9 Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the RS 232 connector perform the PVT in Section 5 2 430 06579 002 Rev 7 04 7 26 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES POWE
114. nclosures as described in Section 7 2 10 Remove the fuses as described in Section 7 2 5 Remove the battery as described in Section 7 2 11 Remove the pump assembly as described in Section 7 2 16 aa amp WN For units with equipotential posts only Using a nutdriver remove the two 3 8 inch hex nuts attaching the equipotential post to the bottom enclosure and three ground wires see Figure 7 16 Remove the equipotential post 7 Remove two lock washers two flat washers two hex nuts and three ground wires from the switch panel stud see Figure 7 19 8 Using the Phillips screwdriver remove the two screws securing the AC line filter to the rear housing 9 Remove the defective AC line filter and install the replacement 10 Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify all cables are freely extended and not pinched 11 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats 12 Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date
115. ned or cleared and system defaults can be changed LCD messages prompt the user through cassette installation priming and cassette test LCD messages prompt the user through a sequence of screens for system programming refer to the System Operating Manual for detailed instructions 430 06579 002 Rev 7 04 4 2 Omni Flow 4000 Plus 4 2 ALARM CONDITIONS 4 1 2 4 CASSETTE TEST After priming the cassette and before programming the device a cassette test is initiated The test begins by pumping into the collection bag from line A followed by a gravity flow from line A to the collection bag This sequence breaks up air pockets and moves any air in the cassette towards the collection bag outlet The device then draws fluid from line A and closes all valves The piston advances into the cassette until the cassette is pressurized The device then checks for a decay in pressure Ifit detects a drop in pressure a POSSIBLE FAULTY CASSETTE message displays with prompts to reprime or replace the cassette Note A cassette test should be performed each time the cassette is replaced 4 2 ALARM CONDITIONS The alarm and warning conditions for the Omni Flow 4000 Plus include the following CASSETTE UNLOCK Cassette lock knob in unlocked position PATIENT LINE OCCLUSION Pressure at the distal end of the patient line has reached or exceeded the maximum occlusion pressure programmed FULL COLLECTION BAG OR OCCLUSION ON LINE A L
116. ol PWA 11 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats 12 Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the rear housing assembly perform the PVT in Section 5 2 Technical Service Manual 7 25 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 7 2 18 SERIAL RS 232 CONNECTOR REPLACEMENT Recommended tools for this procedure are as follows scissors soldering iron a 3 16 inch nutdriver flat blade screwdriver No 1 and No 2 Phillips screwdrivers and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Assembly Cable Internal Comm Printer Hardware Kit RS 232 Note The following procedure can also be used to replace the 25 pin connector found on some devices To replace the serial RS 232 connector refer to Figure 7 17 Switch Panel RS 232 Connector and Bag Hanger then proceed as follows Disconnect the device from AC power Separate the top and bottom e
117. operly seats Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the pump PWA perform the PVT in Section 5 2 430 06579 002 Rev 7 04 7 20 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES PUMP PWA 1 y e E 4 40 x 1 4 PHILLIPS Da PAN HEAD SCREW 5 n n x TO CONTROL PWA 03K02020 Figure 7 12 Pump PWA J17 446 J20 PUMP PWA PUMP ASSEMBLY 03K02042 Figure 7 13 Pump PWA Connections Technical Service Manual 7 21 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 7 2 16 POWER SUPPLY PWA REPLACEMENT Recommended tools for this procedure are as follows a 5 16 inch nutdriver flat blade screwdriver No 1 and No 2 Phillips screwdrivers and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Power Supply Screw 6 32 x 5 16 Hex Head Slotted With Washer Screw 6 32 x 5 16 Pan Head Phillips With Washer Screw 6 32 x 5 8 Hex Head Slotted With Washer Screw 6 32 x 1 Hex Head Slotted With Washer To replace the power supply PWA refer to Figure 7 14 Pump Assembly and Rear Housing and Figure 7 15 Power Supply PWA and Motor Base Mechanism then proceed as follows
118. osition If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the keypad perform the PVT in Section 5 2 E a TAPE 4 FLAT WASHER ae 4 40 1 8 SLOTTED SCREW ESD GROUNDING STRIP lt gt 03K02018 Figure 7 10 Keypad ESD Grounding Strip Bottom View 430 06579 002 Rev 7 04 7 18 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES ESD GROUNDING KEYPAD GROUNDING STRIP 14 PINCONNECTOR DISPLAY WINDOW PIN STRIPE TAPE KEYPAD BONDING SURFACE 03K02019 Figure 7 11 Keypad Replacement 7 2 15 PUMP PWA REPLACEMENT SERIAL NUMBER SPECIFIC CAUTION This replacement procedure is for devices with the following serial numbers four digit serial numbers 3290 and above all other serial numbers above 11133 For devices with serial numbers outside these ranges contact Hospira Recommended tools for this procedure are as follows a 1 16 inch Allen wrench flat blade screwdriver No 2 Phillips screwdriver and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are PWA Pump Therapist Screw 4 40 x 1 4 Pan Head Phillips Technical Service Manual 7 19 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS To replace the pump PWA refer to Figure 7 12 Pump PWA and Figure 7 13
119. osure until the knob properly seats Determine if the serial number and date time information need to be restored by turning the ON CHARGE switch to the ON position If the serial number needs to be restored the Set Serial Number screen will display Technical Service Manual 7 13 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS Enter the device serial number as labeled on the rear of the device Ifthe date time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the control PWA or top enclosure assembly perform the PVT in Section 5 2 ROUND STRAP 6 32 x 5 16 SLOTTED nen HEAD SCREW WITH WASHER GROUND STRAP LUG BATTERY WIRES Do CONNECTOR 10 PIN CONNECTOR CONNECTOR pe E 03K02015 Figure 7 7 Top Enclosure Connectors 430 06579 002 Rev 7 04 7 14 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES 6 32 x 5 16 SLOTTED GROUND STRAP HEX HEAD 7 SCREW WITH y E WASHER 4 v T WHITE INSULATION LAYER 6 32 x 516 PHILLIPS 4 PAN HEAD SCREW H WITH WASHER 14 PIN CONNECTOR LIQUID CRYSTAL DISPLAY GROUNDING STRIP ESD GROUNDING STRIP DISPLAY WINDOW 03K02016 Figure 7 8 Top Enclosure Assembly 7 2 13 LCD REPLACEMENT The LCD assembly is replaceable for pumps with final assemblies 850 06300 013 and below only
120. ottom enclosures as described in Section 7 2 10 Remove the battery as described in Section 7 2 11 Remove the pump assembly as described in Section 7 2 16 Using the nutdriver remove the two hex nuts attaching the equipotential post to the bottom enclosure and three ground wires see Figure 7 16 Remove the equipotential post and install the replacement post 430 06579 002 Rev 7 04 7 28 Omni Flow 4000 Plus 6 7 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify all cables are freely extended and not pinched Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the equipotential post perform the PVT in Section 5 2 7 2 20 POWER CONNECTOR PLATE ASSEMBLY REPLACEMENT Note The power connector plate is replaceable on pum
121. oubleshooting the Omni Flow 4000 Plus 6 1 TECHNICAL ASSISTANCE For technical assistance product return authorization and to order parts accessories or manuals within the United States contact Hospira Technical Support Operations 1 800 241 4002 For additional technical assistance including Technical Service Bulletins technical training and product information visit the website at www hospira com Send all authorized prepaid returns within the United States to the following address Hospira Inc Technical Support Operations 755 Jarvis Drive Morgan Hill California 95037 For technical assistance product return authorization and to order parts accessories or manuals from outside the United States contact the nearest Hospira sales office 6 2 ALARM MESSAGES AND SERVICE CODES Under certain alarm conditions the device stops operating generates an audible alarm activates a red alarm light on the keypad and displays an alarm message on the display screen There are two categories of alarms alarm messages that can be cleared by the operator and service codes that require qualified service personnel Note Alarm events are added to the IV History which retains a minimum of 48 hours of the most recent historical data To aid in alarm analysis the IV History can be reviewed or printed see the System Operating Manual If an alarm sounds proceed as follows 1 Press MUTE to temporarily silence the audible alar
122. padded surface Using the Phillips screwdriver remove the four screws that attach the top and bottom enclosures see Figure 7 4 Set the device upright and lift off the top enclosure Lay the top enclosure with the keypad face down on a padded surface to prevent scratching Keep the ribbon cables and the ground cable attached Disconnect the red wire positive and the black wire negative from the battery see Figure 7 6 6 32 x 2 3 4 PHILLIPS PAN HEAD SCREWS 2 CG 6 32 x 3 4 PHILLIPS HEAD SCREWS 2 03K02013 Figure 7 4 Enclosure Screw Placement 430 06579 002 Rev 7 04 7 10 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES STEPPED SET SCREW CASSETTE LOCKING KNOB TOP ENCLOSURE A 40 x 1 4 PAN HEAD SCREW 5 CONTROL PUMP PWA CABLE ASSEMBLY 6 32 5 16 HEX HEAD WITH WASHER BOTTOM ENCLOSURE 6 32 X 3 4 PAN HEAD SCREW 2 6 32 x 2 3 4 PAN HEAD 03K02034 SCREW 2 Figure 7 5 Top and Bottom Enclosure Separation 7 2 11 BATTERY REPLACEMENT Recommended tools for this procedure are as follows 1 16 inch Allen wrench 1 4 inch nutdriver flat blade screwdriver No 2 Phillips screwdriver and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Battery Assembly Battery Clamp Screw 6 32 x 5 16 Hex Head Slotted with Washer To replace the battery refer to Figure 7 6 Battery Replace
123. period of one year after purchase and b the replaceable battery shall be free from defects in material and workmanship under normal use and service for a period of 90 days after purchase Hospira makes no other warranties express or implied as to merchantability fitness for a particular purpose or any other matter Purchaser s exclusive remedy shall be at Hospira s option the repair or replacement of the product In no event shall Hospira s liability arising out of any cause whatsoever whether such cause be based in contract negligence strict liability other tort or otherwise exceed the price of such product and in no event shall Hospira be liable for incidental consequential or special damages or losses or for lost business revenues or profits Warranty product returned to Hospira must be properly packaged and sent freight prepaid The foregoing warranty shall be void in the event the product has been misused damaged altered or used other than in accordance with product manuals so as in Hospira s judgment to affect its stability or reliability or in the event the serial or lot number has been altered effaced or removed The foregoing warranty shall also be void in the event any person including the Purchaser performs or attempts to perform any major repair or other service on the product without having been trained by an authorized representative of Hospira and using Hospira documentation and approved spare parts For pu
124. proceed as follows 1 Disconnect the device from AC power 2 Using the flat head screwdriver remove the two screws holding the power cord bracket in place and remove the power cord bracket 3 Disconnect the AC power cord from its receptacle 4 Connect the replacement AC power cord into the AC power cord receptacle 5 Reinstall the power cord bracket To verify successful replacement of the AC power cord perform the PVT in Section 5 2 Technical Service Manual 7 5 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS AC POWER CORD A gt POWER CORD BRACKET 6 32 x 3 16 HEX HEAD SCREW WITH WASHER 2 0 6 A FUSE 2 FUSE DRAWER 3 03K02011 Figure 7 2 Power Cord and Fuse Replacement 7 2 5 FUSE REPLACEMENT Recommended tool for this procedure is a small flat blade screwdriver The replacement parts for this procedure are Fuse 0 6 A 250V Slo Blo Drawer Fuse 2 Pole To replace the fuse refer to Figure 7 2 then proceed as follows 1 Remove the AC power cord and retainer bracket as described in Section 7 2 4 2 Remove the plastic fuse drawer located directly below the AC power receptacle Insert the screwdriver blade on one side of the locking tabs on each side of the fuse drawer Press the tab toward the center of the fuse drawer to release that side The fuse drawer will move slightly outward when released from one side Insert the screwdriver blade on the other locking
125. ps with final assemblies 850 06300 007 and below For pumps with final assemblies 850 06300 008 and higher refer to Section 7 2 21 AC Line Filter Assembly Replacement Recommended tools for this procedure are as follows scissors soldering iron set of nutdrivers flat blade screwdriver No 1 and No 2 Phillips screwdrivers and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Assembly Power Connector Plate Assembly Ground Strap Switch Panel Comm Nut 6 32 Hex Steel Cad Zinc Plated Washer Flat 6 0 032 Thick Steel Washer Lock 6 0 018 Thick Internal Tooth To replace the power connector plate assembly refer to Figure 7 16 Rear Housing Components Figure 7 18 Power Connector Plate and Figure 7 19 AC Line Filter Ground Lug Placement then proceed as follows Qu Disconnect the device from AC power Separate the top and bottom enclosures as described in Section 7 2 10 Remove the fuses as described in Section 7 2 5 Remove the battery as described in Section 7 2 11 Remove the pump assembly as described in Section 7 2 16 For units with equipotential posts only Using a nutdriver remove the two 3 8 inch hex nuts attaching the equipotential post and three ground wires to the bottom enclosure see Figure 7 16 Remove the equipotential post Label the wires and connectors on the nurse call jack see Figure 7 16 then cut the shrink
126. r refer to Figure 7 17 then proceed as follows Disconnect the device from AC power Separate the top and bottom enclosures as described in Section 7 2 10 Remove the battery as described in Section 7 2 11 Remove the pump assembly as described in Section 7 2 16 Oi WN Using a nutdriver remove the hex nut attaching the bag hanger and two ground straps to the bottom enclosure see Figure 7 17 Remove the defective bag hanger and install the replacement hanger 6 Reassemble the device in the exact reverse order of its disassembly Tighten the screws attaching the top and bottom enclosures to 10 1 inch pounds Note Verify all cables are freely extended and not pinched 7 Verify top enclosure alignment by placing a cassette in the holster Lock then unlock the cassette locking knob Verify that the knob self seats in the locked position If the knob does not seat then loosen the screws on the bottom enclosure and readjust the top enclosure until the knob properly seats 8 Determine if the date and time information needs to be restored by turning the ON CHARGE switch to the ON position If the date and time information needs to be restored the date time screen will display immediately after completion of the self test To verify successful replacement of the bag hanger perform the PVT in Section 5 2 430 06579 002 Rev 7 04 7 34 Omni Flow 4000 Plus 7 2 24 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES VE
127. r a procedure 430 06579 002 Rev 7 04 1 2 Omni Flow 4000 Plus 1 3 COMPONENT DESIGNATORS 1 3 COMPONENT DESIGNATORS Components are indicated by alpha numeric designators as follows Battery BT Diode D Resistor R Capacitor Fuse F Switch SW Crystal Y Integrated Circuit U Transistor Q The number following the letter is a unique value for each type of component e g R1 R2 Note Alpha numeric designators may be followed with a dash number that indicates a pin number for that component For example U15 13 is pin 13 of the encoder chip U15 on the interface PWA 1 4 ACRONYMS AND ABBREVIATIONS Acronyms and abbreviations used in this manual are as follows A Ampere AC Alternating current ACIA Asynchronous communication interface adapter A D Analog to digital DC Direct current DLY Delay DMM Digital multimeter DPM Digital pressure meter ECG Electrocardiogram EEG Electroencephalogram EL Electroluminescent EMG Electromyogram EPROM Erasable programmable read only memory ESD Electrostatic discharge ETO Ethylene oxide FET Field effect transistor Hz Hertz IC Integrated circuit VO Input output IV Intravenous KHz Kilohertz Technical Service Manual 1 3 430 06579 002 Rev 7 04 SECTION 1 INTRODUCTION KVO Keep vein open LCD Liquid crystal display LED Light emitting diode mA Milliampere MHz Megahertz mL Milliliter MOSFET Metal oxide semiconductor field effect transistor mV Millivolt NMI Non maskable interr
128. r interface cable assembly proceed as follows 1 Disconnect the device and printer from AC power 2 Using the flat blade screwdriver loosen the two slotted screws on the serial RS 232 printer interface cable connector at the rear of the device Loosen the two screws on the cable connector end attached to the printer Remove the defective printer interface cable assembly 3 Install the replacement printer interface cable assembly Secure the assembly by tightening the screws on the device and printer 4 Connect the device and printer to AC power To verify successful replacement of the printer interface cable perform the PVT in Section 5 2 Technical Service Manual 7 9 430 06579 002 Rev 7 04 SECTION 7 REPLACEABLE PARTS AND REPAIRS 7 2 10 SEPARATING THE TOP AND BOTTOM ENCLOSURES Recommended tools for this procedure are as follows 1 16 inch Allen wrench and No 2 Phillips screwdriver The replacement parts for this procedure are Screw 6 32 x 2 3 4 Pan Head Phillips Screw 6 32 x 3 4 Pan Head Phillips To separate the top and bottom enclosures refer to Figure 7 4 Enclosure Screw Placement Figure 7 5 Top and Bottom Enclosure Separation and Figure 7 6 Battery Replacement and proceed as follows 1 2 Disconnect the device from AC power Using the Allen wrench remove the set screw securing the cassette locking knob to the shaft see Figure 7 5 and remove the knob Turn the pump upside down on a
129. r s recommendation Sporicidin Sporicidin International Per manufacturer s recommendation Household Bleach Various Per hospital procedures do not exceed one part bleach in ten parts water 430 06579 002 Rev 7 04 5 2 Omni Flow 4000 Plus 5 2 PERFORMANCE VERIFICATION TEST 5 1 3 SANITIZING Sanitize the external surfaces of the device using a cleaning solution listed in Table 5 1 Note Not all cleaning solutions are sanitizers Check product labeling CAUTION Do not sterilize the device using heat steam ethylene oxide ETO or radiation These methods may cause the device to malfunction 52 PERFORMANCE VERIFICATION TEST The performance verification test PVT consists of the tests described in the following sections The PVT can be used for diagnostic purposes during the troubleshooting of a malfunctioning infusion system The PVT should be used for performance verification before a infusion system is placed back in service after repair If any malfunction is detected as a result of the PVT refer to Table 6 7 System Test Troubleshooting and Table 6 8 PVT Troubleshooting Note The PVT must be performed exactly as described in this manual to assure effective and reliable product evaluation information 5 2 1 EQUIPMENT REQUIRED The PVT requires the following equipment or equivalents o 20 gauge needle 1 5 inches B D P N 305176 Graduated cylinder 25 mL with 0 2 mL graduations Type A
130. ractitioner WARNING POSSIBLE EXPLOSION HAZARD EXISTS IF THE INFUSION SYSTEM IS USED IN THE PRESENCE OF FLAMMABLE ANESTHETICS Patents pending Omni Flow 4000 Plus and LifeCare are registered trademarks of Hospira Coverage HB is a trademark of Steris Corporation Manu Klenz is a registered trademark of Steris Corporation Dispatch and Precise are trademarks of Caltech Industries Formula C is a trademark of JohnsonDiversey Sporicidin is a registered trademark of Sporicidin International X acto is a registered trademark of Hunt Corporation Fluke is a registered trademark of Fluke Biomedical Velcro is a registered trademark of Velcro USA Inc Y Equipment providing an adequate degree of protection against electrical shock and suitable for application to Type CF patient IPX1 Drip Proof Medical Equipment Class 1 Mains supply equipment using protective earth CSA is a registered trademark of the Canadian Standards Association The use of NRTL C adjacent to the CSA mark indicates that the product has been certified by CSA to UL2601 U S and Canadian standards CSA has been accredited by the U S Occupational Safety and Health CSA 601 Administration OSHA as a Nationally Recognized Test NRTL C US Laboratory NRTL Printed in USA Hospira Inc Lake Forest O Illinois 60045 USA Technical Service Manual 430 06579 002 Rev 7 04
131. revision levels 3 Printer Pattern Test see Section 5 2 13 Tests printer settings and cable 4 Set up LT4 Long Term Flow Rate Test Programs for long term accuracy testing 5 Serial Port Loopback Test Performs serial port loopback test 6 Set up LT3 Long Term Test Programs for LT3 long term test 9 System Tests see Section 5 2 5 Sets up functional testing including keypad LEDs and cassette lock detect L1 011 11 Cassette Test even while pumping see Section 5 2 8 Performs on line cassette test IV FLOW SHEET Display purge totals Display purge totals for all lines AM PM Print IV Flow Sheet Prints IV flow sheet requires AC power CLEAR ENTRY Clear IV History Resets IV history LAST Display unformatted A D readings Displays unformatted system voltage readings NEXT Technical Service Manual Display pressure and voltage readings see Section 6 3 4 1 Displays formatted system voltages and cassette pressures 430 06579 002 Rev 7 04 SECTION 6 TROUBLESHOOTING 6 3 4 1 MONITORING CASSETTE PRESSURE AND SYSTEM VOLTAGES Press SPECIAL FUNCTION NEXT to display cassette pressure and system voltages see Table 6 11 Cassette Pressure and System Voltages The following set of values displays on the screen X gt P1 X xx P3 x xx P4 P5 V 5V 5 00 8V 8 07
132. rposes of the preceding sentence major repair or other service means any repair or service other than the replacement of accessory items such as batteries flow detectors detachable AC power cords and patient pendants In providing any parts for repair or service of the product Hospira shall have no responsibility or liability for the actions or inactions of the person performing such repair or service regardless of whether such person has been trained to perform such repair or service It is understood and acknowledged that any person other than a Hospira representative performing repair or service is not an authorized agent of Hospira Technical Service Manual 2 1 430 06579 002 Rev 7 04 SECTION 2 WARRANTY This page intentionally left blank 430 06579 002 Rev 7 04 2 2 Omni Flow 4000 Plus Section 3 SYSTEM OPERATING MANUAL copy of the Omni Flow 4000 Plus System Operating Manual is included with every device Insert a copy here for convenient reference If a copy of the system operating manual is not available contact Hospira see Section 6 1 Technical Assistance Technical Service Manual 3 1 430 06579 002 Rev 7 04 SECTION 3 SYSTEM OPERATING MANUAL This page intentionally left blank 430 06579 002 Rev 7 04 3 2 Omni Flow 4000 Plus Section 4 THEORY OF OPERATION This section describes the Omni Flow 4000 Plus theory of operation Related drawings are provided in Section 9 Drawings The
133. rrected by the operator using the corrective action procedures described in the System Operating Manual If the operator cannot clear the alarm the device should be removed from service Table 6 1 Operator Alarm Messages and Corrective Actions describes both operator level and service level corrective actions Note Ifanalarm persists after the corrective actions are performed contact Hospira Table 6 1 Operator Alarm Messages and Corrective Actions Alarm Messages Corrective Actions CASSETTE UNLOCKED Verify that the cassette lever is in the locked position and pushed POSSIBLE GRAVITY down FLOW Remove and clean cassette locking knob and knob shaft Turn power off then on to reset device xxxxx SERVICE CODE Turn power off then on to reset device Restore previous SERVICE REQUIRED programming and press RESUME then ENTER If service code persists refer to Section 6 2 2 through Section 6 2 5 for service code corrective actions 430 06579 002 Rev 7 04 6 2 Omni Flow 4000 Plus Table 6 1 Alarm Messages 6 2 ALARM MESSAGES AND SERVICE CODES Operator Alarm Messages and Corrective Actions Corrective Actions OCCLUSION IN PATIENT LINE Check patient line for closed clamp or kinks Check for appropriate occlusion pressure setting Note Low occlusion pressure settings may cause patient line occlusion alarms when infusing fluids through microbore tubing at higher rates Two asterisks in the
134. s pumping Technical Service Manual 4 3 430 06579 002 Rev 7 04 SECTION 4 THEORY OF OPERATION 4 3 SYSTEM MALFUNCTION DETECTION When the system detects a malfunction causing a system failure one of the following service codes activates a Self test service code activates when system detects malfunction during self test Pump service code activates when system detects malfunction while device is on or infusing Software service code activates when system detects an unexpected condition in the main program sequence or process System service code activates when system detects an unexpected line status condition while infusing A service code condition causes the following to occur DL L D L O All infusions stop if device is pumping Service code displays on LCD IV history registers the service code Nurse call relay activates Audible alarm sounds Alarm LED lights To recover from a service code condition cycle device power If the condition persists see Section 6 Troubleshooting 4 4 DATA RETENTION Significant data required for device operation and historical data are retained in the control PWA and are described in the following sections 430 06579 002 Rev 7 04 4 4 Omni Flow 4000 Plus 4 5 SYSTEM INTERFACE DESCRIPTION 4 4 1 SIGNIFICANT DATA RETENTION Significant data includes the following Data required to define the system status condition 2 Dose information Volume information
135. self test Technical Service Manual 4 1 430 06579 002 Rev 7 04 SECTION 4 THEORY OF OPERATION Upon successful completion of the self test the device is ready for setup and operation Programming data IV history data alarm history data maximum occlusion pressure KVO rate and other system defaults may now be changed by the user 4 1 2 1 SELF TEST The device self test performs the following functions Displays self test screen L1 Initializes all data except the following history data Alarm history data User selected defaults such as maximum occlusion of KVO Tests RAM and ROM Checks critical data integrity Checks mechanism functionality If the self test fails the device enters a self test service code alarm state 4 1 2 2 MAIN PROGRAM SOFTWARE FUNCTIONS Upon successful completion of the device self test the main program software performs the following functions Monitors keypad Enables watchdog timers Activates screen prompts Monitors system for alarm conditions generates alarm code if condition exists Monitors cassette lock switch retracts piston if knob opened Monitors RAM integrity Monitors ROM integrity Establishes and monitors processor communications DL DL DL DL D D O 4 1 2 3 SETUP The following occurs during setup The pumping mechanism deactivates and the plunger retracts from the cassette to the home position Previous programming and IV history can be maintai
136. synchronous timing of other circuitry 4 6 2 2 EPROM AND RAM Program memory resides in EPROM U18 AT27C256R and contains 256 K bits 32 bytes of nonvolatile read only storage RAM consists of U16 HM6264 and contains 64 K bits 8 K bytes of random access storage Memory access and address decoding is performed by PAL U15 430 06579 002 Rev 7 04 4 10 Omni Flow 4000 Plus 4 6 PWA FUNCTIONAL DESCRIPTION 4 6 2 3 WATCHDOG TIMER Counter U13 divides the 1 2288 MHz clock produced by the microprocessor down to 614 4 KHz for the analog to digital converter U8 U13 also produces a 75 Hz signal that is applied to the non maskable interrupt NMI input of the microprocessor 4 6 2 4 PERIPHERAL ACCESS The microprocessor has two programmable parallel I O ports an eight bit bi directional bus and a five bit input port The eight bit bi directional bus bits function as follows Three bits are unused Three bits are reserved for future use L1 Two bits are used to detect the normally open and normally closed state of the cassette lock microswitch on the retraction knob assembly Software constantly monitors these bits to detect cassette lock activity The five bit input port bits function as follows Two bits are used with open collector Schmitt triggers U17A 0170 to form the communication link with the control PWA One bit supplies the device alarm signal to the control PWA The two remaining bits are
137. ter pattern test proceed as follows 1 Attach the printer cable to the serial port on the printer and to the nine pin RS 232 serial port DB 9 on the rear of device 2 Poweron the printer Press printer ON LINE switch and verify ON LINE LED lights 3 From the base screen press SPECIAL FUNCTION 3 ENTER Verify the printer prints a legible alphanumeric pattern 4 Press ENTER to end test and return to base screen 5 2 14 SAFETY TEST To perform the safety test proceed as follows 1 Connect the AC power cord to an approved safety analyzer Leakage current must not exceed 20 microamperes during open ground test but must be greater than 2 microamperes open ground Lower current could indicate open ground 2 Using the safety analyzer measure the resistance between the ground lug of the AC power cord connector and exposed metal parts of the device such as the ON CHARGE switch or bag hanger Resistance should not exceed 0 1 ohms 100 milliohms 430 06579 002 Rev 7 04 5 12 Omni Flow 4000 Plus 5 3 PERIODIC MAINTENANCE INSPECTION 5 2 15 END OF PVT If all tests have been successful return device to service by performing the following 1 Clear the IV flow sheet data by pressing SPECIAL FUNCTION 9 ENTER 2 Restore the following hospital specific default settings noted in Section 5 2 4 Test Setup Time KVO Patient line occlusion alarm Units of temperature Callbacks 3 Return the d
138. terial in the event it is necessary to return the device to the factory Verify that the shipping container contains a copy of the System Operating Manual 1 8 2 INSPECTION Inspect the infusion system for shipping damage Should any shipping damage be found contact the delivering carrier immediately CAUTION Do not use the device if it appears to be damaged Should damage be found contact Hospira see Section 6 1 Technical Assistance Technical Service Manual 1 5 430 06579 002 Rev 7 04 SECTION 1 INTRODUCTION Inspect the device periodically for signs of defects such as worn accessories broken connections or damaged cable assemblies Also inspect the device after repair or during cleaning Replace any damaged or defective external parts 1 8 3 SELF TEST CAUTION Do not place the Omni Flow 4000 Plus in service if the self test fails To conduct the self test proceed as follows 1 Connect the power cord to a properly grounded AC outlet 2 Toggle the ON CHARGE switch located at the back of the pump to the ON position Note A service code may be displayed if the device is turned on with a cassette locked in the cassette holster If the service code appears remove the cassette and cycle the power to the device 3 Confirm that the green AC power indicator is illuminated and that all other LED indicator lights are off At power on the Omni Flow 4000 Plus performs its self test diagnostics The self test lasts
139. the device for the replacement of the transducer Power off the device Turn off the DMM then move the positive lead from pin 1 to pin 2 transducer out Set the DMM to DC volts Turn on the DMM Power on the device using battery power 10 Verify that the voltage is between 0 41 and 0 42 VDC If the voltage is out of range locate the R26 trim pot next to test connector J15 then adjust it until the voltage is within range Apply GLPT to the R26 trim pot screw Remove the DMM leads then power off the device Reassemble the device in the exact reverse order of its disassembly Tighten the enclosure screws to 10 1 inch pounds To verify successful adjustment of the transducer perform the PVT in Section 5 2 430 06579 002 Rev 7 04 7 4 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES PUMP PWA ML AS Mo 26 TEST CONNECTOR J15 99G01001 Figure 7 1 Pump PWA R26 Trim Pot and Test Connector J15 7 2 4 AC POWER CORD REPLACEMENT Note In some Omni Flow 4000 Plus infusion pumps the AC power cord bracket may be attached to two studs on the pump case with 6 32 hex nuts Recommended tool for this procedure is a flat head screwdriver The replacement parts for this procedure are Cord AC Power Detachable Bracket Power Cord Molded Screw 6 32 x 3 16 Hex Head with Washer To replace the AC power cord refer to Figure 7 2 Power Cord and Fuse Replacement then
140. the multiplexed inputs from the opto interrupter devices U4 U5 U6 and U7 which work with the flags on the motor cam assemblies of the mechanism for motor position sensing 4 6 2 5 ANALOG TO DIGITAL CONVERTER Analog to digital converter A D U8 ADC8090C monitors system voltages battery fuse integrity and the output of the pressure transducer U8 is an eight channel eight bit A D with a 19 53 mV resolution and a maximum input of 5 Vic The microprocessor accesses the A D converter via the address decoder U15 The 5 reference voltage required by the A D converter is generated by regulator U1 An emitter follower applies the 5 Vy reference voltage to the A D converter as stable IC power U8 monitors seven signals 5 Vp reference 5 Vpc system power 8 transducer power 14 system power 21 AC indicator the battery fuse sense signal and the pressure transducer output The last input is unused and tied to 5 Vy reference All of the inputs to the A D are scaled down with voltage dividers to stay within the maximum input of 5 4 6 2 6 PRESSURE TRANSDUCER CONDITIONING AND POWER The device uses an active pressure transducer mounted on the mechanism chassis to monitor pressure within the cassette The transducer requires 8 supply voltage supplied by U2A and 01 The output of the transducer ranges from approximately 1 66 Vic to approximately 1 88 Vy Technical Service Manual 4 11 430 06579 002
141. theory of operation details sequence of operation alarm conditions battery operation system malfunction detection data retention system interface description PWA functional description mechanism functional description disposable cassette description and pressure monitoring 4 1 SEQUENCE OF OPERATION This section describes OFF status and the sequence of events associated with ON status of the device 4 1 1 OFF STATUS If the device is connected to AC power the green AC LED is on and the 14 V regulator is charging the battery Switching the power switch to the CHARGE position causes the following to occur Device becomes inoperable Liquid crystal display LCD and status LEDs deactivate Nurse call circuit disabled Programming data IV history data alarm history data maximum occlusion pressure KVO rate and other system defaults are retained indefinitely If the system battery is completely discharged or disconnected programming data is lost and the system defaults revert to the original factory settings 4 1 2 ON STATUS Switching the power switch to the ON position causes the following to occur 5 Vpc power supply activates LCD and status LEDs activate One of the power source indicators lights as follows Green AC POWER LED lights if the device is connected to AC power Yellow BATTERY LED lights if the battery is charged and the device is disconnected from AC power Device performs
142. time clock 4 8 Serial communications 4 9 Conventions 1 2 D Data retention 4 4 IV history 4 5 Significant 4 5 Disposable cassette description 4 16 Drawings 9 1 Control PWA block diagram 9 17 Exploded view 9 7 Illustrated parts breakdown 9 5 Power supply PWA block diagram 9 21 Power supply wiring diagram 9 23 Pump PWA block diagram 9 19 Pump chassis wiring diagram 9 25 Rear exploded view 9 9 Switch panel exploded view 9 11 System block diagram 9 15 System interconnect block diagram 9 13 430 06579 002 Rev 7 04 SECTION INDEX E End of PVT 5 13 EPROM and RAM 4 8 4 10 Equipment required 5 3 Equipotential post replacement 7 28 F Fuse replacement 7 6 H High flow test 5 9 Hospira 6 1 Illustrated parts breakdown 9 1 9 5 Inspection 1 5 5 1 5 4 Periodic maintenance 5 13 Instrument installation procedure 1 5 Inspection 1 5 Self test 1 6 Unpacking 1 5 Interface AC Power 4 6 Mechanism 4 7 User 4 6 Introduction 1 1 IV history 4 5 Alarm status codes 6 19 Troubleshooting with 6 18 K Keypad replacement 7 17 L LCD backlight and contrast control 4 9 LCD replacement 7 15 M Main program software functions 4 2 Maintenance and service tests 5 1 Battery operation overview 5 13 Performance verification test 5 3 430 06579 002 Rev 7 04 Periodic maintenance inspection 5 13 Routine maintenance 5 1 Mechanism Functional description 4 14 Interface 4
143. time screen will display immediately after completion of the self test To verify successful replacement of the AC line filter perform the PVT in Section 5 2 430 06579 002 Rev 7 04 7 32 Omni Flow 4000 Plus 7 2 REPLACEMENT AND ADJUSTMENT PROCEDURES 4 40 X 3 16 PHILLIPS FLAT HEAD SCREW 2 GROUND STRAP LUGS 2 THROUGH ENCLOSURE WALL TO SWITCH PANEL STUD AC LINE FILTER 03K02040 7 2 22 Figure 7 20 ACLineFilter SWITCH PANEL ASSEMBLY REPLACEMENT Recommended tools for this procedure are as follows soldering iron Phillips screwdriver and torque driver with No 2 Phillips and flat blade heads The replacement parts for this procedure are Assembly Switch Panel Screw 6 32 x 5 8 Pan Head Phillips with Washer Screw 6 32 x 5 8 Hex Head Slotted with Washer To replace the switch panel assembly refer to Figure 7 17 Switch Panel RS 232 Connector and Bag Hanger then proceed as follows Disconnect the device from AC power Separate the top and bottom enclosures as described in Section 7 2 10 Remove the battery as described in Section 7 2 11 Remove the pump assembly as described in Section 7 2 16 Remove the power connector plate assembly as described in Section 7 2 20 Label wires and connectors on ALARM VOLUME potentiometer and ON CHARGE switch then cut the shrink wrap and unsolder the wires Using the flat blade screwdriver remove the four screws attaching
144. upt OSC Oscillator PAL Programmable array logic PWA Printed wiring assembly PIA Peripheral interface adapter psi Pounds per square inch PVT Performance Verification Test RAM Random access memory ROM Read only memory Real time clock V Volt Vac Volts AC Vpc Volts DC Vbatt Battery voltage nA Microampere uL Microliter 1 5 SERIES SPECIFIC INFORMATION When a description or a procedure is specific to a particular series or version of the device the information is shown following the section heading or text For example four digit serial numbers 3290 and above 1 6 USER QUALIFICATION The Omni Flow 4000 Plus is for use at the direction or under the supervision of licensed physicians and by licensed or certified healthcare professionals who are trained in the use of the Omni Flow 4000 Plus and the administration of parenteral or enteral fluids or drugs Training should emphasize preventing related IV complications including appropriate precautions to prevent accidental infusion of air 430 06579 002 Rev 7 04 1 4 Omni Flow 4000 Plus 1 7 ARTIFACTS 7 ARTIFACTS Nonhazardous low level electrical potentials are commonly observed when fluids are administered using infusion devices These potentials are well within accepted safety standards but may create artifacts on voltage sensing equipment such as ECG EMG and EEG machines These artifacts vary at a rate that is associated with the infusion rate If the monitoring
145. ve hours of operation at 125 mL hr low battery alarm activated with approximately 30 minutes of battery life remaining 24 hours with device OFF 2 0 A 30 maximum Standard 1 4 inch phone jack with normally open isolated contacts RS 232 DB 9 connector set to 9600 baud 1 0 mL to 100 mL per hour in 0 1 mL hr increments up to 100 mL 1 0 mL hr increments from 100 to 700 mL hr 600 mL hr maximum for three or four lines 500 mL hr maximum for syringe delivery 1 0 mL to 3000 mL in 0 1 mL increments up to 100 mL 1 0 mL increments from 100 mL to 3000 mL Factory set at 1 0 mL hr Selectable from 1 0 mL to 99 9 mL per hour All standard IV fluids including lipid emulsions blood and packed cells Factory set at 10 psi User selectable from 1 12 psi Pump should alarm when air bubbles are larger than 100 pL 430 06579 002 Rev 7 04 SECTION 8 SPECIFICATIONS This page intentionally left blank 430 06579 002 Rev 7 04 8 2 Omni Flow 4000 Plus pl Section 9 DRAWINGS Figure 9 1 through Figure 9 11 show the illustrated parts breakdown IPB block diagrams and wiring diagrams Table 9 1 Drawings lists drawings by figure number and title Table 9 2 IPB for the Omni Flow 4000 Plus identifies parts by index numbers which correlate to Figure 9 1 Note Drawings are provided as information only and may not exactly reflect current product configuration Table 9 1 Drawings Figure Number Illustrated Parts

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