Welch Allyn Connex Vital Signs Monitor 6000 Series User manual

Welch Allyn Connex®Vital Signs
Monitor 6000 Series™
Service manual

© 2012 Welch Allyn. All rights are reserved. To support the intended use of the product described in this publication,
the purchaser of the product is permitted to copy this publication, for internal distribution only, from the media
provided by Welch Allyn. No other use, reproduction, or distribution of this publication, or any part of it, is permitted
without written permission from Welch Allyn. Welch Allyn assumes no responsibility for any injury to anyone, or for
any illegal or improper use of the product, that may result from failure to use this product in accordance with the
instructions, cautions, warnings, or statement of intended use published in this manual.
Welch Allyn, Connex, SureTemp, and SureBP are registered trademarks of Welch Allyn.
Vital Signs Monitor 6000 Series is a trademark of Welch Allyn.
Oridion is a registered trademark of Oridion Medical 1987 Ltd. No implied license. Possession or purchase of this
device does not convey any express or implied license to use the device with unauthorized CO2 sampling products
which would, alone, or in combination with this device, fall within the scope of one or more of the patents relating to
this device and/or CO2 sampling products.
RRa is a trademark of, and SET, SpHb, rainbow, and Masimo are registered trademarks of, Masimo Corporation.
Possession or purchase of a Masimo-equipped device does not convey any express or implied license to use the
device with unauthorized sensors or cables which would, alone or in combination with this device, fall within the
scope of one or more of the patents relating to this device.
Nellcor is a registered trademark of Nellcor Puritan Bennett Inc.
Braun and ThermoScan are registered trademarks of Braun GmbH.
Software in this product is Copyright 2012 Welch Allyn or its vendors. All rights are reserved. The software is
protected by United States of America copyright laws and international treaty provisions applicable worldwide. Under
such laws, the licensee is entitled to use the copy of the software incorporated with this instrument as intended in
the operation of the product in which it is embedded. The software may not be copied, decompiled, reverse-
engineered, disassembled, or otherwise reduced to human-perceivable form. This is not a sale of the software or
any copy of the software; all right, title, and ownership of the software remain with Welch Allyn or its vendors.
For patent information, please visit www.welchallyn.com/patents.
For information about any Welch Allyn product, call Welch Allyn Technical Support: www.welchallyn.com/about/
company/locations.htm.
104730 (CD)
DIR 80017486 Ver. A
104747 (printed copy)
Material Number 718095
DIR 80017486 Ver. A
Welch Allyn, Inc.
4341 State Street Road
Skaneateles Falls, NY 13153-0220 USA
www.welchallyn.com
Regulatory Affairs Representative
Welch Allyn Limited
Navan Business Park
Dublin Road
Navan, County Meath
Republic of Ireland

Contents
Symbols ................................................................................................... 1
Safety ....................................................................................................... 5
Warnings and cautions ......................................................................................... 5
General safety considerations .............................................................................. 6
Electrostatic discharge (ESD) ............................................................................... 6
Overview .................................................................................................. 9
Purpose and scope .............................................................................................. 9
Technical support services ................................................................................. 10
Recommended service intervals ........................................................................ 14
The Welch Allyn Service Tool ............................................................................ 15
Battery performance .......................................................................................... 16
Controls, indicators, and connectors ................................................... 19
Service menu ......................................................................................... 23
Access the Service screens ............................................................................... 23
General tab ......................................................................................................... 23
Self-tests tab ...................................................................................................... 25
Logs tab ............................................................................................................. 25
Device tab .......................................................................................................... 25
Licensing tab ...................................................................................................... 26
Power-up sequence ............................................................................... 27
Troubleshooting .................................................................................... 29
Symptoms and solutions ................................................................................... 29
Technical alarm messages ................................................................................. 40
Disassembly and repair ........................................................................ 55
Required tools and equipment ........................................................................... 56
Power down the monitor ................................................................................... 56
Remove the battery ........................................................................................... 57
Remove the rear housing ................................................................................... 58
Disassemble the rear housing ........................................................................... 61
Disassemble the main chassis ........................................................................... 69
Functional verification and calibration ................................................ 99
Functional verification tests ............................................................................... 99
iii

Electrical safety testing ....................................................................... 115
Ground stud connector .................................................................................... 115
Options, upgrades, and licenses ........................................................ 117
Available options, upgrades, and licenses ....................................................... 118
Install options ................................................................................................... 120
Masimo parameter upgrades ........................................................................... 122
Configure options ............................................................................................. 123
Field replaceable units ........................................................................ 125
Rear housing .................................................................................................... 125
Bottom housing ............................................................................................... 129
Extended bottom housing ................................................................................ 131
Extended top housing ...................................................................................... 132
Top housing ..................................................................................................... 133
Side panels ....................................................................................................... 134
Front housing and midsection .......................................................................... 135
Miscellaneous parts ......................................................................................... 137
Service tools .................................................................................................... 138
Options ............................................................................................................ 139
Service parts for Braun PRO 4000 and dock .................................................... 143
Licenses ........................................................................................................... 144
Partners in Care service and support agreements ........................................... 145
Service and repair training ................................................................................ 146
Appendices .......................................................................................... 147
Decontamination and cleaning requirements for returns ................................. 147
Clean the CO2 input connector ........................................................................ 149
Identifying the monitor and subsystems ......................................................... 149
Factory defaults ............................................................................................... 156
Disassembly and repair reference ................................................................... 168
Interconnect diagram ....................................................................................... 179
iv Contents Welch Allyn Connex®Vital Signs Monitor 6000 Series™

Symbols
Documentation symbols
WARNING The warning statements in this manual identify conditions or practices that could
lead to illness, injury, or death.
CAUTION The caution statements in this manual identify conditions or practices that could
result in damage to the equipment or other property, or loss of data. This definition applies to
both yellow and black and white symbols.
WARNING Hot surface. Do not touch.
Follow instructions for use — mandatory action.
Consult operating instructions.
Power symbols
Power on/Display power-saving Equipotential terminal
(on the display) monitor is plugged
into Alternating Current power
Battery absent or faulty
(on the monitor, green indicator)
Alternating Current power present,
battery fully charged
Battery charge level
1

(on the monitor, amber indicator)
Alternating Current power present,
battery is charging
Battery cover
Alternating Current (AC) Rechargeable battery
Li-ion battery
Connectivity symbols
USB Ethernet RJ-45
Wireless signal strength
• Best (4 bars)
• Good (3 bars)
• Fair (2 bars)
• Weak (1 bar)
• No signal (no bars)
• No connection (blank)
Nurse call
Miscellaneous symbols
CO2 sampling input CO2 sampling output/exhaust
Manufacturer Limited rotation/Turn completely to
right
Reorder number Serial number
Do not reuse China RoHS markings for control of
pollution caused by electronic
information products. XX indicates
Environmentally Friendly Use
Period in years.
Nonionizing electromagnetic
radiation
Recycle the product separate from
other disposables
Restrictions for use of wireless
device in Europe. European
Community's Class 2 radio
equipment.
Call for maintenance
2Symbols Welch Allyn Connex®Vital Signs Monitor 6000 Series™

Defibrillation-proof Type BF applied
parts
Do not expose to open flame
Altitude range Not for injection
Transport and storage temperature
range
Authorized Representative of the
European Community
Service manual Symbols 3

4Symbols Welch Allyn Connex®Vital Signs Monitor 6000 Series™

Safety
All users of the monitor must read and understand all safety information presented in
this manual before using or repairing the monitor.
United States federal law restricts this device to sale, distribution, or use by or on the
order of a licensed medical practitioner.
Warnings and cautions
WARNING Safety risk. Make frequent electrical and visual checks on
cables, sensors, and electrode wires. All cables, sensors, and electrode
wires must be inspected and properly maintained and in proper working
order to allow the equipment to function properly and to protect patients.
WARNING Safety risk. Place the monitor and accessories in locations
where they cannot harm the patient should they fall from a shelf or mount.
WARNING Fire and explosion hazard. Do not operate the monitor in the
presence of a flammable anesthetic mixture with air, oxygen, or nitrous
oxide; in oxygen-enriched environments; or in any other potentially
explosive environment.
WARNING Inaccurate measurement risk. Dust and particle ingress can
affect the accuracy of blood pressure measurements. Use the monitor in
clean environments to ensure measurement accuracy. If you notice dust or
lint build-up on the monitor’s vent openings, have the monitor inspected
and cleaned by a qualified service technician.
CAUTION To ensure that the monitor meets its performance
specifications, store and use the monitor in an environment that maintains
the specified temperature and humidity ranges.
CAUTION The monitor may not function properly if dropped or damaged.
Protect it from severe impact and shock. Do not use the monitor if you
notice any signs of damage.
CAUTION Do not connect more than one patient to a monitor or connect
more than one monitor to a patient.
CAUTION Do not operate the monitor in the presence of magnetic
resonance imaging (MRI) or hyperbaric chambers.
5

General safety considerations
• If the monitor detects an unrecoverable problem, it displays an error message. For
more information see “Troubleshooting.”
• To ensure patient safety, use only accessories recommended or supplied by Welch
Allyn. (See the accessories list on the user documentation CD or
www.welchallyn.com.) Always use accessories according to your facility’s standards
and according to the manufacturer’s recommendations and instructions. Always
follow the manufacturer’s directions for use.
• Welch Allyn recommends that only Welch Allyn service personnel or an authorized
repair center perform warranty service. Performing unauthorized service on a device
that is within warranty may void the warranty.
Electrostatic discharge (ESD)
CAUTION Electrostatic discharge (ESD) can damage or destroy electronic
components. Handle static-sensitive components only at static-safe
workstation.
CAUTION Assume that all electrical and electronic components of the
monitor are static-sensitive.
Electrostatic discharge is a sudden current flowing from a charged object to another
object or to ground. Electrostatic charges can accumulate on common items such as
foam drinking cups, cellophane tape, synthetic clothing, untreated foam packaging
material, and untreated plastic bags and work folders, to name only a few.
Electronic components and assemblies, if not properly protected against ESD, can be
permanently damaged or destroyed when near or in contact with electrostatically
charged objects. When you handle components or assemblies that are not in protective
bags and you are not sure whether they are static-sensitive, assume that they are static-
sensitive and handle them accordingly.
• Perform all service procedures in a static-protected environment. Always use
techniques and equipment designed to protect personnel and equipment from
electrostatic discharge.
• Remove static-sensitive components and assemblies from their static-shielding bags
only at static-safe workstations—a properly grounded table and grounded floor mat—
and only when you are wearing a grounded wrist strap (with a resistor of at least 1
megohm in series) or other grounding device.
• Use only grounded tools when inserting, adjusting, or removing static-sensitive
components and assemblies.
• Remove or insert static-sensitive components and assemblies only with monitor
power turned off.
• Insert and seal static-sensitive components and assemblies into their original static-
shielding bags before removing them from static-protected areas.
6Safety Welch Allyn Connex®Vital Signs Monitor 6000 Series™

• Always test your ground strap, bench mat, conductive work surface, and ground
cord before removing components and assemblies from their protective bags and
before beginning any disassembly or assembly procedures.
Service manual Safety 7

8Safety Welch Allyn Connex®Vital Signs Monitor 6000 Series™

Overview
Purpose and scope
This service manual is a reference for periodic preventive maintenance and corrective
service procedures for the Welch Allyn Connex Vital Signs Monitor 6000 Series,
firmware version 2.0X. It is intended for use only by trained and qualified service
personnel.
Corrective service is supported to the level of field-replaceable units. These include
circuit-board assemblies and some subassemblies, case parts, and other parts.
CAUTION No component-level repair of circuit boards and subassemblies
is supported. Use only the repair procedures described in this manual.
WARNING When performing a service procedure, follow the instructions
exactly as presented in this manual. Failure to do so could damage the
monitor, invalidate the product warranty, and lead to serious personal
injury.
Find instructions for functional testing and performance verification in the Welch Allyn
Service Tool help files.
This manual applies only to this device. For servicing of any other vital signs monitor, see
the service manual for the specific device.
Service work not described in this manual must be performed by qualified service
personnel at the factory or at an authorized Welch Allyn service center.
Related documents
When using this manual, refer to the following:
•Welch Allyn Connex Vital Signs Monitor 6000 Series Directions for use, software
version 2.0X (on the user documentation CD, part number 104730)
•Welch Allyn Connex Vital Signs Monitor 6000 Series accessories list (on the user
documentation CD, part number 104730)
• Welch Allyn Service Tool CD (part number 103521)
•Welch Allyn Service Tool Installation and Configuration Guide (part number 103820)
•Welch Allyn Braun PRO 4000 Service Manual (part number 701627)
•Welch Allyn 9600 Plus Calibration Tester Directions for use (part number 701754)
•Welch Allyn Radio Configuration Guide: click here to download the PDF
9

• Welch Allyn website: www.welchallyn.com
Technical support services
Welch Allyn offers the following technical support services:
• Telephone support
• Loaner equipment
• Service agreements
• Service training
• Replacement service parts
• Product service
For information on any of these services, go to www.welchallyn.com.
Service loaners
For warranty or non-warranty repairs not covered under a support agreement, loaners are
available for a nominal charge, subject to availability. Payment is required prior to
shipment for all loaners not covered under a support agreement. The loaner fee can be
found on the Welch Allyn loaner price list.
Welch Allyn Service Centers that provide repair service for this product can, on request,
loan a device for use while the device is being repaired. Loaned devices are provided
free of charge for products repaired while under asupport agreement that includes a
free loaner provision.
Loaner equipment for the individual component modules is not available.
10 Overview Welch Allyn Connex®Vital Signs Monitor 6000 Series™

Service options
Partners in Care service agreements
While product warranties provide basic assurance of Welch Allyn hardware quality, they
may not include the full range of services and support you need. Welch Allyn offers
premium service and support through our Partners in Care program. Whether you
service your own devices and require a minimum of support or rely on us to service your
device, Welch Allyn provides a program that will meet your needs. For more information
visit our web site at www.welchallyn.com or call your sales representative.
Warranty service
All repairs on products under warranty must be performed or approved by Welch Allyn.
Refer all warranty service to Welch Allyn Product Service or another authorized Welch
Allyn Service Center. Obtain a Return Material Authorization (RMA) number for all returns
to Welch Allyn Product Service.
CAUTION Unauthorized repairs will void the product warranty.
Non-warranty service
Welch Allyn product service and authorized service centers support non-warranty repairs.
Contact any Welch Allyn regional service center for pricing and service options.
Welch Allyn offers modular repair parts for sale to support non-warranty service. This
service must be performed only by qualified end-user biomedical/clinical engineers using
this service manual.
Service training is available from Welch Allyn for biomedical/clinical engineers. For
information, go to www.welchallyn.com/support/technical/
monitoring_suppt_training.htm.
Repairs
A Welch Allyn Service Center must perform all repairs on products under warranty,
unless you have purchased a Welch Allyn Partners in Care Biomed agreement allowing
you to service the device while under warranty.
CAUTION Unauthorized repairs will void the product warranty.
Qualified service personnel or a Welch Allyn Service Center should repair products out of
warranty.
If you are advised to return a product to Welch Allyn for repair or routine maintenance,
schedule the repair with the service center nearest you.
Welch Allyn Technical Support
If you have a problem with the device that you cannot resolve, call the Welch Allyn
Technical Support Center nearest you for assistance. A representative will assist you in
troubleshooting the problem and will make every effort to solve the problem over the
phone, potentially avoiding an unnecessary return.
If your product requires warranty, extended warranty, or non-warranty repair service, a
Welch Allyn Technical Support representative will record all necessary information to
Service manual Overview 11

issue an RMA number. The support representative will provide you with the address of
the Welch Allyn Service Center to send your device to.
Technical support is available during local business hours.
Returning products
When returning a product to Welch Allyn for service, ensure that you have the following
information:
• Product name, model number, and serial number. This information may be found on
the product and serial number labels on the bottom of the device.
• A complete return shipping address.
• A contact name and phone number.
• Any special shipping instructions.
• A purchase-order number or credit-card number if the product is not covered by a
warranty.
• A full description of the problem or service request.
1. Contact Welch Allyn and request an RMA number.
Note Welch Allyn does not accept returned products without an
RMA.
2. Ship the device to Welch Allyn, observing these packing guidelines:
a. Remove from the package the battery, all hoses, connectors, cables, sensors,
power cords, and other ancillary products and equipment, except those items
that might be associated with the problem.
Recommendations for returning the Lithium Ion battery
• Use ground transportation to return batteries.
• If returning multiple batteries, package each battery individually.
• Do not consolidate multiple batteries in a single package.
• Use packaging provided by Welch Allyn or the battery manufacturer.
• Do not pack a defective battery in checked or carry-on baggage if traveling
by air.
Packaging
• If you return the battery with the device, remove the battery, seal the battery
in an antistatic plastic bag, and place the battery in the position reserved for
the battery in the original shipping carton near the device.
• If you return the battery separately, package the battery in the replacement
battery’s plastic bag and shipping box.
12 Overview Welch Allyn Connex®Vital Signs Monitor 6000 Series™

If the original shipping carton or replacement battery shipping box is unavailable,
consult the manufacturer website for information regarding shipping lithium ion
batteries:
www.iccnexergy.com/regulatory-updates/lithium-shipping
WARNING Safety risk. Do not ship any battery that has
been physically damaged or shows signs of leakage
unless you receive specific instructions which meet the
requirements for the shipment of Lithium batteries.
Dispose of damaged or leaking batteries in an
environmentally safe manner consistent with local
regulations.
Note In the United States, the applicable regulations can be
found in the Code of Federal Regulations (CFR). Refer to
49 CFR 173.185 for shipping lithium batteries by air or
ground. Use 49 CFR 172.102 sections 29, 188, 189, A54,
A55, A100, A101, A103, and A104 to find the special
provisions for shipping lithium batteries.
b. Clean the device.
Note To ensure safe receipt of your device by the service
center and to expedite processing and return of the
device to you, thoroughly clean all residues from the
device before you ship it to Welch Allyn. For
decontamination and cleaning requirements, see the
appendices.
If a returned device is found to be contaminated with
bodily fluids, it will be returned at the owner’s expense.
United States federal regulations prohibit the processing
of any device contaminated with blood-borne pathogens.
Welch Allyn thoroughly cleans all returned devices on
receipt, but any device that cannot be adequately
cleaned cannot be repaired.
c. Put the device, enclosed in a plastic bag with a packing list, into the original
shipping carton with the original packing materials or into another appropriate
shipping carton.
d. Write the Welch Allyn RMA number with the Welch Allyn address on the outside
of the shipping carton.
Service manual Overview 13

Recommended service intervals
To confirm that the device is functioning within the design specifications, perform
periodic service as indicated in the following table. Customers who have the Silver
edition of the Welch Allyn Service Tool can perform the basic functional verification and
calibration procedures referenced in the table by following the instructions in this
manual. If you have the Gold edition of the service tool, use the tool to perform a
complete functional verification and calibration of the device in lieu of performing the
basic tests.
Component Service interval Service procedure
NIBP module Annually Basic functional verification
SpO2 module Annually Basic functional verification
SpHb parameter Annually Basic functional verification
CO2 module Annually or 1200 hours (whichever
comes first)
Calibration (first time only)
Annually or 4000 hours (whichever
comes first)
Calibration
30,000 hours Replace the module
SureTemp Plus Annually Basic functional verification
Braun ThermoScan PRO 4000 Annually Basic functional verification
Battery 300 charge cycles Replace the battery
Use the service tool, Gold edition, to perform a complete functional verification and
calibration of the device whenever any of the following conditions exist:
• Based on the basic functional verification, the device does not meet specifications
• The device has been dropped or otherwise damaged
• The device is malfunctioning
• The case has been opened
• An internal part has been replaced (battery excluded)
Note For instructions on using the Gold edition, see the service tool help files.
Related Links
• “Basic functional verification tests” on page 102
Maintenance
For device maintenance information, see “Maintenance and service” in the device’s
directions for use. Covered topics include the following:
• Replacing the printer paper
• Inspecting and cleaning the device and accessories
14 Overview Welch Allyn Connex®Vital Signs Monitor 6000 Series™

• Changing the battery
The Welch Allyn Service Tool
The Welch Allyn Service Tool is available in the following editions:
•Silver: Accompanies your device.
•Gold: Required to perform complete functional verification and calibration. This
edition requires an additional license. For more information about acquiring this
license, contact Welch Allyn.
Note To qualify for the Gold license, you must attend the
Welch Allyn technical training course or complete online
training for the device.
Clinicians and technical service personnel can use the service tool to manage and
maintain supported Welch Allyn products. You can use the service tool to do the
following:
•Review device information. When connected to the device, the service tool lists
installed modules, installed firmware and hardware versions, warranty and repair
information, status, and usage history.
•Receive notifications when periodic maintenance is needed. The service tool can
help you manage and maintain your entire inventory of supported Welch Allyn
products. Through the remote service function, the service tool can connect to
Welch Allyn Customer Service. With this functionality you can automatically receive
firmware updates and feature upgrades for your supported products, including
software upgrades for the service tool.
•Install updates and upgrades. The service tool can read the firmware version for
each module and check for available updates or upgrades.
•Create a work list. The work list provides information about service actions—
referred to as work orders—that are waiting for you to perform on your maintained
devices. Work orders may include periodic calibrations, upgrades, or license
installations.
•Schedule periodic maintenance. You can use the service tool to set the service
interval for each maintained device.
•View and save logs. You can download and save log files from the device for
analysis to help diagnose and identify reported issues.
•Create user accounts. Administrators can create user accounts and set permission
levels to control access to the features, allowing one group to perform administrative
tasks and another to perform service tasks. Restricting access prevents the service
tool from being used to make unauthorized changes on a connected device.
•Perform functional verification and calibration. The service tool can check any
device requiring calibration and, if necessary, calibrate the device to match the
design specifications. This feature is not supported for all products and requires the
service tool, Gold edition, for each supported product.
•Recover devices. In the rare case where a device can no longer boot because of
corrupted firmware, the service tool can connect the device to Welch Allyn Technical
Support to reinstall the firmware.
•Extensible. The service tool software accepts new plug-ins to support future Welch
Allyn products.
Service manual Overview 15

Some of these features are enabled for any user (Silver edition). Others require special
user account privileges or a Welch Allyn service contract (Gold edition). If you require
gold-level support for a Welch Allyn product, please contact Welch Allyn technical
support.
Battery performance
About the battery
The device uses a rechargeable lithium ion smart battery. Internal circuitry enables the
battery to report its condition to the device. The device displays the battery status via the
LED power indicator, icons on the screen, and status messages appearing in the Device
Status area of the display. Battery information may be collected using the service tool.
New batteries are shipped from the manufacturer with a 30 percent charge to extend
shelf life. When installing a new battery in the device, you must plug the device into AC
power to wake up the battery. If the AC power is not applied to the device, the new
battery will appear discharged.
The Device Status area displays a low-battery status message when 30 minutes of
power remain and again when 5 minutes remain.
Battery charging is provided by the device’s internal power supply.
For a complete list of battery specifications, see the device’s directions for use.
Best practices
The following practices help to extend the life of the battery and the device.
WARNING Safety risk. When handling and storing Lithium batteries: Avoid
mechanical or electrical abuse. Batteries may explode or cause burns, if
disassembled, crushed or exposed to fire or high temperatures. Do not
short or install with incorrect polarity.
• Remove the battery when storing the device.
• Replace batteries that trigger a low battery status message when fully charged.
• Do not use damaged or leaking batteries.
• Store batteries with a 30 to 50 percent charge.
• Store batteries within the temperature range indicated for each period:
○For storage less than 30 days: Maintain temperature between –4 °F and 122 °F
(–20 °C and 50 °C).
○For storage between 30 days and 90 days: Maintain temperature between –4 °F
and 104 °F (–20 °C and 40 °C).
○For storage more than 90 days up to 2 years: Maintain temperature between –4
°F and 95 °F (–20 °C and 35 °C).
• Recycle batteries where ever possible. In the United States call 1-800-8-BATTERY
for information about recycling your Lithium Ion battery or go to the RBRC website at
www.rbrc.org for additional information.
• When recycling is not an option dispose of batteries in an environmentally safe
manner consistent with local regulations.
16 Overview Welch Allyn Connex®Vital Signs Monitor 6000 Series™