Hospira Lifecare PCA3 User manual

TECHNICAL SUPPORT OPERATIONS
ELECTRONIC TECHNICAL SERVICE MANUAL
TECHNICAL SUPPORT OPERATIONS
ELECTRONIC TECHNICAL SERVICE MANUAL
EPS-04566-003 (REV. 1/05)
HOSPIRA
Infusion System
LifeCare PCA3

Infusion System
For use with list number 12384-04
Technical
Service
Manual
PCA
3
LIFECARE
®
430-04566-003 (Rev. 1/05)

430-04566-003 (Rev. 1/05) LifeCare PCA3 Infusion System
© 2005 Hospira, Inc.
This document and the subject matter disclosed herein are proprietary information. Hospira
retains all the exclusive rights of dissemination, reproduction, manufacture, and sale. Any party
using this document accepts it in confidence, and agrees not to duplicate it in whole or in part
nor disclose it to others without the written consent of Hospira.

Technical Service Manual i 430-04566-003 (Rev. 1/05)
Change History
Part Number Description of Change
430-04566-001 (Rev. 11/02) Original issue
430-04566-002 (Rev. 08/03) Second Issue
Updated and revised throughout
430-04566-003 (Rev. 1/05) Third Issue
Incorporated Hospira name change.
Updated Section 1 self test screens.
Updated Section 5 self test screens.
Updated Delivery Accuracy and Occlusion
tests to current specifications.
Updated Section 7 procedures to accomodate
new parts.
Updated Section 8, Specifications, to
accomodate software changes (µg changed to
mcg).

CHANGE HISTORY
430-04566-003 (Rev. 1/05) ii LifeCare PCA3 Infusion System
This page intentionally left blank.

CONTENTS
Technical Service Manual iii 430-04566-003 (Rev. 1/05)
Contents
Section 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 CONVENTIONS . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 COMPONENT DESIGNATORS . . . . . . . . . . . . . . . . . . 1-2
1.4 ACRONYMS AND ABBREVIATIONS . . . . . . . . . . . . . . . . 1-3
1.5 USER QUALIFICATION . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 ARTIFACTS . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 INSTRUMENT INSTALLATION PROCEDURE . . . . . . . . . . . . 1-5
1.7.1 UNPACKING . . . . . . . . . . . . . . . . . . . . . . 1-5
1.7.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 1-6
1.7.3 SELF TEST. . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.7.4 SETTING THE TIME AND DATE . . . . . . . . . . . . . . . 1-7
Section 2
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Section 3
SYSTEM OPERATING MANUAL . . . . . . . . . . . . . . . . . . . . 3-1
Section 4
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . 4-1
4.2 ELECTRONICS OVERVIEW . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 POWER SUPPLY MODULE . . . . . . . . . . . . . . . . . 4-2
4.2.2 INPUT POWER LOGIC . . . . . . . . . . . . . . . . . . . 4-2
4.2.2.1 INPUT VOLTAGE SWITCH-OVER CIRCUITRY. . . . . . . 4-2
4.2.2.2 ETERNAL POWER CIRCUITRY. . . . . . . . . . . . . 4-2
4.2.2.3 POWER CONTROL LOGIC CIRCUITRY . . . . . . . . . 4-3
4.2.3 VOLTAGE SUPERVISION CIRCUIT . . . . . . . . . . . . . . 4-3
4.2.4 MICROCONTROLLER SUPERVISION CIRCUIT . . . . . . . . . 4-3
4.2.5 LITHIUM BATTERY BACKUP . . . . . . . . . . . . . . . . 4-4
4.2.6 BATTERY CHARGER . . . . . . . . . . . . . . . . . . . 4-4
4.2.6.1 LOW BATTERY DETECTION . . . . . . . . . . . . . 4-4
4.2.6.2 DISCHARGED BATTERY DETECTION . . . . . . . . . . 4-5
4.2.7 LOGIC INTERFACE . . . . . . . . . . . . . . . . . . . . 4-5
4.2.7.1 GLUE LOGIC – LCD I/O . . . . . . . . . . . . . . . 4-5
4.2.7.2 GLUE LOGIC – SERIAL I/O CHANNEL ENABLE . . . . . . 4-5
4.2.8 LCD INTERFACE . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.8.1 LCD MODULE . . . . . . . . . . . . . . . . . . . 4-6
4.2.8.2 LCD CONTRAST . . . . . . . . . . . . . . . . . . 4-6
4.2.8.3 LCD BACKLIGHT. . . . . . . . . . . . . . . . . . 4-6
4.2.8.4 BATTERY INDICATOR. . . . . . . . . . . . . . . . 4-6
4.2.8.5 AC POWER INDICATOR . . . . . . . . . . . . . . . 4-7
4.2.9 KEYPAD INTERFACE . . . . . . . . . . . . . . . . . . . 4-7
4.2.10 SERIAL PORT . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.11 BARCODE READER . . . . . . . . . . . . . . . . . . . . 4-7
4.2.12 PATIENT PENDANT . . . . . . . . . . . . . . . . . . . . 4-8
4.2.12.1 PCA INPUT . . . . . . . . . . . . . . . . . . . . 4-8
4.2.13 DOOR SENSOR. . . . . . . . . . . . . . . . . . . . . . 4-8
4.2.14 MECHANISM ASSEMBLY. . . . . . . . . . . . . . . . . . 4-9

CONTENTS
430-04566-003 (Rev. 1/05) iv LifeCare PCA3 Infusion System
4.2.14.1 VIAL SENSOR . . . . . . . . . . . . . . . . . . . 4-10
4.2.14.2 INJECTOR CLAMP SENSOR . . . . . . . . . . . . . 4-10
4.2.14.3 SYRINGE EMPTY SENSOR . . . . . . . . . . . . . . 4-10
4.2.14.4 PRESSURE OCCLUSION SENSOR . . . . . . . . . . . 4-10
4.2.14.5 SHAFT SENSOR . . . . . . . . . . . . . . . . . . 4-10
4.2.14.6 DUAL BIPOLAR DRIVE . . . . . . . . . . . . . . . 4-11
4.2.15 REAL-TIME CLOCK . . . . . . . . . . . . . . . . . . . . 4-11
4.2.16 ALARM LOGIC. . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.16.1 NORMAL ALARM . . . . . . . . . . . . . . . . . 4-12
4.2.16.2 CRITICAL FAILURE ALARM . . . . . . . . . . . . . 4-12
4.2.16.3 NORMAL SHUTDOWN INHIBIT . . . . . . . . . . . . 4-12
4.2.16.4 VOLUME CONTROL . . . . . . . . . . . . . . . . 4-12
4.2.16.5 ALARM TONE . . . . . . . . . . . . . . . . . . . 4-12
4.2.16.6 NORMAL KEY TONE . . . . . . . . . . . . . . . . 4-13
4.2.17 PROGRAM MEMORY . . . . . . . . . . . . . . . . . . . 4-13
4.2.18 DATA MEMORY . . . . . . . . . . . . . . . . . . . . . 4-13
Section 5
MAINTENANCE AND SERVICE TESTS . . . . . . . . . . . . . . . . . . 5-1
5.1 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 CLEANING . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.3 SANITIZING . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 PERFORMANCE VERIFICATION TEST . . . . . . . . . . . . . . . 5-3
5.2.1 REQUIRED EQUIPMENT . . . . . . . . . . . . . . . . . . 5-3
5.2.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.3 TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.4 SELF TEST . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.5 SERVICE MODE TESTS . . . . . . . . . . . . . . . . . . 5-5
5.2.6 DELIVERY ACCURACY TEST . . . . . . . . . . . . . . . . 5-7
5.2.7 OCCLUSION TEST . . . . . . . . . . . . . . . . . . . . 5-8
5.2.8 ELECTRICAL SAFETY TEST . . . . . . . . . . . . . . . . . 5-9
5.2.9 END OF THE PVT . . . . . . . . . . . . . . . . . . . . . 5-9
5.3 PRINTER TEST (OPTIONAL) . . . . . . . . . . . . . . . . . . . 5-10
5.4 PERIODIC MAINTENANCE INSPECTION . . . . . . . . . . . . . . 5-10
5.5 BATTERY OPERATION OVERVIEW . . . . . . . . . . . . . . . . 5-11
Section 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 TECHNICAL ASSISTANCE . . . . . . . . . . . . . . . . . . . 6-1
6.2 DIAGNOSTIC MODE. . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 ALARM MESSAGES AND ERROR CODES . . . . . . . . . . . . . . 6-2
6.3.1 OPERATIONAL ALARM MESSAGES . . . . . . . . . . . . . 6-2
6.3.2 ERROR CODES REQUIRING TECHNICAL SERVICE . . . . . . . . 6-4
6.4 TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . 6-10
Section 7
REPLACEABLE PARTS AND REPAIRS . . . . . . . . . . . . . . . . . . 7-1
7.1 REPLACEABLE PARTS . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 ADJUSTMENT PROCEDURES . . . . . . . . . . . . . . . . . . 7-3
7.2.1 REQUIRED TOOLS AND MATERIALS . . . . . . . . . . . . . 7-3
7.2.2 SEPARATING THE FRONT AND REAR ENCLOSURE ASSEMBLIES . . 7-4
7.2.3 INJECTOR SENSOR SWITCH ADJUSTMENT . . . . . . . . . . 7-5
7.2.4 VIAL SENSOR SWITCH ADJUSTMENT . . . . . . . . . . . . 7-6

CONTENTS
Technical Service Manual v 430-04566-003 (Rev. 1/05)
7.2.5 OCCLUSION ALARM SWITCH TEST
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 7-7
7.2.5.1 OCCLUSION ALARM SWITCH TEST . . . . . . . . . . 7-7
7.2.5.2 OCCLUSION ALARM SWITCH AND PRESSURE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . 7-9
7.2.6 LEAD SCREW LUBRICATION . . . . . . . . . . . . . . . . 7-10
7.3 REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . 7-11
7.3.1 SAFETY AND EQUIPMENT PRECAUTIONS . . . . . . . . . . . 7-11
7.3.2 REQUIRED TOOLS AND MATERIALS . . . . . . . . . . . . . 7-11
7.3.3 FRONT AND REAR ENCLOSURE REPLACEMENT . . . . . . . . 7-12
7.3.4 RUBBER FOOT PAD REPLACEMENT . . . . . . . . . . . . . 7-13
7.3.5 AC POWER CORD REPLACEMENT . . . . . . . . . . . . . . 7-15
7.3.6 BATTERY, BATTERY DOOR, BATTERY DOOR PAD, AND BATTERY
STRAP REPLACEMENT. . . . . . . . . . . . . . . . . . . 7-15
7.3.7 PATIENT PENDANT ASSEMBLY REPLACEMENT . . . . . . . . . 7-16
7.3.8 FRONT ENCLOSURE ASSEMBLY COMPONENT REPLACEMENT . . . 7-17
7.3.8.1 SECURITY DOOR AND DOOR HINGE REPLACEMENT . . . 7-17
7.3.8.2 KEYPAD REPLACEMENT . . . . . . . . . . . . . . . 7-19
7.3.8.3 DOOR LATCH HOOK REPLACEMENT. . . . . . . . . . 7-20
7.3.8.4 CRADLE ASSEMBLY REPLACEMENT . . . . . . . . . . 7-20
7.3.8.5 MECHANISM LEVER ARM REPLACEMENT . . . . . . . . 7-21
7.3.8.6 DOOR LATCH ASSEMBLY REPLACEMENT . . . . . . . . 7-23
7.3.8.7 DOOR LOCK ASSEMBLY REPLACEMENT . . . . . . . . 7-23
7.3.8.8 HANDLE GASKET AND ENCLOSURE GASKET
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-25
7.3.8.9 ELECTRONICS ASSEMBLY REPLACEMENT. . . . . . . . 7-25
7.3.8.10 ELECTRONICS ASSEMBLY COMPONENT
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-26
7.3.8.11 LCD WINDOW REPLACEMENT . . . . . . . . . . . . 7-32
7.3.8.12 MECHANISM ASSEMBLY REPLACEMENT . . . . . . . . 7-32
7.3.8.13 BARCODE READER, GASKET, AND WINDOW
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-33
7.3.8.14 SPLASH SHIELD REPLACEMENT. . . . . . . . . . . . 7-34
7.3.9 REAR ENCLOSURE ASSEMBLY COMPONENT REPLACEMENT . . . 7-34
7.3.9.1 FUSE REPLACEMENT . . . . . . . . . . . . . . . . 7-36
7.3.9.2 POLE CLAMP ASSEMBLY REPLACEMENT . . . . . . . . 7-36
7.3.9.3 VELCRO STRAP AND RETAINER PLATE REPLACEMENT . . 7-37
7.3.9.4 POWER SUPPLY PWA REPLACEMENT . . . . . . . . . . 7-38
7.3.9.5 PAWL/RATCHET ASSEMBLY REPLACEMENT . . . . . . . 7-38
7.3.9.6 REAR ENCLOSURE HARNESS ASSEMBLY, EQUIPOTENTIAL
POST, AND GROUND STRAP REPLACEMENT. . . . . . . 7-39
7.3.9.7 BATTERY PAD REPLACEMENT . . . . . . . . . . . . 7-40
7.3.9.8 SERIAL PORT CABLE ASSEMBLY REPLACEMENT . . . . . 7-41
7.3.9.9 PATIENT PENDANT JACK ASSEMBLY REPLACEMENT . . . 7-42
Section 8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Section 9
DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

FIGURES
430-04566-003 (Rev. 1/05) vi LifeCare PCA3 Infusion System
Figures
Figure 1-1. PCA 3 Self Test Screens . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure 1-2. Setting the Time and Date . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 4-1. Mechanism Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-2. Dual Bipolar Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Figure 5-1. PCA 3 Self Test Screens . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 7-1. Separating the Front and Rear Enclosure Assemblies . . . . . . . . . . . . 7-5
Figure 7-2. Injector Sensor Switch. . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Figure 7-3. Vial Sensor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Figure 7-4. Occlusion Alarm Test Setup . . . . . . . . . . . . . . . . . . . . . . . 7-9
Figure 7-5. Occlusion Alarm Pressure Adjustment . . . . . . . . . . . . . . . . . . 7-10
Figure 7-6. Battery Assembly, AC Power Cord, and Patient Pendant Assembly. . . . . . 7-14
Figure 7-7. Front Enclosure Assembly External Components . . . . . . . . . . . . . . 7-18
Figure 7-8. Front Enclosure Assembly Internal Components . . . . . . . . . . . . . . 7-22
Figure 7-9. Door Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Figure 7-10. Electronics Assembly Components . . . . . . . . . . . . . . . . . . . . 7-27
Figure 7-11. Rear Enclosure External Components . . . . . . . . . . . . . . . . . . . 7-35
Figure 7-12. Rear Enclosure Harness Assembly . . . . . . . . . . . . . . . . . . . . 7-40
Figure 7-13. Rear Enclosure Internal Components . . . . . . . . . . . . . . . . . . . 7-43
Figure 9-1. Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . 9-5
Figure 9-2. Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Figure 9-3. Front Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Figure 9-4. Rear Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Figure 9-5. Electronics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Figure 9-6. Mechanism Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Figure 9-7. MCU PWA Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Figure 9-8. Numeric Display Schematic . . . . . . . . . . . . . . . . . . . . . . . 9-35
Figure 9-9. Icon Display Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Tables
Table 1-1. Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Table 4-1. Motor Step Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Table 5-1. Cleaning Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-2. System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Table 6-1. Operational Alarm Messages . . . . . . . . . . . . . . . . . . . . . . 6-3
Table 6-2. Error Codes Requiring Technical Service . . . . . . . . . . . . . . . . . 6-4
Table 6-3. Troubleshooting with the PVT . . . . . . . . . . . . . . . . . . . . . . 6-11
Table 9-1. Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Table 9-2. Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . 9-1

Technical Service Manual 1 - 1 430-04566-003 (Rev. 1/05)
Section 1
INTRODUCTION
The LifeCare® PCA 3 Infusion System is a patient-controlled analgesia management system
designed to meet the fluid delivery requirements of today’s evolving healthcare
environments. The system is comprised of a pole mounted or tabletop drug infusion pump
(PCA 3), drug vials with a variety of pre-filled drugs and drug concentrations (PCA 3 vial),
and an administration set (PCA 3 set).
The PCA 3 pump is a self-contained, microprocessor-based infusion device with keypad
controls; a prompting alphanumeric display; an LED display; an integral locking system;
a pole clamp; a barcode reader for drug identification; field-upgradeable software;
and a connector for a DataPort, which includes inputs and outputs for devices such as
a computer or printer. The pump is intended to operate on AC power. An internal battery
is provided to maintain operation for short periods of time during patient transport and
when AC power is lost or not available.
1.1
SCOPE
This manual is organized into 11 sections:
❏Section 1 Introduction
❏Section 2 Warranty
❏Section 3 System Operating Manual
❏Section 4 Theory of Operation
❏Section 5 Maintenance and Service Tests
❏Section 6 Troubleshooting
❏Section 7 Replaceable Parts and Repairs
❏Section 8 Specifications
❏Section 9 Drawings
❏Index
❏Technical Service Bulletins
If a problem in device operation cannot be resolved using the information in this manual,
contact Hospira (see Section 6.1, Technical Assistance).
Specific instructions for operating the device are contained in the PCA 3 System Operating
Manual. Provision is made for the inclusion of the system operating manual in Section 3
of this manual.
Note: Figures are rendered as graphic representations to approximate actual product;
therefore, figures may not exactly reflect the product.

SECTION 1 INTRODUCTION
430-04566-003 (Rev. 1/05) 1 - 2 LifeCare PCA 3 Infusion System
1.2
CONVENTIONS
The conventions listed in Table 1-1, Conventions, are used throughout this manual.
Throughout this manual, warnings, cautions, and notes are used to emphasize important
information as follows:
CAUTION: A caution usually appears prior to a procedure or statement. A caution
contains information that could prevent irreversible equipment damage or failure.
Note: A note highlights information that helps explain a concept or procedure.
1.3
COMPONENT DESIGNATORS
Components are indicated by alpha-numeric designators, as follows:
The number following the letter is a unique value for each type of component (e.g., R1, R2).
Note: Alpha-numeric designators may be followed with a dash (-) number that
indicates a pin number for that component. For example, U15-13 is pin 13 of the
encoder chip [U15] on the interface PWA.
Table 1-1. Conventions
Convention Application Example
Italic Reference to a section, figure,
table, or publication
(see Section 6.1, Technical
Assistance)
[ALL CAPS] In-text references to keys
and touchswitches
[SILENCE]
ALL CAPS Screen displays LOW BATTERY
Bold Emphasis CAUTION: Use proper ESD
grounding techniques
when handling
components.
WARNING: A WARNING CONTAINS SPECIAL SAFETY EMPHASIS AND MUST
BE OBSERVED AT ALL TIMES. FAILURE TO OBSERVE A WARNING
IS POTENTIALLY LIFE THREATENING.
Battery BT Diode DResistor R
Capacitor CFuse FSwitch SW
Crystal YIntegrated Circuit UTransistor Q

1.4 ACRONYMS AND ABBREVIATIONS
Technical Service Manual 1 - 3 430-04566-003 (Rev. 1/05)
1.4
ACRONYMS AND ABBREVIATIONS
Acronyms and abbreviations used in this manual are as follows:
AAmpere
AC Alternating current
ADC Analog-to-digital converter
BCR Barcode reader
CMOS Complementary metal-oxide semiconductor
CPU Central processing unit
dB Decibel
DC Direct current
DPM Digital pressure meter
DSLR Display start line register
ECG Electrocardiograph
EEG Electroencephalogram
EMG Electromyogram
EMI Electromagnetic interference
EPROM Erasable/programmable read-only memory
ESD Electrostatic discharge
ETO Ethylene oxide
hr Hour
Hz Hertz
ID Identification
I/O Input/output
IPB Illustrated parts breakdown
IV Intravenous
lbs Pounds
LCD Liquid crystal display
LED Light emitting diode
mA Milliampere
mcg Microgram
MCU Microcontroller unit
mg Milligram
mL Milliliter
MPU Microprocessor unit
ms Millisecond
ns nanosecond
N/A Not applicable

SECTION 1 INTRODUCTION
430-04566-003 (Rev. 1/05) 1 - 4 LifeCare PCA 3 Infusion System
PCL Power control logic
psi Pounds per square inch
PVT Performance verification test
PWA Printed wiring assembly
RAM Random access memory
ROM Read only memory
RTC Real-time clock
SLA Sealed lead acid
SPDT Single pole double throw
SPI Serial peripheral interface
SRAM Static random access memory
UART Universal asynchronous receiver transmitter
VVolt
VAC Volts alternating current
VCC Collector supply voltage
VDC Volts DC
WDI Watchdog input
µAMicroampere
µVMicrovolt
1.5
USER QUALIFICATION
The PCA 3 infusion pump is intended for use at the direction or under the supervision of
licensed physicians or certified health care professionals who are trained in the use of the
pump and the administration of parenteral and enteral fluids and drugs, and whole blood
or red blood cell components. Training should emphasize preventing related IV
complications, including appropriate precautions to prevent accidental infusion of air.
The epidural route can be used to provide anesthesia or analgesia.
1.6
ARTIFACTS
Nonhazardous, low-level electrical potentials are commonly observed when fluids are
administered using infusion devices. These potentials are well within accepted safety
standards, but may create artifacts on voltage-sensing equipment such as ECG, EMG,
and EEG machines. These artifacts vary at a rate that is associated with the infusion rate.
If the monitoring machine is not operating correctly or has loose or defective connections
to its sensing electrodes, these artifacts may be accentuated so as to simulate actual
physiological signals. To determine if the abnormality in the monitoring equipment is
caused by the pump instead of some other source in the environment, set the pump so
that it is temporarily not delivering fluid. Disappearance of the abnormality indicates that
it was probably caused by electronic noise generated by the pump. Proper setup and
maintenance of the monitoring equipment should eliminate the artifact. Refer to the
appropriate monitoring system documentation for setup and maintenance instructions.

1.7 INSTRUMENT INSTALLATION PROCEDURE
Technical Service Manual 1 - 5 430-04566-003 (Rev. 1/05)
1.7
INSTRUMENT INSTALLATION
PROCEDURE
CAUTION: Infusion pump damage may occur unless proper care is exercised during
product unpacking and installation. The battery may not be fully charged upon
receipt of the infusion pump. Do not place the infusion pump in service if it fails the
self test.
CAUTION: Infusion pump performance may be degraded by electromagnetic
interference (EMI) from devices such as electrosurgical units, cellular phones,
and two-way radios. Operation of the infusion pump under such conditions should
be avoided.
The instrument installation procedure consists of unpacking, inspection, self test,
and setting the time and date.
Note: Do not place the infusion pump in service if the battery is not fully charged.
To make certain the battery is fully charged, connect the infusion pump to AC power
for 24 hours (see Section 8, Specifications).
1.7.1
UNPACKING
Inspect the infusion pump shipping container as detailed in Section 1.7.2, Inspection.
Use care when unpacking the infusion pump. Retain the packing slip and save all packing
material in the event it is necessary to return the PCA 3 to the factory. Verify that the
shipping container contains a copy of the system operating manual.

SECTION 1 INTRODUCTION
430-04566-003 (Rev. 1/05) 1 - 6 LifeCare PCA 3 Infusion System
1.7.2
INSPECTION
Inspect the infusion pump shipping container for shipping damage. Should any damage
be found, contact the delivering carrier immediately.
CAUTION: Inspect the infusion pump for evidence of damage. Do not use the pump
if it appears to be damaged. Should damage be found, contact Hospira (see Section
6.1, Technical Assistance).
Inspect the infusion pump periodically for signs of defects such as worn accessories,
broken connections, or damaged cable assemblies. Also inspect the infusion pump after
repair or during cleaning. Replace any damaged or defective external parts.
1.7.3
SELF TEST
CAUTION: Do not place the infusion pump in service if the self test fails.
To perform the self test, refer to Figure 1-1, PCA 3 Self Test Screens, and proceed as follows:
1. Unlock and open the security door.
2. Plug the AC power cord into a grounded, hospital grade, 120 VAC, 50-60 Hz
receptacle. Verify the AC plug indicator on the front panel is illuminated.
3. Press [ON/OFF] to turn the power on. The pump will perform a self test verifying
the integrity of the software, memory, and selected electronic functions.
4. Verify the time and date. To set the time and date, refer to Section 1.7.4, Setting the
Time and Date.
Note: If the quality of earth grounding source is in doubt, use battery power.
Note: When the AC plug indicator is off and the battery indicator on the
display is flashing, this is an indication that the PCA 3 is operating on low
battery power and should be recharged.
5. To confirm the battery is charged before placing the pump in service, plug the AC
power cord into hospital grade 120 VAC and charge for 24 hours.
Note: If an alarm condition occurs during the self test, press [ON/OFF] twice and
repeat the self test. If the alarm condition recurs, note the message and take corrective
action (see Section 6, Troubleshooting). Repeat the self test. If the alarm condition
recurs, remove the PCA 3 from service and contact Hospira.

1.7 INSTRUMENT INSTALLATION PROCEDURE
Technical Service Manual 1 - 7 430-04566-003 (Rev. 1/05)
Figure 1-1. PCA 3 Self Test Screens
1.7.4
SETTING THE TIME AND DATE
To set the time and date, refer to Figure 1-1, PCA 3 Self Test Screens and Figure 1-2, Setting
the Time and Date, and proceed as follows:
1. Unlock and open the security door.
2. Press [ON/OFF] to turn the power on. Wait for the SELF TEST COMPLETE screen
to appear.
3. Press the [SYSTEM SETTINGS] softkey.
4. Press the [TIME/DATE] softkey. A WARNING screen appears.
Note: Changing the time or date will clear all totals.
5. Press the [CONTINUE] softkey.
6. Set the time using the keypad touchswitches. Press the [AM/PM] softkey to toggle
AM/PM.
Note: AM/PM option is available only in 12-hour clock format.
7. Press the [NEXT] softkey to continue.
8. Set the date using the keypad touchswitches.
9. Press the [NEXT] softkey.
10. Press the [CONFIRM] softkey to accept current time and date settings or press
[CHANGE] to change time or date settings.
11. Verify the SAVING DATE AND TIME screen is displayed. Press the [CONFIRM]
softkey.
12. Verify the SELECT SETTING TO CHANGE screen is displayed.
00K06001
LIFECARE PCA 3
SELF TEST
LIFECARE PCA 3
DATE: 11/12/02
SOFTWARE
V4.09
COPYRIGHT
HOSPIRA INC.
2004
SELF TEST
SYSTEM
SETTINGS
LIFECARE PCA 3
SELF TEST
COMPLETE
RAM....OK
FLASH . . OK
CPU ID . OK
CPU....OK
TIMER . . OK
CONTINUE
TIME: 08:45 AM

SECTION 1 INTRODUCTION
430-04566-003 (Rev. 1/05) 1 - 8 LifeCare PCA 3 Infusion System
13. Press the [ON/OFF] softkey when correct time and date are displayed.
Figure 1-2. Setting the Time and Date
SET DATE WITH
NUMBERS
CONFIRM
CURRENT
TIME AND DATE
SETTINGS
TIME/DATE
SELECT
SETTING
TO CHANGE
BUTTONS
01/15/03
NEXT
CHANGE
CANCEL
CONTINUE
CONFIRM
9:21 PM
01/15/03
VOLUME
CONTRAST
SELECT
SETTING
CHANGING THE
DATE OR TIME
WILL CLEAR ALL
TOTALS
WARNING
AM/PM
SET TIME WITH
NUMBERS
BUTTONS
TOGGLE AM/PM
10:43PM
TO CHANGE
VOLUME
CONTRAST
TIME/DATE
CONTINUE
CONTINUE
PREVIOUS
NEXT
00K06019

Technical Service Manual 2 - 1 430-04566-003 (Rev. 1/05)
Section 2
WARRANTY
Subject to the terms and conditions herein, Hospira, Inc. herein referred to as Hospira,
warrants that (a) the product shall conform to Hospira's standard specifications and be
free from defects in material and workmanship under normal use and service for a period
of one year after purchase, and (b) the replaceable battery shall be free from defects in
material and workmanship under normal use and service for a period of 90 days after
purchase. Hospira makes no other warranties, express or implied, as to merchantability,
fitness for a particular purpose, or any other matter.
Purchaser's exclusive remedy shall be, at Hospira's option, the repair or replacement of
the product. In no event shall Hospira's liability arising out of any cause whatsoever
(whether such cause be based in contract, negligence, strict liability, other tort, or
otherwise) exceed the price of such product, and in no event shall Hospira be liable for
incidental, consequential, or special damages or losses or for lost business, revenues, or
profits. Warranty product returned to Hospira must be properly packaged and sent freight
prepaid.
The foregoing warranty shall be void in the event the product has been misused, damaged,
altered, or used other than in accordance with product manuals so as, in Hospira's
judgment, to affect its stability or reliability, or in the event the serial or lot number has
been altered, effaced, or removed.
The foregoing warranty shall also be void in the event any person, including the Purchaser,
performs or attempts to perform any major repair or other service on the product without
having been trained by an authorized representative of Hospira and using Hospira
documentation and approved spare parts. For purposes of the preceding sentence, "major
repair or other service" means any repair or service other than the replacement of accessory
items such as batteries, flow detectors, detachable AC power cords, and patient pendants.
In providing any parts for repair or service of the product, Hospira shall have no
responsibility or liability for the actions or inactions of the person performing such repair
or service, regardless of whether such person has been trained to perform such repair or
service. It is understood and acknowledged that any person other than a Hospira
representative performing repair or service is not an authorized agent of Hospira.

SECTION 2 WARRANTY
430-04566-003 (Rev. 1/05) 2 - 2 LifeCare PCA 3 Infusion System
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Technical Service Manual 3 - 1 430-04566-003 (Rev. 1/05)
Section 3
SYSTEM OPERATING MANUAL
A copy of the system operating manual is included with every LifeCare PCA 3 infusion
system. Insert a copy here for convenient reference. If a copy of the system operating
manual is not available, contact Hospira Technical Support Operations (see Section 6.1,
Technical Assistance).