Welch Allyn Connex 6000 Series

Asset Type

Vital Signs Monitor

Manufacturer

Welch Allyn

Model

Connex 6000 Series

Manual Reference

Welch Allyn Connex Vital Signs Monitor 6000 Series Service Manual, Software versions 2.0X–2.4X, Revision date 2025-06.

Manufacturer Recommendation / AEM Status

The manufacturer service manual is intended for trained and qualified service personnel and includes periodic preventive maintenance and corrective service procedures for the Welch Allyn Connex Vital Signs Monitor 6000 Series.

Manufacturer-Listed PM Items and Frequencies

The manual lists the following preventive maintenance items and service intervals:

• NIBP module: Annually — basic functional verification.
• SpO2 module: Annually — basic functional verification.
• SpHb parameter: Annually — basic functional verification.
• EarlySense module: N/A.
• RRa parameter: N/A.
• CO2 module initial calibration: Annually or 1200 hours, whichever comes first.
• CO2 module ongoing calibration: Annually or 4000 hours, whichever comes first.
• CO2 module replacement: 30,000 hours.
• SureTemp Plus: Annually — basic functional verification.
• ECG: N/A.
• Braun ThermoScan PRO 6000: Annually — basic functional verification.
• Battery: Replace at 300 charge cycles.
• Housing: Annually — clean air vents to prevent dust buildup.

The manual notes that the initial CO2 calibration should occur after 1200 operating hours and should not occur before 720 hours of use. If the initial calibration is performed before 720 hours, the module resets to require the next calibration after 1200 hours instead of after 4000 hours.

Welch Allyn Service Tool Note

The manual states that customers with the Standard unlicensed edition of the Welch Allyn Service Tool can perform the basic functional verification and calibration procedures referenced in the service interval table. If the facility has the Gold licensed edition, the Gold tool can be used to perform a complete functional verification and calibration instead of the basic tests.

Post-Repair / Service Requirements

Use the Welch Allyn Service Tool Gold licensed edition to perform a complete functional verification and calibration whenever any of the following apply:

• Basic functional verification does not meet specifications.
• Device has been dropped or otherwise damaged.
• Device is malfunctioning.
• Case has been opened.
• Internal part has been replaced, excluding the battery.

AEM Note

If a facility performs this PM at a different interval or changes the listed activities, that should be handled under the facility’s approved AEM program, risk assessment, maintenance history, and applicable regulatory requirements.

What This PM Procedure Covers

• Visual inspection.
• Housing and air vent inspection / cleaning.
• Battery cycle-count review.
• Manufacturer-listed functional verification.
• Installed parameter checks.
• CO2 calibration interval review, if equipped.
• Electrical safety testing documentation when applicable.
• Return-to-service decision.

Required Tools and Equipment

Use tools and test equipment based on the installed configuration.

• Welch Allyn Service Tool.
• PC compatible with Welch Allyn Service Tool.
• USB 2.0 / 5-pin Mini-B cable.
• NIBP test volume / repair fixture.
• Pressure meter accurate enough for NIBP testing.
• Blood pressure Y-tube and compatible NIBP hoses.
• SpO2 simulator for installed Nellcor or Masimo configuration.
• Applicable SpO2 extension cable, if needed.
• Cal-key assembly, if SureTemp Plus is installed.
• Welch Allyn 9600 Plus Calibration Tester, if temperature verification is performed.
• Braun PRO 6000 calibration fixture, if Braun PRO 6000 is installed.
• ECG patient simulator, if ECG testing is performed.
• Facility-approved electrical safety analyzer, if electrical safety testing is required.

For electrical safety testing, the manual says to refer to the electrical safety test equipment manuals because field test equipment varies.

Step-by-Step PM Procedure

1. Confirm Device Identification and Configuration

Action: Verify the asset tag, serial number, model, installed parameters, and connected accessories.

Expected outcome: The device matches the CMMS record and the PM steps match the installed configuration.

Why it matters: The Connex 6000 Series can be configured with different modules. Do not document tests for options that are not installed.

2. Remove Device From Patient Use

Action: Confirm the monitor is not connected to a patient. Disconnect patient cables, sensors, blood pressure hoses/cuffs, temperature probes, ECG modules, Braun docks, barcode scanners, and external accessories as applicable.

Expected outcome: Device is safe for PM inspection and testing.

Why it matters: Do not service patient-connected equipment.

3. Visual Inspection

Action: Inspect the monitor and accessories, including the housing, display/touchscreen, light bar, power inlet, ground stud/equipotential terminal, battery door, fan intake and exhaust, USB/Ethernet/nurse call ports if present, NIBP connector, SpO2 connector, temperature probe and probe well if equipped, Braun dock and thermometer if equipped, ECG module and cable if equipped, CO2 port and sampling connection if equipped, printer and printer door if equipped, cuffs, hoses, sensors, cables, and probes.

Expected outcome: No cracks, missing covers, loose parts, contamination, damaged connectors, blocked vents, damaged cables, or signs of liquid ingress.

Remove from service if: Damage, contamination, liquid ingress, unsafe accessory condition, overheating evidence, loose connectors, or missing safety-related parts are found.

4. Inspect and Clean Housing / Air Vents

Action: Inspect the air vents and fan intake/exhaust areas. Clean dust buildup from the vents per facility cleaning practice and manufacturer guidance.

Expected outcome: Airflow openings are clean and unobstructed.

Why it matters: The manufacturer-listed housing maintenance item is annual cleaning of air vents to prevent dust buildup.

5. Battery Review

Action: Check battery condition and cycle count using available device/service tool information. Inspect for swelling, cracking, leakage, damage, charging issues, or poor runtime complaints.

Expected outcome: Battery is physically intact and below replacement threshold unless facility policy requires earlier replacement.

Manufacturer-listed replacement interval: Replace battery at 300 charge cycles.

Remove from service if: Battery is damaged, leaking, swollen, cracked, absent/faulty, or causing unsafe operation.

6. Power-On Self Test / Startup Check

Action: Power on the monitor and observe startup. Verify light bar flashes during startup, startup screen appears, audible tone/chime sounds, home screen appears, printer advances slightly if installed, fan operation is normal, and no system fault remains active.

Expected outcome: Device completes startup without unresolved system fault messages.

Remove from service if: POST fails, fan does not operate normally, the display is unusable, the device enters safe mode, or an unresolved system fault remains.

7. Perform Manufacturer-Listed Functional Verification

Action: Perform basic functional verification for installed parameters using the Welch Allyn Service Tool and applicable test equipment.

Include only installed options:

• NIBP.
• SpO2.
• SpHb.
• SureTemp Plus.
• Braun ThermoScan PRO 6000.
• CO2, if equipped and due.
• ECG, if facility policy requires it even though the manufacturer PM table lists ECG as N/A.
• EarlySense / RRa only if facility policy, troubleshooting, or repair condition requires it because the manufacturer PM table lists these as N/A.

Expected outcome: Installed parameters pass functional verification.

Remove from service if: Any installed parameter fails verification and cannot be corrected.

8. NIBP Verification

Action: Perform NIBP functional verification using the Welch Allyn Service Tool and appropriate NIBP test setup.

Document: Leak test result, NIBP accuracy result, and overpressure test result if performed.

Expected outcome: NIBP passes verification.

Remove from service if: NIBP fails leak, accuracy, overpressure, or service tool verification.

9. SpO2 / SpHb Verification, If Equipped

Action: Use the applicable simulator, sensor/cable setup, and service tool process for the installed Nellcor or Masimo configuration.

Expected outcome: SpO2 and SpHb, if installed, pass verification.

Remove from service if: SpO2/SpHb fails verification, sensor/cable faults cannot be resolved, or readings are unreliable.

10. Temperature Verification, If Equipped

Action: Perform functional verification for the installed temperature option. Use the appropriate setup for SureTemp Plus or Braun ThermoScan PRO 6000.

Expected outcome: Temperature function passes verification.

Remove from service if: Temperature module, probe, dock, or thermometer fails verification.

11. CO2 Calibration Review, If Equipped

Action: Check CO2 calibration due status and operating hours. Perform calibration if due.

Expected outcome: CO2 calibration is current or completed successfully.

Manufacturer-listed CO2 intervals: Initial calibration is annually or 1200 hours, whichever comes first. Ongoing calibration is annually or 4000 hours, whichever comes first. Module replacement is listed at 30,000 hours. The manual also states the first calibration should not occur before 720 hours of use.

12. Alarm / Indicator Check

Action: Verify startup light bar behavior and audible startup tone. Confirm no unresolved alarms, technical messages, or service messages remain after testing.

Expected outcome: Visual and audible indicators operate as expected.

Remove from service if: Light bar, speaker, or system alarm behavior is not reliable.

13. Final Return-to-Service Review

Action: Confirm visual inspection passed, vents are clean, battery condition is acceptable, installed options passed functional verification, CO2 calibration is current or completed if equipped, electrical safety testing is completed if applicable, no unresolved system faults or technical messages remain, and accessories are clean, intact, and appropriate for use.

Expected outcome: Device is ready to return to service.

Electrical Safety Testing if applicable

Hillrom recommends performing only ground continuity and leakage current tests after open-case repairs. The manual does not recommend dielectric strength testing unless there is reason to doubt the integrity of the electrical insulation, such as repeated residual-current device trips or saline liquid ingress. If dielectric strength testing is needed, the manual says to return the device to Hillrom for service.

Ground resistance measured in ohms, expected ≤ 0.5 Ω or facility/NFPA 99 criteria if different.

For this device, the manual provides a stricter ground continuity limit: ground continuity from the EP stud / equipotential terminal to the ground pin of the IEC power connector shall be no greater than 0.1 Ω.

Touch/chassis leakage measured in microamps:

• Facility limit used =
• Manufacturer-listed leakage limit: less than 500 µA from the EP stud to mains line and neutral pins of the IEC power connector.
• Result =
• Pass / Fail =

Electrical Safety Documentation Fields

Ground continuity from EP stud / equipotential terminal to IEC ground pin:
Manufacturer-listed limit: ≤ 0.1 Ω
Result =

Leakage current from EP stud / equipotential terminal to IEC mains line and neutral pins:
Manufacturer-listed limit: < 500 µA
Result =
Pass / Fail =

Dielectric strength / HiPot:
Not recommended by Hillrom unless there is reason to doubt electrical insulation integrity. If needed, return device to Hillrom for service.

Pass / Fail Criteria

PM Pass Criteria

Pass PM if:

• Device passes visual inspection.
• Housing and vents are clean and unobstructed.
• Battery is acceptable and below replacement threshold.
• Device powers on and completes startup without unresolved faults.
• Installed parameter modules pass functional verification.
• CO2 calibration is current or completed, if equipped.
• Electrical safety testing passes when applicable.
• No unresolved service messages remain.

Remove From Service Criteria

Remove from service if:

• Device is damaged, cracked, contaminated, or has signs of liquid ingress.
• Fan does not run normally during power-up.
• Device fails POST or displays unresolved system faults.
• Installed parameter verification fails.
• CO2 calibration fails or is overdue and cannot be completed.
• Battery is damaged, faulty, leaking, swollen, or past manufacturer-listed replacement criteria.
• Electrical safety testing fails.
• Case was opened or an internal part was replaced and required Gold-level verification/calibration has not been completed.

Use the manufacturer service manual, facility policy, and approved AEM program to determine the final PM interval and return-to-service requirements.