Care Fusion Alaris 8110 series User manual

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RATE (mL/h)
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CHANNEL
SELECT
CHANNEL
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PAUSE
RESTART
RATE (mL/h)
Technical Service Manual
Alaris®Syringe Module, 8110 Series
Alaris®PCA Module, 8120 Series
Supports: Guardrails® (Suite v7 or Later)
November 2010

General Contact Information
Customer Advocacy - North America
Clinical and technical feedback.
Phone: [phone]
E-Mail: [e-mail]
Technical Support - North America
Maintenance and service information support; troubleshooting.
United States:
Phone:
888.876.4287
Canada:
Phone:
800.387.8309
Customer Care - North America
Instrument return, service assistance, and order placement.
United States:
Phone: [phone]
Canada:
Phone: [phone]
CareFusion
San Diego, California
http://www.carefusion.com/alaris

TABLE OF CONTENTS
i
Chapter 1 - General Information
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Precaution Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Operating Features, Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Alarms, Errors, Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6.1 Silencing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Trumpet and Start-Up Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chapter 2 - Checkout and Configuration
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 New Instrument Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Configuration Options and Defaults - Syringe Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.1 Factory Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Configuration Setup - Syringe Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4.1 All Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4.2 Auto Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4.3 Back Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4.4 Fast Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4.5 KVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4.6 Max Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.7 Near End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4.8 Pressure Limit - Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.4.9 Pressure Limit - No Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.4.10 Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.5 Configuration Setup - Shared Infusion Pump and Syringe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6 Configuration Options and Defaults - PCA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Chapter 3 - Preventive Maintenance
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Regular and Preventive Maintenance Inspections, Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Chapter 4 - Principles of Operation
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Display Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual

ii
TABLE OF CONTENTS
Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
Chapter 4 - Principles of Operation (Continued)
4.3.1 Microcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.2 LED Display Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.3 Comparator/Safety Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.4 Status and Backlight LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Logic Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 Drivetrain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.6 Drive Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.7 Plunger Head Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.8 Force Sensor Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.9 Pressure Sensor Subsystem (Syringe Module Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.10 Patient Handset Circuit and Door Lock Sensor Circuit (PCA Module Only) . . . . . . . . . . . . . . . . . . . . . . 4-5
Chapter 5A - Corrective Maintenance - Syringe Module
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-1
5.2 Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
5.2.1 Removing Latch Assembly and Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-3
5.2.2 Removing IUI Connector Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4
5.2.3 Separating Rear Case from Chassis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5
5.2.4 Removing Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-6
5.2.5 Removing Flex Cable Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-7
5.2.6 Removing IUI Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-8
5.2.7 Removing Logic Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-9
5.2.8 Removing Internal Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-10
5.2.9 Removing Drivetrain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-11
5.2.10 Removing Display Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-12
5.2.11 Removing Pressure Sensor Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-13
5.2.12 Removing Top Disk Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-14
5.2.13 Removing Sensor Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-15
5.2.14 Removing Syringe Size Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-16
5.2.15 Removing Syringe Barrel Clamp Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-17
5.2.16 Removing Status Indicator Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-19
5.2.17 Removing Housing Assembly and Guide Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-20
5.2.18 Removing Motor/Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-21
5.2.19 Removing Leadscrew Assembly and Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-22
5.2.20 Removing Linear Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-23
5.2.21 Removing Force Sensor and Actuator Knob Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-24
5.2.22 Removing Actuator Knob Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-25

TABLE OF CONTENTS
iiiAlaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
Chapter 5B - Corrective Maintenance - PCA Module
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-1
5.2 Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2
5.2.1 Removing Latch Assembly and Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3
5.2.2 Removing IUI Connector Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4
5.2.3 Removing Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5
5.2.4 Removing Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6
5.2.5 Removing Rear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-8
5.2.6 Removing Flex Cable Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-9
5.2.7 Removing IUI Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10
5.2.8 Removing Logic Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11
5.2.9 Removing Internal Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-12
5.2.10 Removing Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-13
5.2.11 Removing Latch Module and Drivetrain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
5.2.12 Removing Display Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-15
5.2.13 Removing Sensor Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-16
5.2.14 Removing Syringe Size Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17
5.2.15 Removing Syringe Barrel Clamp Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-18
5.2.16 Removing Status Indicator Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-20
5.2.17 Removing Handset Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-21
5.2.18 Removing Latch Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-22
5.2.19 Removing Housing Assembly and Guide Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-23
5.2.20 Removing Motor/Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24
5.2.21 Removing Leadscrew Assembly and Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-25
5.2.22 Removing Linear Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-26
5.2.23 Removing Force Sensor and Actuator Knob Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-27
5.2.24 Removing Actuator Knob Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-28
Chapter 6 - Troubleshooting
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Chapter 7A - Illustrated Parts Breakdown - Syringe Module
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
7.2 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
7.3 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-1
7.4 Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2

iv
TABLE OF CONTENTS
Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
Chapter 7B - Illustrated Parts Breakdown - PCA Module
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
7.2 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
7.3 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-1
7.4 Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2
List of Figures
4-1 Block Diagram: Syringe and PCA Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
7A-1 Actuator Knob Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-7
7A-2 Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-8
7A-3 Drivetrain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-9
7A-4 Front Case Assembly - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-11
7A-5 Front Case Assembly - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-12
7A-6 Top Disk Holder - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-13
7A-7 Front Case, Syringe Barrel Clamp Assembly, Top Disk Holder -- Interchangeability . . . . . . . . . . 7A-14
7A-8 Front Case Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-15
7A-9 Drivetrain Assembly - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-16
7A-10 Internal Frame Assembly - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-17
7A-11 Logic Board and IUI Board Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-18
7A-12 Flex Cable Retainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-19
7A-13 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-20
7A-14 Rear Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-22
7A-15 Display Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-23
7A-16 IUI Interface Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-24
7A-17 Logic Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-25
7B-1 Actuator Knob Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-7
7B-2 Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-8
7B-3 Drivetrain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-9
7B-4 Front Case Assembly - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-11
7B-5 Front Case Assembly - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-12
7B-6 Latch Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-13
7B-7 Drivetrain Assembly - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-14
7B-8 Internal Frame Assembly - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-15
7B-9 Logic Board and IUI Board Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-16
7B-10 Flex Cable Retainer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-17
7B-11 Rear Case - Front Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-18
7B-12 Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-19
7B-13 Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-21
7B-14 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-22

TABLE OF CONTENTS
List of Figures (continued)
7B-15 Key Kit and Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-23
7B-16 Display Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-24
7B-17 IUI Interface Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-25
7B-18 Logic Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-26
List of Tables
1-1 Abbreviations, Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
5A-1 Required Materials, Supplies and Tools - Syringe Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
5A-2 Torque Values - Syringe Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-26
5A-3 Level of Testing Guidelines- Syringe Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-27
5B-1 Required Materials, Supplies and Tools - PCA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2
5B-2 Torque Values - PCA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-29
5B-3 Level of Testing Guidelines- PCA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-30
6-1 Technical Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 Subsystem Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-3 Error Code Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-4 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
7A-1 Parts List - Syringe Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3
7B-1 Parts List - PCA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-2
vAlaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual

vi
TABLE OF CONTENTS
Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
THIS PAGE
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1GENERAL INFORMATION

1.1 INTRODUCTION
This manual describes how to service the
Alaris®Syringe Module (“Syringe Module”,
8110 Series)and Alaris®PCA Module (“PCA
Module”, 8120 Series). Use this manual in
conjunction with the following Alaris®System
documents and software:
• Alaris®Point-of-Care unit (“PC Unit”, 8000
Series) / Alaris®Pump Module (“Pump
Module”, 8100 Series)Technical Service
Manual
• Alaris®System Directions for Use (DFU)
• Maintenance Software and User Manual
(Software v7.x or later)
PRODUCT NAME NOTE: The “Alaris®
System” was formerly known as the “Medley™
System” and is described in the Alaris®
System DFU.
This manual is intended for personnel
experienced in analysis, troubleshooting,
and repair of analog/digital microprocessor-
based electronic equipment.
If either module requires service while under
warranty, it must be serviced only by
CareFusion authorized service
personnel. Refer to the “Warranty” and
“Service Information” sections of the Alaris®
System DFU.
The Alaris®System is a modular infusion
and monitoring system intended for use in
adult, pediatric and neonatal healthcare.
The Syringe Module is intended for facilities
that use syringe pumps to deliver fluids,
medications, blood, and blood products
using continuous or intermittent delivery
through clinically acceptable routes of
administration, such as intravenous (IV),
intra-arterial (IA), subcutaneous, epidural,
enteral, or irrigation of fluid spaces.
Chapter 1 — GENERAL INFORMATION
1-1
Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
To avoid damaging the keypad, do not use sharp
objects (pens, pencils, etc.) to activate switches.
CAUTION
Any attempt to service this product by anyone
other than an authorized CareFusion Service
Representative while the product is under
warranty may invalidate the warranty.
CAUTION

The PCA Module is intended for facilities
that use syringe pumps to deliver fluids or
medications using continuous or intermittent
delivery through clinically acceptable routes
of administration, such as intravenous (IV),
subcutaneous, or epidural.
Refer to the product-specific (Syringe
Module or PCA Module) section of the
Alaris®System DFU for a list of features and
detailed information regarding setup and
operation.
1.2 PRECAUTION DEFINITIONS
Refer to the Alaris®System DFU .
1.3 SPECIFICATIONS
Refer to the product-specific section of the
Alaris®System DFU.
1.4 OPERATING FEATURES, CONTROLS
AND INDICATORS
Refer to the product-specific section of the
Alaris®System DFU.
1.5 ACCESSORIES
The Syringe Module uses standard, single-
use, disposable syringes (with luer-lock
connectors) and administration sets
designed for use on syringe pumps.
The PCA Module uses standard or pre-filled,
single-use disposable syringes (with luer-
lock connectors) and non-dedicated
administration sets with integrated anti-
siphon valves designed for use on syringe-
type PCA devices. For specific
administration set instructions, reference the
directions for use provided with the set.
1.6 ALARMS, ERRORS, MESSAGES
Alarm messages are displayed on the
scrolling Message Display bar. Refer to the
product-specific section of the Alaris®
System DFU for detailed information.
1.6.1 Silencing Alarms
All alarms can be temporarily silenced by
pressing the SILENCE key on the PC Unit.
1.7 TRUMPET AND START-UP CURVES
Refer to the product-specific section of the
Alaris®System DFU.
Use only specified syringes and
administration sets with the Syringe and
PCA Modules. Using other syringes or
administration sets can cause improper
instrument operation, inaccurate fluid
delivery or pressure sensing, or other
potential hazards. For a list of compatible
syringes, refer to the product-specific
section of the Alaris®System DFU. For a list
of compatible administration sets, refer to
the module’s Administration Set
Compatibility Card/Insert (provided
separately).
WARNING
If an alarm condition on the module occurs
while the audio alarm is silenced, the only
alarm indications will be visual displays and
symbols related to the alarm condition.
WARNING
GENERAL INFORMATION
1-2 Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
1.1 INTRODUCTION (Continued)

GENERAL INFORMATION
1-3Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
CHSE HD cheese head (screw)
DB0 database zero
DFU Directions for Use
IA intra-arterial
IUI inter-unit interface
NEOI near end of infusion
TR HD truss head (screw)
VDAC voltage DAC
Table 1-1. Abbreviations, Acronyms
Various abbreviations and acronyms are used throughout this manual. The following are those that are
not commonly known or easily recognized.

GENERAL INFORMATION
1-4 Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
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2CHECKOUT & CONFIGURATION

Chapter 2 — CHECKOUT AND CONFIGURATION
2-1Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
2.1 INTRODUCTION
This chapter describes initial setup and
configuration for the Syringe and PCA
Modules.
NOTE: Due to product changes over time,
configurations described in this chapter may
differ from the instrument under service. If
there are any questions, contact CareFusion
Technical Support.
2.2 NEW INSTRUMENT CHECKOUT
Prior to placing a new instrument in use,
perform a check-in procedure using the
Maintenance Software.
When powering up the instrument, verify the
instrument beeps and all display LED
segments flash. This confirms that the
instrument has performed its self test and is
operating correctly. During operation, the
instrument continually performs a self test,
and will alarm and display a message if it
detects an internal malfunction.
Contact CareFusion authorized service
personnel if the instrument has physical
damage, fails to satisfactorily pass the
startup sequence, fails a self test, or
continues to alarm.
Should an instrument be jarred severely or
dropped, remove it from use immediately. It
should be thoroughly tested and inspected by
qualified service personnel to ensure proper
function prior to reuse.
CAUTION

2.3 CONFIGURATION OPTIONS AND
DEFAULTS - SYRINGE MODULE
NOTES:
• Changes to the factory default values are
retained after a power cycle.
• If Factory Default is Yes, then all the
configuration settings are set to their
factory default.
• If Factory Default is No, then one or
more of the configuration settings has
been changed. Setting Factory Default
to Yes sets all configuration settings to
their factory default.
• With the Profiles feature enabled, the
settings are configured independently for
each profile. A hospital-defined, best-
practice data set must be uploaded to
enable the Profiles feature. Date and
Time is a system setting and is the same
in all profiles.
Refer to the Alaris®System DFU for the
following:
• System Settings
• Shared Infusion Settings (Pump Module
and Syringe Module)
• Syringe Module Settings
2.3.1 Factory Default Setting
To allow changes to System Configuration
parameters:
1. Hold OPTIONS key at power up.
2. Press Factory default soft key.
3. Press No soft key.
4. To accept change, press EXIT soft key.
• Option setting changes and main
System Config - Module screen
displays.
2.4 CONFIGURATION SETUP - SYRINGE
MODULE
NOTES:
• Pressing the EXIT soft key while in a
System Config - Module screen
immediately powers the system down, with
no “Powering Down” display.
• Pressing the EXIT soft key while in a
System Config - Syringe screen returns
the display to the main System Config -
Module screen.
CHECKOUT AND CONFIGURATION
2-2 Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
>Select an Option
or EXIT
EXIT
Factory default:
Yes
System Config - Module 1 of 2
PC Unit
Shared Infusion Settings
Pump Module
SPO2 Module
PAGE
DOWN
EXIT
System Configuration
FactoryDefault
Settings?
Yes
No
Selection of Yes sets all
System Configuration
parameters to the factory
default setting.

NOTES: (Continued)
• Pressing the CONFIRM soft key while in a
System Configuration option screen:
♦accepts existing setting or setting
change
♦displays next option setting screen (if
applicable) or returns display to System
Config - Syringe screen
• Pressing the PC Unit CANCEL key while in
a System Configuration option screen:
♦leaves setting unchanged
♦returns display to System Config -
Syringe screen
To access System Configuration options:
1. Hold OPTIONS key at power up.
2. Press PAGE DOWN soft key.
3. Press Syringe Module soft key.
4. To view additional options, press PAGE
DOWN soft key.
2.4.1 All Mode
Enabling All mode allows ALL to be
selected as the volume to be infused (VTBI),
to deliver the entire contents of the syringe.
CHECKOUT AND CONFIGURATION
2-3
Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
>Select an Option
or EXIT
EXIT
Factory default:
No
System Config - Module 1 of 2
PC Unit
Shared Infusion Settings
Pump Module
SPO2 Module
PAGE
DOWN
2.4 CONFIGURATION SETUP - SYRINGE
MODULE (Continued)
>Select an Option
or EXIT
EXIT
Syringe Module
System Config - Module 2 of 2
PAGE
UP
EtCO2 Module
>Select an Option
or EXIT
EXIT
System Config - Syringe 2 of 2
Pressure limit-Disc:1000 mmHg
PAGE
UP
Pressure limit-NoDisc: Med
Near End:
Priming: Disabled
Max rate:
999 mL/h
Disabled
>Select an Option
or EXIT
EXIT
System Config - Syringe 1 of 2
PAGE
DOWN
Back Off:
Disabled
Disabled
Fast Start:
KVO:
Auto Pressure:
Disabled
Disabled
Disabled
All Mode:
If KVO and ALL modes are both enabled,
the ALL mode will not deliver the entire
syringe contents. A small percentage of the
syringe contents will be left available for
KVO operation.
CAUTION

1. After accessing System Config -
Syringe options display, press All Mode
soft key.
2. To change option setting, press soft key
next to applicable option (Enable or
Disable).
• Option setting changes and System
Config - Syringe page 1displays.
2.4.2 Auto Pressure
Enabling Auto Pressure allows the Auto
Pressure option to be displayed in the
Pressure Limit screen when a pressure
sensing disc is in use. Auto Pressure
automatically sets the alarm limit for a
shorter time to alarm, as follows:
• If current pressure is 100 mmHg or less,
system adds 30 mmHg to current
pressure, to create a new alarm limit.
• If current pressure is greater than
100 mmHg, system adds 30% to current
pressure, to create a new alarm limit.
1. After accessing System Config -
Syringe options display, press Auto
Pressure soft key.
2. To change option setting, press soft key
next to applicable option (Enable or
Disable).
• Option setting changes and System
Config - Syringe page 1displays.
2.4.3 Back Off
When Back Off mode is enabled and a
pressure sensing disc is in use, the motor
reverses plunger movement during an
occlusion until the pressure returns to
preocclusion levels, automatically reducing
bolus flow.
1. After accessing System Config -
Syringe options display, press Back Off
soft key.
2. To change option setting, press soft key
next to applicable option (Enable or
Disable).
• Option setting changes and System
Config - Syringe page 1displays.
CHECKOUT AND CONFIGURATION
2-4 Alaris®Syringe Module (8110 Series)
Alaris®PCA Module (8120 Series)
Technical Service Manual
2.4 CONFIGURATION SETUP - SYRINGE
MODULE (Continued)
2.4.1 All Mode (Continued)
System Configuration - Syringe
Back Off mode
Enable
Disable
Allows use of the
back off feature.
System Configuration - Syringe
Auto Pressure
Enable
Disable
Allows use of the
auto pressure feature.
System Config - Pump 2 of 3
System Configuration - Syringe
All mode
Allows use of the
All mode feature.
Enable
Disable