Connex Integrated Wall System Service Manual Ver D

© 2012 Welch Allyn. All rights are reserved. To support the intended use of the product described in this publication, the purchaser of the product is permitted to copy this publication, for internal distribution only, from the media provided by Welch Allyn. No other use, reproduction, or distribution of this publication, or any part of it, is permitted without written permission from Welch Allyn. Welch Allyn assumes no responsibility for any injury to anyone, or for any illegal or improper use of the product, that may result from failure to use this product in accordance with the instructions, cautions, warnings, or statement of intended use published in this manual. Welch Allyn, Connex, SureTemp, and SureBP are registered trademarks of Welch Allyn. SpHb and Rainbow are trademarks of, and SET and Masimo are registered trademarks of, Masimo Corporation. Possession or purchase of a Masimo SpO2- or Masimo SpHb-equipped device does not convey any express or implied license to use the device with unauthorized sensors or cables which would, alone or in combination with this device, fall within the scope of one or more of the patents relating to this device. Nellcor is a registered trademark of Nellcor Puritan Bennett Inc. Braun and ThermoScan are registered trademarks of Braun GmbH. Software in this product is Copyright 2012 Welch Allyn or its vendors. All rights are reserved. The software is protected by United States of America copyright laws and international treaty provisions applicable worldwide. Under such laws, the licensee is entitled to use the copy of the software incorporated with this instrument as intended in the operation of the product in which it is embedded. The software may not be copied, decompiled, reverse-engineered, disassembled, or otherwise reduced to human-perceivable form. This is not a sale of the software or any copy of the software; all right, title, and ownership of the software remain with Welch Allyn or its vendors. For information about any Welch Allyn product, call Welch Allyn Technical Support: USA +1 800 535 6663 +1 315 685 4560 Canada +1 800 561 8797 European Call Center +353 46 90 67790 Germany +49 695 098 5132 Japan +81 42 703 6084 Malaysia +603 7884 3329 Singapore +65 6419 8100 Spain +34 917 499 357 United Kingdom +44 207 365 6780

Australia +61 2 9638 3000 China +86 21 6327 9631 France +33 155 69 58 49 Italy +39 026 968 2425 Latin America +1 305 669 9003 Netherlands +31 202 061 360 South Africa +27 11 777 7555 Sweden +46 85 853 6551

104066 (CD) Manual 80016503 Ver. D

104092 (printed copy) Material Number 718748, 80016503 Ver. D

Welch Allyn, Inc. 4341 State Street Road Skaneateles Falls, NY 13153-0220 USA

Regulatory Affairs Representative Welch Allyn Limited Navan Business Park Dublin Road Navan, County Meath Republic of Ireland

www.welchallyn.com

iii

Contents Symbols ... 1 Safety ... 3 Warnings and cautions ... 3 General safety considerations ... 4 Electrostatic discharge (ESD) ... 4

Overview ... 7 Purpose and scope ... 7 Technical support services ... 8 Recommended service intervals ... 12 The Welch Allyn Service Tool ... 13 Battery performance ... 14

Controls, indicators, and connectors ... 17 Service menu ... 21 Access the Service screens ... 21 General tab ... 22 Self-tests tab ... 24 Logs tab ... 25 Device tab ... 26 Licensing tab ... 27

Power-up sequence ... 29 Troubleshooting ... 31 Symptoms and solutions ... 32 Technical alarm messages ... 42

Disassembly and repair ... 53 Required tools and equipment ... 54 Power down the system ... 54 Module replacement - bottom housing ... 54 Module replacement - main housing ... 56 Remove the system from the wall and remove the battery ... 57 Remove the handle module assembly ... 58 Remove the handles ... 59 Remove the 767 controller PCBA ... 59 Remove the handle cradle and optical assemblies ... 60 Open the chassis ... 61

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Welch Allyn Connex® Integrated Wall System

Remove the power supply ... 62 Remove the ground plug, harness assembly, and IEC connector ... 63 Remove the communications board ... 64 Remove the radio board and antenna ... 65 Remove the light bar ... 66 Remove the fan ... 67 Remove the power panel ... 68 Remove the speaker ... 70 Remove the battery board ... 70 Remove the power wire harness and main wire harness ... 70 Remove the main board ... 71 Remove the LCD ... 73 Remove the module well ... 75 Remove the front housing ... 76 Replace the power button ... 78 Remove the chassis ... 78

Functional verification and calibration ... 79 Functional verification tests ... 79

Electrical safety testing ... 93 Ground stud connector ... 93

Options, upgrades, and licenses ... 95 Available options, upgrades, and licenses ... 95 Install options ... 97 Masimo Hemoglobin (SpHb) upgrade ... 97 Configure options ... 99

Field replaceable units ... 101 Front housing ... 101 Chassis ... 103 Handles ... 105 Modules ... 107 Miscellaneous parts ... 108 Licenses ... 109 Partners in Care service and support agreements ... 109 Service and repair training ... 110

Appendices ... 111 Decontamination and cleaning requirements ... 111 Configuration options ... 112 Factory defaults ... 114 Disassembly and repair reference ... 123 Connex Integrated Wall System interconnect diagram ... 132

1

Symbols Documentation symbols WARNING The warning statements in this manual identify conditions or practices that could lead to illness, injury, or death.

Caution The caution statements in this manual identify conditions or practices that could result in damage to the equipment or other property, or loss of data. This definition applies to both yellow and black and white symbols. Consult operating instructions.

Power symbols Power on/standby

Equipotential terminal

(on the display) monitor is plugged into Alternating Current power

Battery absent or faulty

(on the monitor, green indicator) Alternating Current power present, battery fully charged

Battery charge level

(on the monitor, amber indicator) Alternating Current power present, battery is charging

Battery cover

Alternating Current (AC)

Rechargeable battery

Li-ion battery

AC input power

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Welch Allyn Connex® Integrated Wall System

Symbols

Connectivity symbols USB

Ethernet RJ-45

Wireless signal strength • Best (4 bars) • Good (3 bars) • Fair (2 bars) • Weak (1 bar) • No signal (no bars) • No connection (blank)

Nurse call

Miscellaneous symbols Meets essential requirements of European Medical Device Directive 93/42/EEC

Authorized Representative in the European Community

Call for maintenance

Defibrillation-proof Type BF applied parts

Manufacturer

Recycle

Reorder number

Serial number

Do not reuse

China RoHS markings for control of pollution caused by electronic information products. XX indicates Environmentally Friendly Use Period in years.

Nonionizing electromagnetic radiation

Recycle the product separate from other disposables

Restrictions for use of wireless device in Europe. European Community's Class 2 radio equipment.

3

Safety All users of the system must read and understand all safety information presented in this manual before using or repairing the system. United States federal law restricts this device to sale, distribution, or use by or on the order of a licensed medical practitioner.

Warnings and cautions WARNING Safety risk. Make frequent electrical and visual checks on cables, sensors, and electrode wires. All cables, sensors, and electrode wires must be inspected and properly maintained and in proper working order to allow the equipment to function properly and to protect patients. WARNING Safety risk. Place the system and accessories in locations where they cannot harm the patient should they fall from a shelf or mount. WARNING Fire and explosion hazard. Do not operate the system in the presence of a flammable anesthetic mixture with air, oxygen, or nitrous oxide; in oxygenenriched environments; or in any other potentially explosive environment. WARNING Inaccurate measurement risk. Dust and particle ingress can affect the accuracy of blood pressure measurements. Use the system in clean environments to ensure measurement accuracy. If you notice dust or lint build-up on the system’s vent openings, have the system inspected and cleaned by a qualified service technician. Caution To ensure that the system meets its performance specifications, store and use the system in an environment that maintains the specified temperature and humidity ranges. Caution The system may not function properly if dropped or damaged. Protect it from severe impact and shock. Do not use the system if you notice any signs of damage. Caution Do not connect more than one patient to a system or connect more than one system to a patient. Caution Do not operate the system in the presence of magnetic resonance imaging (MRI) or hyperbaric chambers. Caution Do not autoclave the system. Autoclave accessories only if the manufacturer’s instructions clearly approve it.

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Welch Allyn Connex® Integrated Wall System

Safety

General safety considerations •

If the system detects an unrecoverable problem, it displays an error message. For more information see “Troubleshooting.”

•

To ensure patient safety, use only accessories recommended or supplied by Welch Allyn. (See the accessories list in the Welch Allyn Connex Integrated Wall System Directions for use (part number 104092).) Always use accessories according to your facility’s standards and according to the manufacturer’s recommendations and instructions. Always follow the manufacturer’s directions for use.

•

Welch Allyn recommends that only Welch Allyn service personnel or an authorized repair center perform warranty service. Performing unauthorized service on a device that is within warranty may void the warranty.

Electrostatic discharge (ESD)

Caution Electrostatic discharge (ESD) can damage or destroy electronic components. Handle static-sensitive components only at static-safe workstation. Caution Assume that all electrical and electronic components of the system are static-sensitive. Electrostatic discharge is a sudden current flowing from a charged object to another object or to ground. Electrostatic charges can accumulate on common items such as foam drinking cups, cellophane tape, synthetic clothing, untreated foam packaging material, and untreated plastic bags and work folders, to name only a few. Electronic components and assemblies, if not properly protected against ESD, can be permanently damaged or destroyed when near or in contact with electrostatically charged objects. When you handle components or assemblies that are not in protective bags and you are not sure whether they are static-sensitive, assume that they are static-sensitive and handle them accordingly. •

Perform all service procedures in a static-protected environment. Always use techniques and equipment designed to protect personnel and equipment from electrostatic discharge.

•

Remove static-sensitive components and assemblies from their static-shielding bags only at static-safe workstations-a properly grounded table and grounded floor mat-and only when you are wearing a grounded wrist strap (with a resistor of at least 1 megohm in series) or other grounding device.

•

Use only grounded tools when inserting, adjusting, or removing static-sensitive components and assemblies.

•

Remove or insert static-sensitive components and assemblies only with system power turned off.

•

Insert and seal static-sensitive components and assemblies into their original static-shielding bags before removing them from static-protected areas.

Service manual

Safety

•

Always test your ground strap, bench mat, conductive work surface, and ground cord before removing components and assemblies from their protective bags and before beginning any disassembly or assembly procedures.

5

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Safety

Welch Allyn Connex® Integrated Wall System

7

Overview Purpose and scope This service manual is a reference for periodic preventive maintenance and corrective service procedures for the Welch Allyn Connex Integrated Wall System. It is intended for use only by trained and qualified service personnel. Corrective service is supported to the level of field-replaceable units. These include circuit-board assemblies and some subassemblies, case parts, and other parts. Caution No component-level repair of circuit boards and subassemblies is supported. Use only the repair procedures described in this manual. WARNING When performing a service procedure, follow the instructions exactly as presented in this manual. Failure to do so could damage the system, invalidate the product warranty, and lead to serious personal injury. Find instructions for functional testing and performance verification in the Welch Allyn Service Tool help files. This manual applies only to this device. For servicing of any other device, see the service manual for the specific device. Service work not described in this manual must be performed by qualified service personnel at the factory or at an authorized Welch Allyn service center.

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Welch Allyn Connex® Integrated Wall System

Overview

Technical support services Welch Allyn offers the following technical support services: •

Telephone support

•

Loaner equipment

•

Service agreements

•

Service training

•

Replacement service parts

•

Product service

For information on any of these services, call the Welch Allyn Service Center nearest you.

Service loaners For warranty or non-warranty repairs not covered under a support agreement, loaners are available for a nominal charge, subject to availability. Payment is required prior to shipment for all loaners not covered under a support agreement. The loaner fee can be found on the Welch Allyn loaner price list. Welch Allyn Service Centers that provide repair service for this product can, on request, loan a device for use while the device is being repaired. Loaned devices are provided free of charge for products repaired while under a support agreement that includes a free loaner provision. Loaner equipment for the individual component modules is not available.

Service manual

Overview 9

Service options Partners in Care service agreements While product warranties provide basic assurance of Welch Allyn hardware quality, they may not include the full range of services and support you need. Welch Allyn offers premium service and support through our Partners in Care program. Whether you service your own devices and require a minimum of support or rely on us to service your device, Welch Allyn provides a program that will meet your needs. For more information visit our web site at www.welchallyn.com or call your sales representative.

Warranty service All repairs on products under warranty must be performed or approved by Welch Allyn. Refer all warranty service to Welch Allyn Product Service or another authorized Welch Allyn Service Center. Obtain a Return Material Authorization (RMA) number for all returns to Welch Allyn Product Service. Caution Unauthorized repairs will void the product warranty.

Non-warranty service Welch Allyn product service and authorized service centers support non-warranty repairs. Contact any Welch Allyn regional service center for pricing and service options. Welch Allyn offers modular repair parts for sale to support non-warranty service. This service must be performed only by qualified end-user biomedical/clinical engineers using this service manual. Service training is available from Welch Allyn for biomedical/clinical engineers. For information, go to www.welchallyn.com/support/technical/monitoring_suppt_training.htm.

Partners in Care service and support agreements Material no. Item

Material no. Item

S1-CIWS

Connex Integrated Wall System, Comprehensive partnership program 1 year

S1-CIWS-2

Connex Integrated Wall System, Comprehensive, Comprehensive partnership program 2 years

S2-CIWS

Connex Integrated Wall System, Bio-med partnership program 1 year

S2-CIWS-2

Connex Integrated Wall System, Bio-med partnership program 2 years

S4-CIWS (International only)

Connex Integrated Wall System, extended warranty, 1 year

S4-CIWS-2 (International only)

Connex Integrated Wall System, extended warranty, 2 years

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Welch Allyn Connex® Integrated Wall System

Overview

Repairs A Welch Allyn Service Center must perform all repairs on products under warranty, unless you have purchased a Welch Allyn support agreement allowing you to service the device while under warranty. Caution Unauthorized repairs will void the product warranty. Qualified service personnel or a Welch Allyn Service Center should repair products out of warranty. If you are advised to return a product to Welch Allyn for repair or routine maintenance, schedule the repair with the service center nearest you. Welch Allyn Technical Support If you have a problem with the device that you cannot resolve, call the Welch Allyn Technical Support Center nearest you for assistance. A representative will assist you in troubleshooting the problem and will make every effort to solve the problem over the phone, potentially avoiding an unnecessary return. If your product requires warranty, extended warranty, or non-warranty repair service, a Welch Allyn Technical Support representative will record all necessary information to issue an RMA number. The support representative will provide you with the address of the Welch Allyn Service Center to send your device to. Technical support is available during local business hours.

Returning products Your product must be returned in its original Welch Allyn supplied packing material. If you need this material, contact Welch Allyn. When returning a product to Welch Allyn for service, please include the following information: •

Product name, model number, and serial number. This information may be found on the product and serial number labels on the bottom of the system.

•

A complete return shipping address.

•

A contact name and phone number.

•

Any special shipping instructions.

•

A purchase-order number or credit-card number if the product is not covered by a warranty.

•

A full description of the problem or service request.

1.

Contact Welch Allyn and request a Return Material Authorization number. Note

Welch Allyn does not accept returned products without an RMA.

Service manual

Overview

2.

11

Ship the system to Welch Allyn, observing these packing guidelines: a.

Remove the battery, all hoses, connectors, cables, sensors, power cords, and other ancillary products and equipment, except those items that might be associated with the problem. Recommendations for returning the Lithium Ion battery •

Use ground transportation to return batteries.

•

If returning multiple batteries, package each battery individually.

•

Use packaging provided by Welch Allyn or the battery manufacturer.

•

Do not pack a defective battery in checked or carry-on baggage if traveling by air.

Packaging •

If you return the battery with the system, remove the battery, seal the battery in an antistatic plastic bag, and place the battery in the position reserved for the battery in the original shipping carton near the system.

•

If you return the battery separately, package the battery in the replacement battery plastic bag and shipping box.

If the original shipping carton or replacement battery shipping box is unavailable, consult the manufacturer website for information: www.nexergy.com/lithium-shipping.htm WARNING Safety risk. Do not ship any battery that has been physically damaged or shows signs of leakage unless you receive specific instructions which meet the requirements for the shipment of Lithium batteries. Dispose of damaged or leaking batteries in an environmentally safe manner consistent with local regulations. Note

b.

Clean the system. Note

c.

In the United States, the applicable regulations can be found in the Code of Federal Regulations (CFR). Refer to 49 CFR 173.185 for shipping lithium batteries by air or ground. Use 49 CFR 172.102 sections 29, 188, 189, A54, A55, A100, A101, A103, and A104 to find the special provisions for shipping lithium batteries.

To ensure safe receipt of your system by the service center and to expedite processing and return of the system to you, thoroughly clean all residues from the system before you ship it to Welch Allyn. For decontamination and cleaning requirements, see “Decontamination and cleaning” in the appendices. If a returned device is found to be contaminated with bodily fluids, it will be returned at the owner’s expense. United States federal regulations prohibit the processing of any device contaminated with blood-borne pathogens. Welch Allyn thoroughly cleans all returned systems on receipt, but any system that cannot be adequately cleaned cannot be repaired.

Put the system and a packing list into the original shipping carton with the original packing materials or into another appropriate shipping carton.

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Welch Allyn Connex® Integrated Wall System

Overview

d.

Write the Welch Allyn RMA number with the Welch Allyn address on the outside of the shipping carton.

Recommended service intervals To confirm that the device is functioning within the design specifications, perform periodic service using the Welch Allyn Service Tool, as indicated in the following table. Component

Service interval

Service procedure

Device

Annually

Functional verification using the Silver Level Welch Allyn Service Tool

NIBP module

Annually

Functional verification and calibration if necessary

SpO2 module

Annually

Functional verification

SpHb parameter

Annually

Functional verification

SureTemp Plus

Annually

Functional verification

Braun ThermoScan PRO Annually 4000

Functional verification

Battery

Replace battery

300 charge cycles

Perform a complete functional verification of the device using the Gold Level Welch Allyn Service Tool whenever any of the following conditions exist: •

Out-of-specification results from the Silver Level tests

•

The device has been dropped or otherwise damaged

•

The device is malfunctioning

•

The case has been opened

•

A part has been replaced

For details on performing the functional verification, see the section on functional verification.

Maintenance For system maintenance information, see “Maintenance and service” in the Welch Allyn Connex Integrated Wall System Directions for Use. Covered topics include the following: •

Inspecting and cleaning the system and accessories

•

Changing the battery

Service manual

Overview

13

The Welch Allyn Service Tool The Welch Allyn Service Tool is available in the following editions: •

Silver: Accompanies your device.

•

Gold: Required to perform complete functional verification and calibration. This edition requires an additional license. For more information about acquiring this license, contact Welch Allyn. Note

To qualify for the Gold license, you must attend the Welch Allyn technical training course or complete online training for the device.

Clinicians and technical service personnel can use the service tool to manage and maintain supported Welch Allyn products. You can use the service tool to do the following: •

Review device information. When connected to the device, the service tool lists installed modules, installed firmware and hardware versions, warranty and repair information, status, and usage history.

•

Receive notifications when periodic maintenance is needed. The service tool can help you manage and maintain your entire inventory of supported Welch Allyn products. Through the remote service function, the service tool can connect to Welch Allyn Customer Service. With this functionality you can automatically receive firmware updates and feature upgrades for your supported products, including software upgrades for the service tool.

•

Install updates and upgrades. The service tool can read the firmware version for each module and check for available updates or upgrades.

•

Create a work list. The work list provides information about service actions-referred to as work orders-that are waiting for you to perform on your maintained devices. Work orders may include periodic calibrations, upgrades, or license installations.

•

Schedule periodic maintenance. You can use the service tool to set the service interval for each maintained device.

•

View and save logs. You can download and save log files from the device for analysis to help diagnose and identify reported issues.

•

Create user accounts. Administrators can create user accounts and set permission levels to control access to the features, allowing one group to perform administrative tasks and another to perform service tasks. Restricting access prevents the service tool from being used to make unauthorized changes on a connected device.

•

Perform calibration check. You can use the service tool to test the device to ensure that its performance meets calibration specifications. A calibration check is required to meet the periodic maintenance requirements.

•

Perform functional verification and calibration. The service tool can check any device requiring calibration and, if necessary, calibrate the device to match the design specifications. This feature is not supported for all products and requires the service tool, Gold edition, for each supported product.

•

Recover devices. In the rare case where a device can no longer boot because of corrupted firmware, the service tool can connect the device to Welch Allyn Technical Support to reinstall the firmware.

•

Extensible. The device accepts new plug-ins to support future Welch Allyn products.

Some of these features are enabled for any user (Silver edition). Others require special user account privileges or a Welch Allyn service contract (Gold edition). If you require gold-level support for a Welch Allyn product, please contact Welch Allyn technical support.

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Welch Allyn Connex® Integrated Wall System

Overview

Battery performance About the battery The system uses a three-cell, rechargeable lithium ion smart battery. The Welch Allyn Connex Integrated Wall System is intended to be used while connected to AC power at all times. The purpose of the battery is to provide backup power in the event of a power loss. Internal circuitry enables the battery to report its condition to the system. The system displays the battery status via the LED power indicator, icons on the screen, and status messages appearing in the Device Status area of the display. Battery information may be collected using the service tool. New batteries are shipped from the manufacturer with a 30 percent charge to extend shelf life. When installing a new battery in the system, you must plug the system into AC power to wake up the battery. If the AC power is not applied to the system, the new battery appears discharged. The Device Status area displays a low-battery status message when 30 minutes of power remain and again when 5 minutes remain. Battery charging is provided by the system’s internal power supply. For a complete list of battery specifications, see Welch Allyn Connex Integrated Wall System Directions for use.

Best practices The following practices help to extend the life of the battery and the system. WARNING Safety risk. When handling and storing Lithium batteries: Avoid mechanical or electrical abuse. Batteries may explode or cause burns, if disassembled, crushed or exposed to fire or high temperatures. Do not short the terminals or install the battery with incorrect polarity. •

Remove the battery when storing the system.

•

Replace batteries that trigger a "Low Battery" status message when fully charged.

•

Do not use damaged or leaking batteries.

•

Store batteries with a 30 to 50 percent charge.

•

Store batteries within the temperature range indicated for each period: ○ For storage less than 30 days: Maintain temperature at –4 °F and 122 °F (–20 °C and 50 °C). ○

For storage between 30 days and 90 days: Maintain temperature at –4 °F and 104 °F (–20 °C and 40 °C).

○

For storage more than 90 days up to 2 years: Maintain temperature at –4 °F and 95 °F (–20 °C and 35 °C).

•

Recycle batteries wherever possible. In the United States call 1-800-8-BATTERY for information about recycling your Lithium Ion battery or go to the RBRC website at www.rbrc.org for additional information.

•

When recycling is not an option, dispose of batteries in an environmentally safe manner consistent with local regulations.

Factors affecting battery operating time The following settings and conditions affect the battery operating time.

Service manual

Overview

•

The display brightness setting

•

The display power-saver setting

•

The system power-down setting

•

Frequency and duration of alarms and alerts

•

Amount of motion artifact during NIBP measurements

•

Radio searching for an access point

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Overview

Welch Allyn Connex® Integrated Wall System