Vital Signs Monitor 300 Series Model 53XXX Service Manual Rev A Dec 2003

Contents 1 - Safety Summary... 5 General Safety Considerations...5 Electrostatic Discharge (ESD)...6 Symbols...7

2 - Overview... 11 Purpose and Scope...11 Technical Support Services...11 Returning Products...12 Product Configurations...13 Recommended Service Intervals...13 Service Options...14 Warranty Service...14 Non-Warranty Service...14 Related Documents...14 Service Menu...15

3 - Functional Verification... 17 Functional Verification Overview...17 Equipment Required...18 Functional Verification Procedure...19 System/Power...19 NIBP...22 Inflation...25 Pressure Dump...25 Printer...26 SpO2...28 Temperature...30 Nurse Call...31 Battery...32 Patient Isolation Test...32 Checklist and Test Results Report Form...35

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Contents

4 - Troubleshooting and Repair... 37 Troubleshooting Chart...37 Requirements for Module-level Repair and Replacement...39 NIBP Characterization...39 Welch Allyn Monitor Service Utility...40 Monitor Software Utility Introduction...40 Monitor Software Utility Installation...40 Monitor Software Utility Setup...40 Characterizing NIBP...41

5 - Disassembly Procedure... 43 Procedures Overview...43 Screws...43 Connectors...44 Remove and Disconnect the Battery...46 Separate the Front and Rear Chassis...47 Disassemble the Front Chassis Assembly...50 Remove the LCD Display from the Main Board...53 Remove the Main Board from the Rear Chassis Assembly...53 Disassemble and Remove the NIBP Assembly...58 Remove and Disassemble the Printer Assembly...61 Disassemble the Temperature Module...68 Disassemble the SpO2 Assembly...71

6 - Replacement Parts... 77

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Vital Signs Monitor Series 300

1 - Safety Summary This safety summary, and all additional specific warnings and cautions located throughout the documentation, must be read and understood by all users of the Vital Signs Monitor Series 300 monitor. Caution End-user software service tools used for previous models of the VSM must not be used with the VSM Model 300 Series. This includes the “Custom Repair Software”, part number 130S29E, and any other RS232 utility other than the Welch Allyn Monitor Service Utility (840-0676-XX). Use of any tool other than this service utility may set the monitor in an undefined and unrecoverable state. United States federal law restricts this device to sale, distribution, or use by or on the order of a licensed medical practitioner.

General Safety Considerations Always consider the following safety points when using the monitor: •

Place the monitor and accessories in locations where they cannot harm the patient should they fall from a shelf or mount.

•

Do not connect more than one patient to a monitor.

•

Do not connect more than one monitor to a patient.

•

Do not use the monitor in an MRI suite or hyperbaric chamber.

•

Do not autoclave the monitor.

•

Accessories can be autoclaved only if the manufacturer’s instructions clearly approve it. Many accessories can be severely damaged by autoclaving.

•

Inspect the power adapter cord periodically for fraying or other damage. Replace the adapter as needed. Do not operate the monitor from mains power if the adapter, the adapter cord, or the cord plug are damaged.

•

Frequently check all cables, both electrically and visually.

•

To avoid explosion, do not operate the monitor in the presence of flammable anesthetics.

•

To ensure patient safety, use only accessories recommended or supplied by Welch Allyn. (See the Products and Accessories Guide, part number 810-0409-XX.) 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.

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Electrostatic Discharge (ESD)

Safety Summary

•

A monitor that has been dropped or otherwise damaged or abused must not be used until it has been tested and verified by qualified service personnel for proper operation.

•

If the monitor detects an unrecoverable problem, an error code and a brief message appear in the message display. Report all such errors to Welch Allyn.

•

While under warranty, the monitor must be serviced only by a Welch Allyn service technician.

Electrostatic Discharge (ESD)

ATTENTION CAUTION

OBSERVE PRECAUTIONS FOR HANDLING

SENSITIVE ELECTRONIC DEVICES

ELECTROSTATIC SENSITIVE DEVICES

DO NOT SHIP OR STORE NEAR STRONG ELECTROSTATIC, ELECTROMAGNETIC, MAGNETIC OR RADIOACTIVE FIELDS.

Warning Electrostatic discharge (ESD) can damage or destroy electronic components. Handle static-sensitive components only at static-safe workstation. Consider all electrical and electronic components of the monitor as staticsensitive.

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.

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Vital Signs Monitor Series 300

Safety Summary

Symbols

•

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

•

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

•

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

•

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.

Symbols The symbols illustrated on the following pages appear on the monitor or in this document. Documentation Symbols

Indicates important information related to the current topic of discussion.

Caution Indicates a condition or practice which, if continued or not corrected immediately, could cause damage to the equipment. Warning Indicates a condition or practice which, if continued or not corrected immediately, could lead to serious illness, injury, or death.

Certification and Operation Labels

C

US

This device has been tested and certified by the Canadian Standards Association International to comply with applicable U.S. and Canadian medical safety standards.

Urgent alarm notification (output to Nurse Call system)

The CE Mark and Notified Body

Recycle used batteries properly and in accordance with local regulations.

0123 Registration Number signify that the device meets all essential requirements of the European Medical Device Directive 93/42/ EEC.

Vital Signs Monitor Series 300

Do not dispose of batteries in refuse containers.

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Symbols

Safety Summary

Australian Registered Importer N344

Sealed lead-acid battery, 6V 4 Ah

WELCH ALLYN PTY LTD 5/38-46 SOUTH STREET RYDALMERE, NSW 2116 AUSTRALIA

Pb Patient connections are Type BF, and protected against defibrillation.

Refer to the product documentation.

Shipping, Storing, and Environment Labels Keep this end of the package or shipping crate up.

Protect the monitor from exposure to rain.

Fragile contents-handle with care.

n

Do not expose the monitor to relative humidity above this limit.

Do not subject the monitor to altitudes outside these limits.

Limit stacking to this number of units.

Do not expose the monitor to temperatures outside these limits.

Monitor Connector Labels SpO2

Temperature Probe Cable Connector

SpO2 Sensor Cable Connector

RS232 Cable Connector

AC Power Adapter Cable Connector

Nurse Call Cable Connector

NIBP Hose Connector

Printer Door Label Press to open the printer door

Service Manual

Load paper this direction

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Vital Signs Monitor Series 300

Safety Summary

Symbols

The monitor front panel controls are described in more detail throughout this document. Front Panel Controls Set alarm limits

Power on/off

Silence alarms

Print patient data

Scroll up/down Scroll forward/back Increase/decrease value

Review patient data

(The scroll icon appears as these two arrows in the documentation.) Start/stop an NIBP cycle

Set an NIBP automatic measurement interval

(AUTO button)

Cycle to the next menu selections

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Symbols

Safety Summary

Front Panel Displays and Indicators SYS DIA SpO2

Systolic pressure Diastolic pressure Arterial hemoglobin oxygen saturation

Temperature

Pulse rate

message window

pulse amplitude indicator

Pulse strength

MAP (mean arterial pressure)

Neonatal

°C

Degrees Celsius

Pediatric

°F

Degrees Fahrenheit

Adult

M

Monitored temperature

AC power Battery charging (flashing) Battery charged (steady)

Battery low Battery fully discharged

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Vital Signs Monitor Series 300

2 - Overview Purpose and Scope This service manual is a reference for periodic preventive maintenance and corrective service procedures for the Vital Signs Monitor 300 Series. Corrective service is supported to the level of field-replaceable units. These include some circuit-board assemblies and some subassemblies, case parts, and other parts. (See Replacement Parts (page 77) for a complete list of user-replaceable service parts.) Repair and replacement of the main board is not supported. All service work on the main board must be performed by certified and qualified service personnel at an authorized Welch Allyn service center. 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 monitor, invalidate the product warranty, and lead to serious personal injury.

This guide provides troubleshooting information, assembly procedures, and instructions for functional testing and performance verification. It is intended for use only by technically qualified service personnel. This guide applies only to the Vital Signs Model 300 Series. For servicing the previous (52000series) version of the Vital Signs Monitor, refer to Welch Allyn service manual 95P445E, which is available on the TechView CD (900298-1).

Technical Support Services Welch Allyn offers the following technical support services: Telephone support Loaner equipment Service agreements Service training Replacement service parts Factory Service For information on any of these services, contact Welch Allyn at the customer-service numbers listed on page 2.

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Returning Products

Overview

Returning Products To return a product for service, contact Welch Allyn Technical Support and request a Return Material Authorization (RMA) number. Welch Allyn does not accept returned products without an RMA.

When requesting an RMA, please have the following information available: •

Product name, model number, and serial number

•

A complete return shipping address, including a contact name and phone number; include any special shipping instructions

•

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

•

A full description of the problem or service request

To ship the unit, please observe these packing guidelines: •

Remove from the package all hoses, connectors, cables, sensors, power cords, and other ancillary products and equipment, except those items that might be associated with the problem.

•

Use the original shipping carton and packing materials, or as close an approximation as possible.

•

Include a packing list.

•

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

United States federal regulations require that any unit received by Factory Service must be free from blood-borne pathogens before processing. All incoming products are cleaned as well as possible, but products that cannot be effectively cleaned cannot be accepted for repair. Please thoroughly clean all organic residues from the product before shipment. This will ensure safe receipt, processing and repair, and will help expedite the return of your monitor.

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Vital Signs Monitor Series 300

Overview

Product Configurations

Product Configurations Model numbers for the configurations are as follows: Model Number

Monitoring Parameters

53000

NIBP

5300P

NIBP, Printer

530T0

NIBP, Temperature

530TP

NIBP, Temperature, Printer

53N00

NIBP, SpO2

53N0P

NIBP, SpO2, Printer

53NT0

NIBP, SpO2, Temperature

53NTP

NIBP, SpO2, Temperature, Printer

Serial Number Prefix

JA

Recommended Service Intervals Interval or Condition

Action Recommended

Procedure

Page

Every 6 - 24 months (per hospital protocols)

Complete functional test

Functional Verification

17

Battery does not hold a charge

Check battery capacity

Functional Verification

17

Replace battery

Disassembly Procedure

43

Monitor has been dropped or otherwise damaged

Complete functional test

Functional Verification

17

Monitor malfunctioning

Complete functional test

Functional Verification

17

Monitor does not pass Functional Verification

Troubleshooting and repair followed by functional test

Troubleshooting and Repair Disassembly Procedure Functional Verification

37 43 17

Return to authorized service center

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Service Options

Overview

Service Options Warranty Service All repairs on products under warranty must be performed or approved by Welch Allyn. Refer all warranty service to Welch Allyn Factory Service or another authorized Welch Allyn Service Center. Obtain an RMA number for all returns to Welch Allyn Factory Service – see Returning Products (page 12).

Caution Unauthorized repairs will void the product warranty.

Non-Warranty Service Welch Allyn Factory 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. The Welch Allyn Monitor Service Utility supports certain service functions. For information, see page 40.

Related Documents Title

Part Number

Reorder Number

Vital Signs Monitor 300 Series Directions for Use (English)

810-1632-XX

810-1726-XX

Vital Signs Monitor 300 Series Directions for Use (French)

810-1716-XX

810-1727-XX

Vital Signs Monitor 300 Series Directions for Use (Spanish)

810-1715-XX

810-1729-XX

Vital Signs Monitor 300 Series Directions for Use (German)

810-1713-XX

810-1728-XX

Vital Signs Monitor 300 Series Directions for Use (Italian)

810-1712-XX

810-1725-XX

Welch Allyn Parts and Accessories Guide

810-0409-XX

810-0409-XX

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Vital Signs Monitor Series 300

Overview

Service Menu

Service Menu To see the service menu, first power the monitor off. Press and hold for 3 seconds. While is depressed, press . The monitor displays the message Service Mode, runs a self-test, and then displays the main software version number (M: 1.00.00). Press repeatedly to cycle to the menu selection of interest.

/min SYS

SpO2 %

DIA

3 seconds

SERVICE MODE Power-up Self-test

Main SW version

RESET TO DEFAULT YES

M: X.XX.XX

NO

NIBP SW version

BP CYCLES:XXXXXX

N:XX.XX.XX

RUN TIME:XXXXX

POWER OFF Exit Service Mode SpO2 SW version

BATTERY:X.XX V

S:X.X.X.X

Temperature SW version

NIBP TEST

T:X.X

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Service Menu

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Overview

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Vital Signs Monitor Series 300

3 - Functional Verification Functional Verification Overview This section describes the procedure for a complete functional test to support recommended preventive-maintenance schedules. The verification includes tests for a monitor configured with the printer, temperature, and SpO2 options. Perform only the tests applicable to the actual configuration. A checklist of the functional tests is provided on page 35. It is recommended that you print a copy of the checklist each time you perform the functional verification procedure, so that you can record and save the test results. If the monitor ever requires service, the records of test results can often facilitate troubleshooting. Functional verification does not require opening the monitor case.

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Equipment Required

Functional Verification

Equipment Required The following equipment is required for functional verification of a fully configured monitor. Commercially Available General-purpose/Medical Test Equipment Item

Manufacturer Part Number/Specification

Power supply

Variable, 0-8 VDC, 0.75A (minimum), with voltage and current indicators (for 1mA current measurement)

Digital pressure meter

Netech Digimano 1000 or equivalent

AC withstand voltage (hi-pot) tester

Associated Research 3605 or equivalent

SpO2 functional tester (for testing the monitor only)

Nellcor SRC-MAX

SpO2 extension cable (required for SRC-MAX)

Nellcor DEC-8

SpO2 simulator (for testing the monitor and the SpO2 sensor)

Fluke (Biotek) Index2 XL/XLFE or equivalent

Syringe, 60 mL, Slip tip, Luer

BD (Becton, Dickinson) 309654 or equivalent

Hi-pot cable connectors

See page 34.

Timer

Welch Allyn Accessories and Test Equipment Temperature test key (for testing the monitor only)

06138-000

9600 Temperature calibration tester (for testing the monitor and the temperature probe)

01800-210, 110V 01800-500, 220V 01800-810, 220V UK 01800-910, 220V Australia

Neonatal cuff hose, 96”

008-0265-XX

Neonatal #1 cuff, disposable, box of 10

008-0620-XX

500 cc air volume

T112854

DC power adapter

5200-101A

Battery substitution connector (Use the female end from the cable set)

660-0237-XX

Welch Allyn Monitor Service Utility (required for NIBP repair or replacement; not required for functional testing)

840-0676-XX

Service Serial Cable (for use with the Welch Allyn Monitor Service Utility 840-0676-XX)

008-0842-XX

NIBP tubing connector, threaded

600-0021-XX

tubing, 1’

600-0179-XX

Tee, plastic

600-0043-XX

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Vital Signs Monitor Series 300

Functional Verification

Functional Verification Procedure

Functional Verification Procedure System/Power Setup •

If the monitor is configured with the temperature option, connect the temperature probe and insert it into the probe well.

•

If you are using the optional Welch Allyn Model 9600 Calibration Tester (01800-200), plug it in and set it to 96.4° F (35.8° C).

•

If the monitor is configured with the SpO2 option, connect the SpO2 sensor.

Battery Charge and Beeper 1. Disconnect the power adapter from the monitor. 2. Verify that the charge LED

is off.

3. Connect the power adapter. The monitor emits a single beep tone. 4. Verify that the charge LED

is on.

Depending on the charge level of the battery, the charge LED may be either flashing or steady. flashing indicates that the monitor is running on AC, the battery is charging, and the battery is charged to less than 90% capacity. steady indicates that the monitor is running on AC, the battery may or may not be charging, and the battery is charged to at least 90% capacity.

Battery Substitution Cable Setup 1. Disconnect the power adapter. 2. Remove the battery cover and remove and disconnect the battery. 3. Separate the connector pair (660-0237-00). Use the end that is identical to the connector on the battery as a battery substitution test cable. 4. Connect the open-ended red (+) and black (-) wires of this cable to the variable DC power supply. 5. Set the power supply to 6.0 V ± 50 mV. 6. Connect the test power cable to the battery connector on the monitor.

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Functional Verification Procedure

Functional Verification

Monitor-Off Current With the monitor powered down, verify that the current draw from the power supply is less than 1 mA.

Power-On Self-Test 1. Power the monitor on. If the monitor displays error E38, power the monitor off and then power it on again.

2. Verify that the start-up tone (double beep) is audible. 3. Verify that all front-panel lights (background indicators, LCD pixels, and LED segments and periods) come on in the proper order: left, center, and right.

Initialization/Idle Mode Current If your monitor is configured without the temperature option and without the SpO2 option, skip these steps and proceed to Baseline Current Draw.

1. If the temperature option is present: a. Verify that the temperature probe is in the probe well. b. Set the temperature mode to MONITOR. c. Remove the temperature probe from the probe well. d. Verify that the temperature reading appears within 4 seconds. e. Do not return the probe to the probe well. 2. If the SpO2 option is present: a. Verify that the SpO2 sensor cable is connected to the monitor. b. Verify that the current draw from the bench power supply is less than 800 mA. 3. Disconnect the SpO2 sensor (if equipped). 4. Insert the temperature probe (if the monitor is so equipped) into the probe well.

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Functional Verification

Functional Verification Procedure

Baseline Current Draw 1. With the monitor powered on, wait for the monitor LEDs to blank. In this state, the SpO2 % reads - -, the time of day is displayed in the message window, and the rest of the displays are blank. 2. Note and record the exact current from the power supply. (This value will be used in the NIBP and printer tests.)

Battery Voltage 1. Power the monitor off. 2. Simultaneously press and hold and to bring up the monitor in SERVICE MODE. (When the monitor completes the power-on self-test in service mode, the main software version number appears in the message display.) 3. Press

repeatedly until BATTERY VOLTAGE appears in the message display.

4. Verify that the displayed battery voltage is within 0.1 volt of the DC power supply input. 5. Exit Service Mode by turning off the monitor and then turning it on again.

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