Hospira PLUM XL Series Operating manual

TECHNICAL SUPPORT OPERATIONS
ELECTRONIC TECHNICAL SERVICE MANUAL
TECHNICAL SUPPORT OPERATIONS
ELECTRONIC TECHNICAL SERVICE MANUAL
EPS-00587-008 (REV. 2/05)
HOSPIRA
Infusion Systems
Plum XL Series

For use with the following list numbers:
Technical Service Manual
Plum XL 11555-04, 12570-04
LifeCare XL 11555-09, 11555-13, 11555-27, 11555-29, 11555-36,
11555-46, 11555-54, 11555-88
Plum XLM 11846-04
LifeCare XLM 11846-09, 11846-27, 11846-29, 11846-36, 11846-42,
11846-46, 11846-54, 11846-88
Plum XLM
with DataPort
11859-04
Plum XLM
with DataPort
Veterinary
12570-04
LifeCare XLM
with DataPort
11859-09, 11859-27, 11859-29, 11859-36, 11859-42,
11859-54, 11859-63, 11859-69, 11859-71, 11859-88
430-00587-008 (Rev. 2/05)

430-00587-008 (Rev. 2/05) Plum XL Series
© 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 430-00587-008 (Rev. 2/05)
Change History
Part Number
Description of
Change
Remove and
Destroy Pages
Insert
Change
Pages
430-00587-001 (Rev. 11/93) Original issue
430-00587-002 (Rev. 7/94) Second issue
430-00587-A02 (Rev. 11/94) Updated cover Cover Cover
Updated Change
History
i, ii i, ii
Added error code 59-1
to Table 6-2
6-7 to 6-10 6-7 to 6-10
430-00587-003 (Rev. 2/96) Third issue
430-00587-004 (Rev. 12/97) Fourth issue
430-00587-005 (Rev. 2/99) Fifth issue
Updated Table 5-1
Included international
DataPort content
430-00587-006 (Rev. 10/99) Sixth issue
Included nurse call
adapter information
430-00587-007 (Rev. 08/01) Seventh issue
Updated PVT in
Section 5
Updated replacement
procedures in
Section 7
Updated IPB graphics
in Section 9
430-00587-008 (Rev. 2/05) Eighth issue
Incorporated Hospira
name change
Included
IEC 60601-1-2
specifications in
Appendix and
throughout manual
Updated replacement
procedures in
Section 7
Updated IPB graphics
in Section 9

CHANGE HISTORY
430-00587-008 (Rev. 2/05) ii Plum XL Series
This page intentionally left blank.

Technical Service Manual iii 430-00587-008 (Rev. 2/05)
Contents
Section 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 GLOBAL PRODUCT CONFIGURATIONS . . . . . . . . . . . . . . 1-2
1.3 CONVENTIONS . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4 COMPONENT DESIGNATORS . . . . . . . . . . . . . . . . . . 1-6
1.5 ACRONYMS AND ABBREVIATIONS . . . . . . . . . . . . . . . . 1-6
1.6 USER QUALIFICATION . . . . . . . . . . . . . . . . . . . . . 1-7
1.7 ARTIFACTS . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.8 INSTRUMENT INSTALLATION PROCEDURE . . . . . . . . . . . . 1-8
1.8.1 UNPACKING . . . . . . . . . . . . . . . . . . . . . . 1-8
1.8.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 1-9
1.8.3 SELF TEST. . . . . . . . . . . . . . . . . . . . . . . . 1-9
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 PWA . . . . . . . . . . . . . . . . . . . 4-2
4.2.1.1 SWITCHER CIRCUITRY . . . . . . . . . . . . . . . 4-2
4.2.1.2 VOLTAGE REGULATOR CIRCUITRY . . . . . . . . . . 4-3
4.2.1.3 BATTERY CHARGER CIRCUITRY . . . . . . . . . . . 4-4
4.2.2 POWER SUPPLY PWA . . . . . . . . . . . . . . . . . . . 4-5
4.2.2.1 SWITCHER CIRCUITRY . . . . . . . . . . . . . . . 4-5
4.2.2.2 VOLTAGE REGULATOR CIRCUITRY . . . . . . . . . . 4-6
4.2.2.3 BATTERY CHARGER CIRCUITRY . . . . . . . . . . . 4-6
4.2.3 MCU PWA. . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.3.1 WATCHDOG CIRCUITRY . . . . . . . . . . . . . . 4-7
4.2.3.2 SERIAL COMMUNICATION CIRCUITRY . . . . . . . . . 4-7
4.2.3.3 ALARM CIRCUITRY (XL) . . . . . . . . . . . . . . . 4-8
4.2.3.4 ALARM CIRCUITRY (XLM) . . . . . . . . . . . . . . 4-8
4.2.3.5 ALARM POWER BACKUP CIRCUITRY . . . . . . . . . . 4-8
4.2.3.6 MOTOR DRIVER CIRCUITRY . . . . . . . . . . . . . 4-9
4.2.3.7 PIN DETECTOR CIRCUITRY . . . . . . . . . . . . . 4-9
4.2.3.8 UART (XLM WITH DATAPORT) . . . . . . . . . . . . 4-9
4.2.3.9 NURSE CALL ALARM
(XLM WITH DATAPORT - NURSE CALL) . . . . . . . . . 4-10
4.2.4 BUZZER PWA (XLM) . . . . . . . . . . . . . . . . . . . . 4-10
4.2.4.1 HIGH VOLUME AUDIBLE ALARM . . . . . . . . . . . 4-10
4.2.4.2 LOCKOUT SWITCH . . . . . . . . . . . . . . . . . 4-11
4.2.5 DISPLAY PWA . . . . . . . . . . . . . . . . . . . . . . 4-11
4.2.5.1 DISPLAY CIRCUITRY (XL) . . . . . . . . . . . . . . 4-11
4.2.5.2 DISPLAY CIRCUITRY
(XLM DISPLAY PWA -003 AND LOWER) . . . . . . . . . 4-11

CONTENTS
430-00587-008 (Rev. 2/05) iv Plum XL Series
4.2.5.3 DISPLAY CIRCUITRY
(XLM DISPLAY PWA -004 AND HIGHER) . . . . . . . . . 4-11
4.2.5.4 EL PANEL DRIVER CIRCUITRY (XL) . . . . . . . . . . 4-12
4.2.5.5 LED BACKLIGHT PANEL AND DRIVER (XLM) . . . . . . 4-12
4.2.5.6 RUN INDICATOR CIRCUITRY. . . . . . . . . . . . . 4-12
4.2.5.7 LINE POWER INDICATOR CIRCUITRY . . . . . . . . . 4-12
4.2.5.8 CONTROL KNOB CIRCUITRY (XL) . . . . . . . . . . . 4-13
4.2.5.9 CONTROL KNOB CIRCUITRY (XLM) . . . . . . . . . . 4-13
4.2.6 SENSOR PWA . . . . . . . . . . . . . . . . . . . . . . 4-13
4.2.6.1 PRESSURE AMPLIFIER/FILTER CIRCUITRY. . . . . . . . 4-13
4.2.6.2 AC AMPLIFIER CIRCUITRY . . . . . . . . . . . . . . 4-14
4.2.6.3 VOLTAGE REFERENCE CIRCUITRY . . . . . . . . . . 4-14
4.2.6.4 OPTO INTERRUPTER CIRCUITRY . . . . . . . . . . . 4-14
4.2.6.5 EEPROM CIRCUITRY . . . . . . . . . . . . . . . . 4-14
4.2.7 BUBBLE SENSOR PWA . . . . . . . . . . . . . . . . . . . 4-14
4.2.7.1 TRANSMITTER CIRCUITRY . . . . . . . . . . . . . 4-15
4.2.7.2 RECEIVER CIRCUITRY . . . . . . . . . . . . . . . 4-15
4.2.7.3 PIN DETECTOR FLEX CIRCUITRY . . . . . . . . . . . 4-15
4.3 MECHANICAL OVERVIEW . . . . . . . . . . . . . . . . . . . 4-16
4.3.1 CASSETTE . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.3.2 MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . 4-18
4.3.2.1 MOTOR AND VALVE ASSEMBLIES. . . . . . . . . . . 4-19
4.3.2.2 PRIMARY/SECONDARY VALVE SUBSYSTEM . . . . . . . 4-19
4.3.2.3 INLET/OUTLET VALVE SUBSYSTEM . . . . . . . . . . 4-20
4.3.2.4 PLUNGER DRIVE SUBSYSTEM . . . . . . . . . . . . 4-20
Section 5
MAINTENANCE AND SERVICE TESTS . . . . . . . . . . . . . . . . . . 5-1
5.1 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 INSPECTING THE INFUSION SYSTEM. . . . . . . . . . . . . 5-1
5.1.2 CLEANING THE INFUSION SYSTEM . . . . . . . . . . . . . 5-1
5.1.3 SANITIZING THE INFUSION SYSTEM . . . . . . . . . . . . . 5-2
5.1.4 CLEANING THE BUZZER . . . . . . . . . . . . . . . . . . 5-3
5.2 PERFORMANCE VERIFICATION TEST . . . . . . . . . . . . . . . 5-4
5.2.1 EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . 5-4
5.2.2 ICONS AND ENGLISH LANGUAGE EQUIVALENTS . . . . . . . 5-5
5.2.3 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 5-6
5.2.4 TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.2.5 SELF TEST . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.2.6 KEYPAD AND CONTROL KNOB TEST . . . . . . . . . . . . . 5-8
5.2.7 OPEN DOOR ALARM TEST . . . . . . . . . . . . . . . . . 5-9
5.2.8 ALARM LOUDNESS TEST (XL) . . . . . . . . . . . . . . . . 5-9
5.2.9 ALARM LOUDNESS AND LOCK FUNCTION TESTS (XLM) . . . . . 5-9
5.2.10 BATTERY LEGEND TEST . . . . . . . . . . . . . . . . . . 5-10
5.2.11 FREE FLOW TEST . . . . . . . . . . . . . . . . . . . . . 5-10
5.2.12 PROXIMAL OCCLUSION TEST. . . . . . . . . . . . . . . . 5-10
5.2.13 DISTAL OCCLUSION TEST . . . . . . . . . . . . . . . . . 5-11
5.2.14 DELIVERY ACCURACY TEST . . . . . . . . . . . . . . . . 5-12
5.2.15 EMPTY CONTAINER/AIR-IN-LINE ALARM TEST . . . . . . . . . 5-12
5.2.16 ELECTRICAL SAFETY TEST . . . . . . . . . . . . . . . . . 5-13
5.2.17 END OF PERFORMANCE VERIFICATION TEST . . . . . . . . . 5-14
5.3 PERIODIC MAINTENANCE INSPECTION . . . . . . . . . . . . . . 5-14
5.4 BATTERY OPERATION OVERVIEW . . . . . . . . . . . . . . . . 5-14
5.4.1 BATTERY CHARGER CURRENT TEST (OPTIONAL) . . . . . . . . 5-15
5.5 DATAPORT CONNECTION AND GROUND CONTINUITY TEST
(OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.6 NURSE CALL FUNCTION TEST (OPTIONAL). . . . . . . . . . . . . 5-18

CONTENTS
Technical Service Manual v 430-00587-008 (Rev. 2/05)
Section 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 TECHNICAL ASSISTANCE. . . . . . . . . . . . . . . . . . . . 6-1
6.2 ALARM MESSAGES AND ERROR CODES . . . . . . . . . . . . . . 6-1
6.2.1 OPERATIONAL ALARM MESSAGES . . . . . . . . . . . . . 6-2
6.2.2 ERROR CODES REQUIRING TECHNICAL SERVICE . . . . . . . . 6-6
6.2.3 SERVICE MODE . . . . . . . . . . . . . . . . . . . . . 6-11
6.2.3.1 ALARM HISTORY . . . . . . . . . . . . . . . . . 6-11
6.2.3.2 SOFTWARE REVISION NUMBER . . . . . . . . . . . . 6-12
6.2.3.3 RUN TIME AND BATTERY RUN TIME . . . . . . . . . . 6-12
6.2.3.4 PARAMETER PROGRAMMING
(XLM WITH DATAPORT) . . . . . . . . . . . . . . . 6-12
6.3 TROUBLESHOOTING PROCEDURES. . . . . . . . . . . . . . . . 6-14
Section 7
REPLACEABLE PARTS AND REPAIRS . . . . . . . . . . . . . . . . . . 7-1
7.1 REPLACEABLE PARTS . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . 7-3
7.2.1 SAFETY AND EQUIPMENT PRECAUTIONS . . . . . . . . . . . 7-3
7.2.2 REQUIRED TOOLS AND MATERIALS . . . . . . . . . . . . . 7-3
7.2.3 RUBBER FOOT PAD REPLACEMENT . . . . . . . . . . . . . 7-4
7.2.4 BATTERY WITH WIRE HARNESS ASSEMBLY, BATTERY DOOR, AND
BATTERY DOOR PAD REPLACEMENT . . . . . . . . . . . . . 7-6
7.2.5 SEPARATING THE FRONT ENCLOSURE ASSEMBLY, REAR ENCLOSURE
ASSEMBLY, AND MAIN CHASSIS ASSEMBLY . . . . . . . . . . 7-7
7.2.6 FRONT ENCLOSURE ASSEMBLY, REAR ENCLOSURE ASSEMBLY, OR
MAIN CHASSIS ASSEMBLY REPLACEMENT . . . . . . . . . . 7-9
7.2.7 FRONT ENCLOSURE ASSEMBLY COMPONENT REPLACEMENT . . . 7-10
7.2.7.1 DISPLAY PWA AND MCU/DISPLAY CABLE
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-11
7.2.7.2 FRONT PANEL KEY REPLACEMENT . . . . . . . . . . 7-12
7.2.7.3 CONTROL KNOB, KNOB DETENT, WASHER, GASKET, SNAP
RETAINER, AND DETENT RING REPLACEMENT . . . . . 7-13
7.2.7.4 FRONT PANEL LABEL REPLACEMENT . . . . . . . . . 7-14
7.2.8 REAR ENCLOSURE ASSEMBLY COMPONENT REPLACEMENT . . . 7-14
7.2.8.1 FUSE REPLACEMENT . . . . . . . . . . . . . . . . 7-15
7.2.8.2 POWER SUPPLY PWA REPLACEMENT . . . . . . . . . . 7-17
7.2.8.3 VELCRO RETAINER STRAP REPLACEMENT . . . . . . . 7-19
7.2.8.4 AC (MAINS) POWER CORD AND STRAIN RELIEF BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-19
7.2.8.5 AC (MAINS) POWER CORD REPLACEMENT
(INTERNATIONAL) . . . . . . . . . . . . . . . . . 7-21
7.2.8.6 AC RECEPTACLE, EMI SHIELD, AND EQUIPOTENTIAL POST
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-22
7.2.8.7 LIFECARE AC RECEPTACLE, BRACKET, GASKET, SEAL, AND
EQUIPOTENTIAL POST REPLACEMENT . . . . . . . . . 7-23
7.2.8.8 DATAPORT/MCU CABLE ASSEMBLY REPLACEMENT
(XLM WITH DATAPORT) . . . . . . . . . . . . . . . 7-25
7.2.8.9 LIFECARE DATAPORT/MCU CABLE ASSEMBLY REPLACEMENT
(XLM WITH DATAPORT) . . . . . . . . . . . . . . . 7-27
7.2.8.10 POLE CLAMP EXTRUSION, POLE CLAMP BACKING PLATE,
AND ADHESIVE-BACKED INSULATOR REPLACEMENT . . . 7-28
7.2.8.11 POLE CLAMP SHAFT/KNOB ASSEMBLY AND POLE CLAMP
SHAFT TIP REPLACEMENT . . . . . . . . . . . . . . 7-30
7.2.8.12 BUZZER PWA AND MCU/BUZZER CABLE
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-31

CONTENTS
430-00587-008 (Rev. 2/05) vi Plum XL Series
7.2.9 MAIN CHASSIS ASSEMBLY COMPONENT REPLACEMENT . . . . 7-32
7.2.9.1 MCU PWA AND SENSOR/MCU CABLE ASSEMBLY
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-33
7.2.9.2 MECHANISM ASSEMBLY REPLACEMENT . . . . . . . . 7-35
7.2.9.3 CASSETTE DOOR AND MECHANISM SHIELD
REPLACEMENT . . . . . . . . . . . . . . . . . . 7-36
7.2.9.4 OPENER HANDLE ASSEMBLY REPLACEMENT . . . . . . 7-41
Section 8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 PLUM XL AND XLM . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 LIFECARE XL AND XLM . . . . . . . . . . . . . . . . . . . . 8-2
Section 9
DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

FIGURES
Technical Service Manual vii 430-00587-008 (Rev. 2/05)
Figures
Figure 1-1. Plum XL Icon Based and English Language Front Panels . . . . . . . . 1-4
Figure 1-2. Plum XLM Icon Based and English Language Front Panels . . . . . . . 1-4
Figure 1-3. Plum XL LCD Test Screens . . . . . . . . . . . . . . . . . . 1-10
Figure 1-4. Plum XLM LCD Test Screens. . . . . . . . . . . . . . . . . . 1-10
Figure 4-1. Major Elements of the Dual-Channel Cassette. . . . . . . . . . . . 4-17
Figure 4-2. Fluid Path in the Cassette . . . . . . . . . . . . . . . . . . . 4-18
Figure 4-3. Mechanism Valve Pins and Sensor Locations . . . . . . . . . . . . 4-20
Figure 5-1. Cleaning the Buzzer . . . . . . . . . . . . . . . . . . . . . 5-3
Figure 5-2. Icons and English Language Equivalents . . . . . . . . . . . . . 5-5
Figure 5-3. Plum XL LCD Test Screens . . . . . . . . . . . . . . . . . . 5-7
Figure 5-4. Plum XLM LCD Test Screens. . . . . . . . . . . . . . . . . . 5-8
Figure 5-5. Distal Occlusion Test Setup . . . . . . . . . . . . . . . . . . 5-11
Figure 5-6. Special Cassettes with Bubble Sensor Tips Removed . . . . . . . . . 5-13
Figure 5-7. Battery Charger Current Test Configuration . . . . . . . . . . . . 5-16
Figure 5-8. DataPort Connector . . . . . . . . . . . . . . . . . . . . . 5-17
Figure 7-1. Bottom View of the Infusion System . . . . . . . . . . . . . . . 7-5
Figure 7-2. Front Enclosure, Main Chassis Assembly, and Rear Enclosure . . . . . . 7-8
Figure 7-3. Display PWA and MCU/Display Cable . . . . . . . . . . . . . . 7-10
Figure 7-4. Front Enclosure Assembly Components . . . . . . . . . . . . . . 7-11
Figure 7-5. Fuse Replacement (115 VAC) . . . . . . . . . . . . . . . . . . 7-16
Figure 7-6. Fuse Replacement (220 VAC) . . . . . . . . . . . . . . . . . . 7-16
Figure 7-7. Power Supply PWA . . . . . . . . . . . . . . . . . . . . . 7-18
Figure 7-8. AC Power Cord (115 VAC - Plum XL) . . . . . . . . . . . . . . . 7-20
Figure 7-9. AC Power Cord (115 VAC - Plum XLM) . . . . . . . . . . . . . . 7-21
Figure 7-10. AC Power Cord (220 VAC - Plum XLM) . . . . . . . . . . . . . . 7-23
Figure 7-11. AC Power Cord (220 VAC - Plum XLM) . . . . . . . . . . . . . . 7-24
Figure 7-12. DataPort Assembly (Domestic) . . . . . . . . . . . . . . . . . 7-26
Figure 7-13. DataPort Assembly (International) . . . . . . . . . . . . . . . . 7-28
Figure 7-14. XL Series Pole Clamp . . . . . . . . . . . . . . . . . . . . 7-30
Figure 7-15. Buzzer PWA . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Figure 7-16. Exploded View of the Main Chassis Assembly . . . . . . . . . . . 7-34
Figure 7-17. Top View of the Main Chassis Assembly . . . . . . . . . . . . . 7-35
Figure 7-18. Mechanism Shield Replacement . . . . . . . . . . . . . . . . 7-38
Figure 7-19. Cassette Door Replacement (1 of 3). . . . . . . . . . . . . . . . 7-39
Figure 7-20. Cassette Door Replacement (2 of 3). . . . . . . . . . . . . . . . 7-39
Figure 7-21. Cassette Door Replacement (3 of 3) . . . . . . . . . . . . . . . 7-40
Figure 7-22. Cassette Door Replacement, Bottom View . . . . . . . . . . . . . 7-40
Figure 7-23. Opener Handle Assembly Replacement (1 of 3) . . . . . . . . . . . 7-42
Figure 7-24. Opener Handle Assembly Replacement (2 of 3) . . . . . . . . . . . 7-43
Figure 7-25. Opener Handle Assembly Replacement (3 of 3) . . . . . . . . . . . 7-43
Figure 9-1. Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . 9-7
Figure 9-2. Front Enclosure, Rear Enclosure, and Main Chassis Assemblies . . . . . 9-11
Figure 9-3. Front Enclosure Assembly . . . . . . . . . . . . . . . . . . . 9-13
Figure 9-4. Rear Enclosure Assembly (XL Domestic). . . . . . . . . . . . . . 9-15
Figure 9-5. Rear Enclosure Assembly (XL International) . . . . . . . . . . . . 9-17
Figure 9-6. Rear Enclosure Assembly (XLM Domestic) . . . . . . . . . . . . . 9-19
Figure 9-7. Rear Enclosure Assembly (XLM International) . . . . . . . . . . . 9-21
Figure 9-8. Rear Enclosure Assembly (XLM with DataPort - Domestic) . . . . . . . 9-23
Figure 9-9. Rear Enclosure Assembly (XLM with DataPort - International ) . . . . . 9-25
Figure 9-10. Rear Enclosure Assembly (Lifecare XLM with DataPort) . . . . . . . . 9-27
Figure 9-11. Main Chassis Assembly. . . . . . . . . . . . . . . . . . . . 9-29
Figure 9-12. Battery Replacement . . . . . . . . . . . . . . . . . . . . . 9-31
Figure 9-13. Mechanical Assembly . . . . . . . . . . . . . . . . . . . . 9-33

FIGURES
430-00587-008 (Rev. 2/05) viii Plum XL Series
Figure 9-14. Plum XL Block Diagram . . . . . . . . . . . . . . . . . . . 9-37
Figure 9-15. MCU PWA Schematic (XL) . . . . . . . . . . . . . . . . . . 9-39
Figure 9-16. MCU PWA Schematic (XLM) . . . . . . . . . . . . . . . . . . 9-43
Figure 9-17. MCU PWA Schematic (XLM with DataPort) . . . . . . . . . . . . 9-47
Figure 9-18. Display PWA Schematic (XL). . . . . . . . . . . . . . . . . . 9-83
Figure 9-19. Display PWA Schematic (XLM) . . . . . . . . . . . . . . . . . 9-85
Figure 9-20. Bubble Sensor PWA Schematic . . . . . . . . . . . . . . . . . 9-99
Figure 9-21. Sensor PWA Schematic . . . . . . . . . . . . . . . . . . . . 9-105
Figure 9-22. Pin Detector Flex Circuit Schematic . . . . . . . . . . . . . . . 9-107
Figure 9-23. Power Supply PWA Schematic (XL Domestic). . . . . . . . . . . . 9-109
Figure 9-24. Power Supply PWA Schematic (XL International) . . . . . . . . . . 9-113
Figure 9-25. Power Supply PWA Schematic (XLM Domestic) . . . . . . . . . . . 9-117
Figure 9-26. Power Supply PWA Schematic (XLM International) . . . . . . . . . 9-121
Figure 9-27. Power Supply PWA Schematic (XLM with DataPort) . . . . . . . . . 9-129
Figure 9-28. Buzzer PWA Schematic . . . . . . . . . . . . . . . . . . . . 9-137
Tables
Table 1-1. Global Product Configurations . . . . . . . . . . . . . . . . . 1-2
Table 1-2. Conventions . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Table 4-1. Battery Charge Current States . . . . . . . . . . . . . . . . . 4-4
Table 5-1. Cleaning Solutions . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-2. Battery Charger Current Test Parameters . . . . . . . . . . . . . 5-16
Table 6-1. Operational Alarm Messages and Corrective Actions . . . . . . . . . 6-2
Table 6-2. Error Codes Requiring Technical Service . . . . . . . . . . . . . 6-6
Table 6-3. Service Mode Control Knob Settings . . . . . . . . . . . . . . . 6-11
Table 6-4. Sub-Modes of Parameter Programming . . . . . . . . . . . . . . 6-12
Table 6-5. Communication Circuitry Selections . . . . . . . . . . . . . . . 6-13
Table 6-6. PVT Troubleshooting . . . . . . . . . . . . . . . . . . . . 6-14
Table 7-1. Wire Color Coding . . . . . . . . . . . . . . . . . . . . . 7-18
Table 9-1. Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Table 9-2. IPB for the Infusion System . . . . . . . . . . . . . . . . . . 9-2
Table A-1. Guidance and Manufacturer’s Declaration - Electromagnetic Emissions . . A-1
Table A-2. Guidance and Manufacturer’s Declaration - Electromagnetic Immunity . . A-2
Table A-3. Guidance and Manufacturer’s Declaration - Electromagnetic Immunity for
Life-Supporting Equipment and Systems . . . . . . . . . . . . . A-3
Table A-4. Recommended Separation Distances Between Portable and Mobile RF
Communications Equipment and the LifeCare XLM with DataPort . . . . A-5

Technical Service Manual 1 - 1 430-00587-008 (Rev. 2/05)
Section 1
INTRODUCTION
The Plum XL™, XL Micro/Macro, and XL Micro/Macro with DataPort Infusion Systems are
dual-line volumetric infusion systems designed to meet the growing demand for
hospital-wide device standardization. The infusion system provides primary line,
secondary line, and piggyback fluid delivery capabilities to furnish a wide range of general
floor, critical care, and home care applications. Compatibility with LifeCare®5000
PlumSet®administration sets and accessories make the infusion system convenient and
cost-effective. The Plum XL Micro/Macro is herein referred to as XLM. The Plum XL Micro/
Macro with DataPort is herein referred to as Plum XLM with DataPort.
Note: References to the Plum XL and XLM Infusion Systems apply to the LifeCare
XL and XLM Infusion Systems as well.
Note: Unless otherwise stated, references to the Plum XLM include the Plum XLM
with DataPort.
Note: Do not connect DataPort when infusing.
1.1
SCOPE
This Technical Service Manual applies to Plum XL series infusion systems only. It is
organized into the following 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 Repair
❏Section 8 Specifications
❏Section 9 Drawings
❏Appendices
❏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).

SECTION 1 INTRODUCTION
430-00587-008 (Rev. 2/05) 1 - 2 Plum XL Series
Specific instructions for operating the device are contained in the Plum XL System
Operating Manual, Plum XL Micro/Macro System Operating Manual, and Plum XL Micro/
Macro with DataPort System Operating Manual. Provision is made for the inclusion of the
system operating manual in Section 3 of this manual.
Note: In this manual, the terms “device” and “infusion system” refer to all
configurations of the Plum XL series infusion system unless otherwise specified.
Display messages and key labels may vary slightly, depending on the configuration
of the infusion system in use.
Note: Figures are rendered as graphic representations to approximate actual
product; therefore, figures may not exactly reflect the product.
1.2
GLOBAL PRODUCT CONFIGURATIONS
The design of the infusion system facilitates its operation in many countries with slight
modification to the product. Three configurations presented in this manual are detailed
in Table 1-1, Global Product Configurations. The front panels of the English language and
icon based system are shown in Figure 1-1, Plum XL Icon Based and English Language
Front Panels and Figure 1-2, Plum XLM Icon Based and English Language Front Panels.
Table 1-1. Global Product Configurations
Group
Icon List Number Country
Power
Supply Rear Case LCD
11555-04
11846-04
11859-04
12570-04
USA 100-130
VAC
Nondetachable AC
(mains) power cord
English
11555-13 French
Canadian
100-130
VAC
Nondetachable AC
(mains) power cord
Icons
11555-88
11846-88
11859-88*
Spanish
11555-27
11846-27
11859-27*
Australia 210-260
VAC
Detachable AC
(mains) power cord
English
11555-54
11846-54
11859-54*
UK
11555-09
11846-09
11859-09*
Spanish
(Latin
America)
210-260
VAC
Detachable AC
(mains) power cord
Icons
115 V
220 V

1.2 GLOBAL PRODUCT CONFIGURATIONS
Technical Service Manual 1 - 3 430-00587-008 (Rev. 2/05)
* Complies with IEC/EN 60601-1-2: 2001
11555-29
11846-29
11859-29*
French
11555-36
11846-36
11859-36*
Europe
11846-42
11859-42*
Italy
11555-46
11846-46
Swedish
11859-63* Poland
11859-69* Hungary
11859-71* Czech
Republic
Table 1-1. Global Product Configurations
Group
Icon List Number Country
Power
Supply Rear Case LCD
EN-2

SECTION 1 INTRODUCTION
430-00587-008 (Rev. 2/05) 1 - 4 Plum XL Series
Figure 1-1. Plum XL Icon Based and English Language Front Panels
Figure 1-2. Plum XLM Icon Based and English Language Front Panels
PRI
SEC
TITRATE
SET RATE
SET VTBI
RUN
HOLD/RESET
CLEAR
VOL
OFF
CHARGE
SILENCE
0000 mL
mL
mL / H
ICON BASED ENGLISH LANGUAGE
04K01021
BACK
PRIME
mL
mL/H 0000 mL SET RATE
SET VTBI
RUN
HOLD/RESET
CLEAR
VOL
QUICKSET
TITRATE
PRI
BACK
PRIME
SEC
SILENCE
OFF
CHARGE
12
04K01022
ICON BASED ENGLISH LANGUAGE

1.3 CONVENTIONS
Technical Service Manual 1 - 5 430-00587-008 (Rev. 2/05)
1.3
CONVENTIONS
The conventions listed in Table 1-2, Conventions, are used throughout this manual.
Throughout this manual, warnings, cautions and notes are used to emphasize important
information.
CAUTION: A CAUTION usually appears in front of a procedure or statement. It
contains information that could prevent hardware failure, irreversible damage to
equipment or loss of data.
Note: A note highlights information to help clarify a concept, procedure or statement.
: Information applies to IEC/EN 60601-1-2: 2001 compliant devices.
Table 1-2. Conventions
Convention Application Example
Italic Reference to a section, figure,
table, or publication
(see Figure 5-4, Distal
Occlusion Test Setup)
[ALL CAPS] In-text references to keys are
described in all caps and
enclosed in brackets
[TITRATE]
ALL CAPS
Initial Caps with lowercase
Screen displays DOOR/CASSETTE
Self test in progress
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 MAY RESULT IN PATIENT INJURY AND IS
POTENTIALLY LIFE THREATENING.
EN-2

SECTION 1 INTRODUCTION
430-00587-008 (Rev. 2/05) 1 - 6 Plum XL Series
1.4
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.
1.5
ACRONYMS AND ABBREVIATIONS
Acronyms and abbreviations used in this manual are as follows:
AAmpere
AC Alternating current
ACE Asynchronous communication element
AC RMS Alternating current root mean square
A/D Analog-to-digital
CMOS Complementary metal-oxide semiconductor
CPU Central processing unit
DC Direct current
DMM Digital multimeter
DPM Digital pressure meter
ECG Electrocardiograph
EEG Electroencephalogram
EEPROM Electrically erasable programmable read-only memory
EL Electroluminescent
EMG Electromyogram
EMI Electromagnetic interference
ETO Ethylene oxide
FET Field-effect transistor
HKDC Housekeeping DC
hr Hour
Hz Hertz
IC Integrated circuit
Battery BT Diode DResistor R
Capacitor CFuse FSwitch SW
Crystal YIntegrated Circuit UTransistor Q

1.6 USER QUALIFICATION
Technical Service Manual 1 - 7 430-00587-008 (Rev. 2/05)
IEC International Electrotechnical Commission
IPB Illustrated parts breakdown
IV Intravenous
kHz Kilohertz
KVO Keep vein open
LCD Liquid crystal display
LED Light-emitting diode
mA Milliampere
MCU Micro controller unit
MHz Megahertz
mL Milliliter
mV Millivolt
PLL Phase-lock loop
PVT Performance verification test
PSI Pounds per square inch
PWA Printed wiring assembly
SPSTIN Single-pole, single-throw in
UART Universal asynchronous receiver/transmitter
VAC Volts AC
VCO Voltage-controlled oscillator
VCC Collector supply voltage
VDC Volts DC
VDIG Digital voltage
VMOT Motor voltage
Vpp Volts peak-to-peak
VTBI Volume to be infused
µA Microampere
µL microliter
µS microsecond
1.6
USER QUALIFICATION
The Plum XL series infusion system is for use at the direction or under the supervision of
licensed physicians or certified healthcare professionals who are trained in the use of the
infusion system 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.

SECTION 1 INTRODUCTION
430-00587-008 (Rev. 2/05) 1 - 8 Plum XL Series
1.7
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 infuser instead of some other source in the environment, set the infuser so
that it is temporarily not delivering fluid. Disappearance of the abnormality indicates that
it was probably caused by electronic noise generated by the infuser. Proper setup and
maintenance of the monitoring equipment should eliminate the artifact. Refer to the
appropriate monitoring system documentation for setup and maintenance instructions.
1.8
INSTRUMENT INSTALLATION
PROCEDURE
CAUTION: Infusion system 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 system. Do not place the infusion system in service if it
fails the self test.
CAUTION: Infusion system performance may be degraded by electromagnetic
interference (EMI) from devices such as electrosurgical units, cellular phones, and
two-way radios. Operation of the infusion system under such conditions should be
avoided.
CAUTION: Before operating the infusion system next to, or in a stacked
configuration with other electrical equipment, confirm the infusion system’s
operational performance in that configuration.
CAUTION: The use of any accessory, transducer or cable with the LifeCare XLM
with DataPort other than those specified may result in increased emissions or
decreased immunity of the LifeCare XLM with DataPort.
The instrument installation procedure consists of unpacking, inspecting, and self test.
Note: Do not place the infusion system in service if the battery is not fully charged.
To make certain the battery is fully charged, connect the infusion system to AC
(mains) power for eight hours (see Section 8, Specifications).
1.8.1
UNPACKING
Inspect the infusion system shipping container as detailed in Section 1.8.2, Inspection.
Use care when unpacking the infusion system. Retain the packing slip and save all packing
materials in the event it is necessary to return the infusion system to the factory. Verify
that the shipping container includes a copy of the system operating manual.

1.8 INSTRUMENT INSTALLATION PROCEDURE
Technical Service Manual 1 - 9 430-00587-008 (Rev. 2/05)
1.8.2
INSPECTION
Inspect the infusion system for shipping damage. Should any damage be found, contact
the delivering carrier immediately.
CAUTION: Do not use the infusion system if it appears to be damaged. Should
damage be found, contact Hospira (see Section 6.1, Technical Assistance). Do not use
the infusion system if it appears to be damaged.
Inspect the infusion system periodically for signs of defects such as worn accessories,
broken connections, or damaged cable assemblies. Also inspect the infusion system after
repair or during cleaning. Replace any damaged or defective external parts.
1.8.3
SELF TEST
CAUTION: Do not place the infusion system in service if the self test fails.
To perform the self test, refer to Figure 1-3, Plum XL LCD Test Screens and Figure 1-4, Plum
XLM LCD Test Screens, and proceed as follows:
1. Connect the infusion system AC (mains) power cord to a grounded AC (mains) outlet
and confirm the AC (mains) power icon (next to the OFF/CHARGE setting)
illuminates.
2. Open the door assembly (cassette door) by lifting up on the cassette door handle.
3. Hold a primed cassette by its handle and insert the cassette into the cassette door
guides. Do not force the cassette into position.
4. Close the cassette door handle to lock the cassette in place.
5. Turn the control knob to SET RATE to initiate the self test.
6. Verify the following screens display in succession:
- LCD test screen
- Four backward Cs (approximately two seconds)
- Set rate screen
7. Disconnect the infusion system from AC (mains) power and confirm BATTERY
displays on the LCD screen.
8. Turn the control knob to OFF/CHARGE and remove the administration set.
9. To allow the battery to charge fully, connect the infusion system to AC (mains) power
for a minimum of eight hours with the control knob in the OFF/CHARGE position.
Confirm the AC (mains) power icon illuminates.