Colleague Service Bulletin Monochrome Display assembly 0727000002

Applicable Documents 07-19-D1-499 Global Service Manual 07-19-x9-653 Global Service Manual (Spanish, where “x” = the most current revision) Procedure Refer to the following attachments when servicing COLLEAGUE Pumps with monochrome displays: 

Attachment A – Identifying Monochrome Display Pumps with CCFL and LED Based Backlights



Attachment B – CCFL to LED Based Backlight Monochrome Display Conversion



Attachment C – Removal/Replacement Procedures: Front Bezel Assembly for Monochrome Pumps with LED Based Backlight



Attachment D – Illustrated Parts Breakdown        

Figure D1 Pump Assembly, COLLEAGUE Monochrome Pumps Figure D2 User Interface Module Assembly, COLLEAGUE Monochrome Pumps Figure D3 Front Bezel Assembly, Monochrome Figure D4 Front Bezel Assembly, Monochrome with LED Based Backlight Figure D5 Center Housing Assembly, COLLEAGUE Monochrome Figure D6 Pump Assembly, COLLEAGUE 3 Monochrome Figure D7 User Interface Module Assembly, COLLEAGUE 3 Monochrome Figure D8 Center Housing Assembly, COLLEAGUE 3 Monochrome

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Attachment A Identifying Monochrome Display Pumps with CCFL and LED Based Backlight Pumps that have the new monochrome displays with LED based backlight do not require use of an Inverter PCB Module. Instead they utilize an Interface PCB, which is installed in place of the Inverter PCB Module within the front bezel. While the Inverter PCB Module is green, features component circuitry, and is a component that can be ordered, the Interface PCB is blue in color, lacks component circuitry (see Figure A1), and comes only as a component of the new monochrome display service assembly (the Interface PCB is not an orderable part).

Figure A1: Identifying Monochrome Display Pumps with CCFL and LED Backlights Any calibration procedures required following a repair are listed at the end of the procedure. See Chapter 10, “Calibration” in the Global Service Manual for calibration procedures. Before returning the pump to use, check the pump’s event history for evidence of any additional problems, and correct them. Perform the Operational Checkout in Chapter 11 of the Global Service Manual after a repair to verify that a pump is operating properly and within specifications.



NOTE:

Refer to the exploded parts drawings in Attachment D, and Chapter 9 of the Global Service Manual. The drawings show the parts available from Baxter and provide important compatibility information.

CAUTION

It is the facility’s responsibility that tools and measuring equipment used during repair, calibration, and testing are not damaged and have been properly calibrated.

When disassembling the pump, note the routing of wiring harnesses, placement of connectors, and location of tie wraps. Installing these items in their original position simplifies reassembly of the pump.

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WARNING!

This device should be repaired only by Baxter authorized service personnel or Baxter-trained hospital biomedical engineering personnel, using only Baxter recommended parts. There are risks associated with using anything other than Baxter recommended parts. Baxter will assume no responsibility for incidents which may occur if the product was not repaired in accordance with procedures authorized by Baxter. Baxter’s warranty is immediately null and void where non-Baxter parts are used to repair Baxter devices.

CAUTION

 Wear a grounding wrist strap when assembling and disassembling the pump.  Do not lay the pump face down on components or tools that could scratch or damage the keypad.  Ensure that wires are not pinched or overstressed.

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Attachment B CCFL to LED Based Backlight Monochrome Display Conversion This section provides detailed instructions on replacing a monochrome display with CCFL backlight with a monochrome display with LED based backlight. Refer to Attachment A for information on Identifying Monochrome Display Pumps with CCFL and LED Based Backlight. Refer to the Global Service Manual for a listing of tools and consumable materials required to service COLLEAGUE Pumps.



NOTE:

Figures referenced in the “Location of part(s)” sections are found in Attachment D of this Service Bulletin.

1.

Power the pump off and disconnect it from AC power.

2.

Place the pump on an anti-static mat.

3.

(COLLEAGUE pumps only.) Use a 2.5mm hex driver to remove the six screws that secure the front bezel assembly: Location of part(s):  Screws: Figure D2, item 8 (COLLEAGUE 3 pumps only.) Use a 2.5 mm hex driver to remove five screws that secure the front bezel assembly, and one long screw securing the tubing guide. Location of part(s):  Screws: Figure D7, item 8  Long Screw: Figure D6 item 25

4.



Separate the front bezel from the center housing by slowly pulling it forward enough to access the connectors on the UIM PCB.

NOTE:

If the bezel-main and/or handle gaskets come out, put them back on the center housing.

Location of part(s):  Bezel-main gasket: Figure D2, item 2 or Figure D7, item 2  Handle gasket: Figure D2, item 26 or Figure D7, item 26

CAUTION

To avoid damage, DO NOT pull the wires. Hold both wires and connector (P12) when handling.

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5.

Disconnect the connectors from the UIM PCB in the following order (Figure B1 shows the location of the UIM PCB connectors):    

P2: 6-wire header connector (DC power) P8: 4-wire header connector (pump module power) P3: ribbon cable connector from pump module(s) P12 (UIM-rear interface harness)

Figure B1: Location of Monochrome UIM PCB Connectors 6.

Disconnect CON1: 3-wire header connector (part of J12 wiring harness) connects to the inverter PCB located under the UIM PCB. The wiring harness lies across the top of the UIM PCB.

7.

Use a 5.5 mm socket to remove the nut, washer and tooth washer that secure the SP/UI membrane earth harness to the front bezel. Location of part(s):  Nut: Figure D2, item 11 or Figure D7, item 11  Flat washer: Figure D2, item 12 or Figure D7, item 12  Tooth washer: Figure D2, item 13 or Figure D7, item 13  SP/UI membrane earth harness: Figure D5, item 22 or Figure D8, item 23

8.

Remove the front bezel assembly.

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CAUTION

Check the bezel for broken or missing alignment tabs. You may remove damaged tabs by cutting or breaking them off. After inspecting the interior of the pump to verify that no broken pieces remain, mark the remnants of the broken tab(s) in the bezel with indelible ink to indicate that the broken pieces have been accounted for and removed.

9.

Inspect the internal case components for evidence of contamination such as residue, oxidation and deposits. The case components may be cleaned using any approved cleaning solution as described in “Cleaning,” 6-4 of the Global Service Manual. If necessary, use isopropyl alcohol (70%) to clean external housing areas that contain grease residue from the gaskets. If cracks in the case are present, replace the case component.

10.

Inspect the six fastener bosses of the center housing as shown in Figure B2. If there are any visible cracks, remove and replace the center housing as described in “Center Housing,” 8-169 of the Global Service Manual.

Figure B2: Center Housing Inspection Points



NOTE:

The appearance of tarnish on the silver metallic parts of the UIM PCB is normal and does not affect performance. Unless there are other reasons to suspect that fluids may be entering the UIM area, tarnish on the UIM PCB is not indicative of a fluid ingress problem.



NOTE:

When removing the UIM PCB, do not disconnect the backup battery pack assembly connector P1. Doing so when the main batteries are disconnected causes a loss of all configuration and history data.

11.

Disconnect the following connectors from the UIM PCB (see Figure B1 for the monochrome pump UIM PCB): BAXTER and COLLEAGUE are registered trademarks of Baxter International Inc. All other products and registered trademarks appearing herein are the property of their respective owners.

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CAUTION   



Failure to unlock locking connectors before disconnecting them could result in damage to the cable harnesses or the connectors on the PCBs.

P10: Locking 3-wire header connector from volume control P4: Two 6-conductor flat ribbon harnesses from keypad P15: 6-wire header connector from the LED PCB

NOTE:

Remove RTV from LED harness connector and socket of P15.

CAUTION

Ensure that the locking flange on connector J5 is fully unlocked before removing the flat ribbon cable. Attempting to remove the cable while the flange is locked can damage the ribbon, cable and connector.

12.

Note the flat ribbon cable connected to UIM PCB connector J5. On connector J5 use a small flat-blade screwdriver, or other suitable right angled tool, to lift the locking flange alternately from each end.

13.

With the locking flange fully raised, carefully withdraw the flat ribbon cable from connector J5. Carefully remove the flat ribbon cable from the ferrite ring.

14.

Use a #2 crosstip driver to remove the four screws and plastic washers that secure the UIM PCB. Location of part(s):  Screws: Figure D3, item 16  Plastic washers: Figure D3, item 6

CAUTION

When removing the UIM PCB, use caution so that the bottom surface of the UIM PCB does not contact metal surfaces.

15.

Position the UIM PCB on an anti-static mat next to the front bezel assembly to gain access to the backup battery pack assembly.

16.

Use a 5.5 mm socket to remove the two nuts and washers that secure the backup battery pack assembly to the front bezel assembly: Location of part(s):  Backup battery pack assembly: Figure D3, item 21  Nuts: Figure D3, item 7  Washers: Figure D3, item 11

17.

Remove the backup battery from the front bezel assembly.

18.

Remove and discard the left and right standoffs. The standoffs, which the UIM PCB is secured to, are rated for one-time use only. BAXTER and COLLEAGUE are registered trademarks of Baxter International Inc. All other products and registered trademarks appearing herein are the property of their respective owners.

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Location of part(s):  Standoffs: Figure D3, items 39 and 40 19.

Use a small pair of diagonal cutters to carefully remove the heat shrink encasing the contrast control connection.

20.

Disconnect contrast control locking pigtail connector from contrast control wiring harness.

21.

Disconnect the 2-wire header connector from connector CON2 on the inverter PCB.

22.

Use a #2 crosstip driver to remove the three screws and washers that secure the right bevel shim adjacent to the main display assembly. Remove the right bevel shim. Location of part(s):  Right bevel shim: Figure D3, item 3  Screws: Figure D3, item 22  Washers: Figure D3, item 11

23.

Use a #2 crosstip driver to remove the four screws and washers that secure the EMI shield. Location of part(s):  Screws: Figure D3 12 and 17  Washers: Figure D3, item 11

24.

Carefully remove together the EMI shield, LCD back guard and main display by sliding the assembly out from the front bezel.

25.

Separate the EMI shield, LCD back guard and main display, and place them on an anti-static mat.

26.

Use a #1 crosstip driver to remove the plastic screws that secure the inverter PCB to the front bezel. Location of part(s):  Plastic screws: Figure D3, item 43 (two screws)

27.

Remove the inverter PCB and set the inverter PCB standoffs off to the side since they are not secured to the front bezel. Location of part(s):  Inverter PCB: Figure D3, item 20  Inverter PCB standoffs: Figure D3, item 42 (two standoffs)

28. Discard the inverter PCB and main display.

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

To minimize the potential of a main display failure caused by mechanical stressing of the display LCD, refer to the following guidelines for proper handling.

NOTE:



Follow the established facility ESD procedures when working with displays.



Handle the encased display as shown in Figure B3. Do not handle the encased display by the shorter edges or near the connector opening. Handle the encased display using the longer sides of the display only.

Figure B3: Proper Handling of the Monochrome Display 

Do not twist or flex the display frame while handling the display.



Do not twist or flex when picking up or putting down the display.



The display panel is made of glass. Fractures to the display panel could result from mechanical stress due to mishandling or dropping the display or pump.



If present, slowly peel off protective fill since static electricity may be generated.



Enclose the display in ESD (Electrostatic Discharge) protective bag prior to transport.

CAUTION 29.

Tighten fasteners to the torque values specified in the procedures below.

Blow out any lint or foreign matter from the back of the front bezel. BAXTER and COLLEAGUE are registered trademarks of Baxter International Inc. All other products and registered trademarks appearing herein are the property of their respective owners.

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30.

Ensure that the edges of the main display assembly are wrapped with 1-inch KAPTON tape as shown in Figure B4. If the tape is in good condition, proceed to the next step. Location of part(s):  One-inch KAPTON tape: Figure D4, item 38 If the tape around the main display is missing or damaged, remove the damaged tape, and apply the KAPTON tape to all four sides as shown in Figure B4. Ensure that no edges of the main display remain exposed.

Figure B4: KAPTON Tape on Monochrome Display Edges 31.

Ensure that the LCD flex cable is encased in KAPTON tape as shown in Figure B4. If the tape is in good condition, proceed to the next step. If the tape is missing or damaged, remove any damaged tape, and wrap a piece of 1-inch KAPTON tape so that it extends 2.0 mm (minimum) beyond the edge of the LCD flex cable in all directions.

32.

Ensure that the front portion of the main display has four pieces of LCD foam tape applied as shown in Figure B4. Location of part(s):  LCD foam tape: Figure D4, items 44 and 48

33.

Ensure that a piece of 1-inch KAPTON tape is placed over the backlight wires from CN5 as shown in Figure B5.

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Figure B5: KAPTON Tape over Backlight Wires 34.

Ensure that the bottom edge of the EMI shield is wrapped in 1-inch KAPTON tape as shown in Figure B6. Location of part(s):  EMI shield: Figure D4, item 13  One-inch KAPTON tape: Figure D4, item 38 If the KAPTON tape is missing or damaged, remove any damaged tape, and wrap a piece of 1inch KAPTON tape around the bottom edge of the EMI shield as shown in Figure B6, ensuring that the entire exposed edge is covered.

Figure B6: KAPTON Tape on EMI Shield Bottom Edge 35.

Place the LCD back guard over the back of the main display, ensuring that the flex circuit cutout is aligned with the display ribbon cable, as shown in Figure B7. Location of part(s): BAXTER and COLLEAGUE are registered trademarks of Baxter International Inc. All other products and registered trademarks appearing herein are the property of their respective owners.

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

LCD back guard: Figure D4, item 46

Figure B7: LCD Back Guard on Monochrome Display 36.

Place the EMI shield over the LCD back guard and main display, as shown in Figure B8.

Location of part(s):  EMI shield: Figure D4, item 13

Figure B8: EMI Shield over LCD Back Guard and Main Display 37.

 38.

Hold the EMI shield, LCD back guard and main display assembly in the mounting position and slide the assembly onto the LCD chassis that is attached to the inner side of the front bezel, making sure that no wiring is pinched by shield edges.

NOTE:

To ensure correct reassembly, note that two of the EMI shield securing screws are 10 mm long and the other two screws are 6 mm long.

Using a #2 crosstip driver, secure the EMI shield with four screws and washers. Tighten to 7 kgf-cm (6 lb-in). BAXTER and COLLEAGUE are registered trademarks of Baxter International Inc. All other products and registered trademarks appearing herein are the property of their respective owners.

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Location of part(s):  Screws: Figure D4, items 12 and 17  Washers: Figure D4, item 11 39. Slide a 40 mm (1.5 inch) piece of heat shrink tubing onto the contrast control wires. Location of part(s):  Heat shrink tubing: Figure D4, item 37 40.

Connect the contrast control locking pigtail connector to contrast control wiring harness.

41.

Route the pigtail and harness as shown in Figure B9.

Figure B9: Contrast Control Harness Routing

CAUTION

42.

Use proper precautions when using a heat gun to prevent damage to the housing and PCB components.

Slide the heat shrink over the connector as shown in Figure B10. Use a heat gun to shrink it into place. Ensure all exposed pins of the connection are covered as shown in Figure B10.

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Figure B10: Heat Shrink over Contrast Control Connection 43.

Noting the correct orientation of the right bevel shim, place the right bevel shim in the mounting position, and secure it with three screws and washers. Tighten to 9 kgf-cm (7.8 lb-in) using a #2 crosstip driver. Location of part(s):  Right bevel shim: Figure D4, item 3  Screws: Figure D4, item 22  Washers: Figure D4, item 11

44.

Ensure that the inverter PCB standoffs are present on the front bezel mounting posts. Location of part(s):  Inverter PCB standoffs: Figure D4, item 42

45.

Place the blue interface PCB, included with new display, in the mounting position, in the location previously occupied by the inverter PCB.

46.

Secure the interface PCB with two plastic screws. Tighten to 1.0 kgf-cm (0.9 lb-in). Location of part(s):  Plastic screws: Figure D4, item 43

47.

If not already connected, connect the 3-wire header connector to connector CN8 on the interface PCB.

48.

Refer to the Main Display (monochrome pumps) section in the Internal Inspection Checklist of the Global Service Manual before proceeding.

49.

Verify UIM PCB trimmer potentiometers R109 and R162 (see Figure B1) have RED GLPT varnish applied. If not, apply RED GLPT varnish to potentiometer adjustment screws. Do not cover entire adjustment slots of the potentiometers.

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 50.

NOTE:

If the UIM PCB must be replaced with a new one, refer to “Replacement of the User Interface Main PCB Assembly for Monochrome Pumps (with LED Based Backlights)” in Attachment C.

Route the excess backlight wiring alongside the LED PCB, as shown in Figure B11.

Figure B11: Routing of Excess Backlight Wiring Alongside LED PCB 51.

If the front bezel and keypad assembly is not being replaced, install new left and right standoffs onto the front bezel tabs that support the UIM PCB. Location of part(s):  Standoffs: Figure D4, items 39 and 40

52.

53.

Place the backup battery pack assembly into mounting position.

CAUTION

When installing the UIM PCB, use caution so that the bottom surface of the UIM PCB does not contact metal surfaces.

CAUTION

Ensure that connectors are mated and observe the correct orientation.

Using a 5.5 mm socket, secure the backup battery pack assembly using two nuts and washers. Tighten to 7 kgf-cm (6 lb-in). Location of part(s):  Backup battery pack assembly: Figure D4, item 21

54.

Place the UIM PCB in the mounting position.

55.

Using a #2 crosstip driver, secure the UIM PCB using four screws and plastic washers. Tighten to 4.0 kgf-cm (3.5 lb-in). BAXTER and COLLEAGUE are registered trademarks of Baxter International Inc. All other products and registered trademarks appearing herein are the property of their respective owners.

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Location of part(s):  Screws: Figure D4, item 16  Plastic Washers: Figure D4, item 6 56.

Carefully insert the main display flat ribbon cable through the ferrite ring

57.

Apply a thin film of NYOGEL 760G grease on flat ribbon cable contacts prior to installation. With the locking flange on connector J5 in the unlocked position, carefully insert the flat ribbon cable into the connector. While holding the flat ribbon cable fully engaged and squarely seated into the connector, lock the flange on the connector.

58.

See Figure B1 for UIM PCB connector locations. Connect the wiring harness connectors in the following order:

CAUTION   



LED PCB harness connector P15 is not keyed. Make certain that the connector is correctly oriented before connecting. The connector is correctly oriented when the black, yellow, and green leads face toward the handle (top) of the front bezel housing.

P15: 6-wire header connector from LED PCB P10: Locking 3-wire header connector from VOL. Control P4: Two 6-conductor flat ribbon harnesses from keypad

NOTE:

Apply silicone adhesive sealant RTV744 along the whole top perimeter of the gap between the LED harness and connector (P15), as shown in Figure B12.

Figure B12: Silicone Adhesive Sealant RTV744 along Top Perimeter. 59.

Verify that the volume and contrast control wires are routed as shown in Figure B13.

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Figure B13: Volume and Contrast Control Wiring for Monochrome Pumps 60.

 61.

Refer to the UIM PCB section in the Internal Inspection Checklist of the Global Service Manual before proceeding.

WARNING!

Loose parts inside the housing can cause damage to pump components. If any cracks are visible in these areas, replace the case components.

CAUTION

Tighten fasteners to the torque values specified in the procedures.

NOTE:

When handling gaskets, take precautions to not transfer grease from gaskets to exposed areas of pump. Grease residue on external case components can be removed by cleaning the area with isopropyl alcohol (70%).

Assess the suitability and condition of the gaskets installed on the center housing mounting surface as described in “Pump Gasket Inspection/Replacement,” 8-212 of the Global Service Manual, and re-grease or replace as appropriate. Location of part(s):  Bezel-main gasket: Figure D2, item 2 or Figure D7, item 2  Handle gasket: Figure D2, item 26 or Figure D7, item 26

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WARNING! 62.

Do not overtorque fasteners. If the specified torque value cannot be obtained, or if the measured torque value suddenly decreases when tightening a screw, inspect for stripping and/or breakage. Replace cracked, broken, or stripped housing parts.

Place a tooth washer and SP/UI membrane earth harness lead over the stud on front bezel chassis. Secure the SP/UI membrane earth harness lead using one nut and flat washer. Ensure that the tooth washer is placed between front bezel chassis and the ring terminal, and that the ring terminal is parallel to the case edge as shown in Figure B14. Tighten to a torque of 5 kgfcm (4.3 lb-in). Location of part(s):  Tooth washer: Figure D2, item 13 or Figure D7, item 13  Flat washer: Figure D2, item 12 or Figure D7, item 12  Nut: Figure D2, item 11 or Figure D7, item 11  SP/UI membrane earth harness: Figure D5, item 22 or Figure D8, item 23

Figure B14: Ring Terminal Parallel to Case Edge

 63.

CAUTION

To avoid damage, DO NOT pull the wires. Hold both wires and connector (P12) when handling.

CAUTION

Ensure that the connectors are mated correctly. Failure to correctly orient connector P8 or P2 can cause a blown fuse.

NOTE:

To help prevent stress on the wires, which could loosen previously connected wires, use long nosed pliers with insulated jaws to manipulate and reconnect the connectors. Verify that all connections are properly mated.

Connect the wiring harnesses to the UIM PCB in the following order. Figure B1 shows the location of the monochrome UIM PCB connectors.

CAUTION

CON1 is not keyed and the innermost pin is NOT used. See Figure B15 for proper orientation.

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    

P12: (UIM-rear interface harness) CON1: 3-wire header connector (part of J12 wiring harness) connects to CN9 of the interface PCB located under the UIM PCB. The wiring harness lies across the top of the UIM PCB P3: ribbon cable connector to pump module(s) P8: 4-wire header connector (pump module power) P2: 6-wire header connector (DC power)

Figure B15: Proper Orientation of CON1 64.

Ensure that the bezel-main and handle gaskets are present on the center housing. Also ensure that the gaskets on the center housing mounting surfaces fit properly within the channels on the center housing. Location of part(s):  Bezel-main gasket: Figure D2, item 2 or Figure D7, item 2  Handle gasket: Figure D2, item 26 or Figure D7, item 26

65.

Refer to the Front Bezel (monochrome and color pumps) section in the Internal Inspection Checklist, of the Global Service Manual before proceeding.

66.

Using finger pressure, fully mate the front bezel with the pump chassis. Inspect the mating surface for a uniform gap between the front bezel and the pump chassis.



CAUTION

Ensure that wiring is not pinched between the front bezel and center housing.

NOTE:

Ensure a criss-cross pattern is used when tightening the front bezel screws to avoid gaps in the housing mating surfaces.

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