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BAXTER Flo-gard 6301 Infusion Pump Service Manual

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4. lt gt m O Q OQ x n oooo gt EJXIZOX EOX coco oooo RES Meter err YE tee ee O 54 4 t OOOO lt lt o4 o4 X V VV AIRTXI AIRTX 2 10 6 Figure 10 4 CPU Board Block Diagram CPUPCB3 MPA 07 19 A1 729 F103 UL 125V 3A QFS B1006CCZZ DC POWER SUPPLY COMBINATION INLET POWER TRANSFORMER RDENC1004MC 301 RTRNP1006MC F101 239 800 800mA 250V 102 239 800 800mA 250V 302 AC CORD SET QACCD7613QCN4 Figure 10 5 Power Supply Section 07 19 A1 729 10 7 02 2 c11 YEL d 100u 10 2 93 41 0612201 1200u 50V x2 254953 2503692 RED 1 L1 D1 d 3 154 5010 2006 4068 9 12 101 O i 56 2200p 500 18881 vil ML asa 13 65V 20VAC R20 4 5830093 1 2K 1 44 1 28 10 1K 1W ii O B2P VH c9 1u 50Y 0 047u 50v BLK GRN YEL THI C15 1 26 V R 3N ES pr R16 330K R6 10K R17 R18 68K 150K R14 10K FG 1 1 19 C 2 2 1
5. oe cw lt lt m gt ao m A m gt lt o lt gt v orz TALMMON RTS gt l lt e ALARMS 2 a 10 11 Figure 10 9 Master CPU Block Diagram 07 19 A1 729 j 102 Vepu 224 6 37 ALUMINUM Q Q crpe y RPI14A v101 cpu GND 22K Y 8 1 RP112A 27 15 10k RP1128 10 TRESETM gt RESETN m 11120 7 2 d TACLINE LACLINE PMR ONL R158 SLYTX 479 rPwRONZ gt SLC SENSE SLCSENSE TPWREXOR IPMREXOR Q I1RQ gt 1184 32 CCED HR ALARNM THTTOCKT gt INTLOCK1 2 gt INTLOCK2 BANK 00 BANK 00 Dy EARK DI 16 C105 22u 6 3V ALUMINUM 2 2 25 gt gt gt gt lt lt ALMPM2 2 1 lt TPUNPEZ 1 2 lt ALMBIA ALMBZM lt gt v zl m ocoooooooo MAW gt 52 4 22K rrr 3 RP113C 5 6 217 RP113B 1 8 KR tw BACKBZM B lt BACKBZM 1 3 6 lt TROM Ex Hum S 01977 11 34A ps pii n 22K 12 COPTIONLED OPT
6. Olin iu CO lt lt io Lei S DV amp Q wl 2 Fi 1 1 ajo a o 2 ojola lt lt NA fe kad Sp ZZZ A Of ze o Oo ojoj ojala CIO 1 1 lt lt lt lt lt j ajajaja joju 21 1 eoo 22 22 1 ojoje ee oe gt lt lt 7 105568 10 24 Figure 10 22 PPI Block 2 RP610A 1 07 19 1 729 GN D T S C856 0 1 PUMP 1 UPSTREAM OCCL C855 C852 C853 RB55 22u 6 3V 510p 430p ALUMINUM MICA MICA 3k UPOCCLI R GND R GND Va R852 C854 R854 5 1 qasi His DWNOCCLI 10k 2504081 0 022u 470 25K374 R852 5 10k C851 R853 R856 0 022u 2 2k 150k Va NY 7 NY 4 CNB51 R GND A GNO A GNO j R GND R GND a D 5 4 bj PUMP 1 DOWNSTREAM OCCL 5 C859 R861 C861 C858 330p 3 3k 0 1u B6B XH A 470p MICA DMNOCCLI A GND D gt Va 857 MICA C860 8860 INTU OCKI 0853 5 TEIA 10k 2504081 0 022u 470 SKITA R858 8625 10k C857 859 150k 0 022u 2 2k NY V4 NY NY A GND A GNO A GND A GNO R GND 3 C867 0 lu PUMP 2 UPSTREAM OCCL C866 C863 C864 R867 22u 6 3V 510p 510p ALUMINUM MICA MICA 3 3k UPOCCL2 A GNO R GND Va R863 C865 R866 D O A gt 0855
7. 1 CARTON Individual Singapore 1 CUSHION Right 1 Left x oc e 1 POUCH Polyethylene 1 MANUAL Operator S op ur 1 LABEL Slide Cimp Slot 1 POUCH Polyethylene TAG Batt Recharge 8 47 Illustrated Parts Breakdown Item Sve Part UKOG1013 B UKOG1020 A 1021 722003396 722003397 3009035001 072601228 Loctite Inc Parts list for Accessories and Options Mfg Part F049230002 3009090008 3009090007 72 20 03 396 72 20 03 397 3009035001 07 26 01 228 Description GAUGE Occl Sensor Cal XIRACTOR UPP EXTRACTOR Wire Harness SHIM Air Sensor Tubing guide ADHESIVE Loctite Prism 454 LIES AIO eee Esc be LABEL Batt disposal 8 48 07 19 A1 729 Section 9 Warranty and Service Information 9 1 Warranty Information Baxter Healthcare Corporation Baxter warrants that the equipment shall be free from defects in material and workmanship when delivered to the original purchaser Baxter s sole obligation shall be limited to repair or replacement at Baxter s option and expense of the defective part or unit excluding batteries for a period of one year following the date of initial delivery The war ranty for batteries is limited to a period of six months following the date of initial delivery The warranty
8. Lock o m lt Ox zjn A oo 0 0 0 mn a UP0710556GB RP603A 0 1 8 RP605A 22K RP6058B 22K RP605D 22K RP605C V 22K GND 606 22K RP606B 9112 22K y THN ER gt 1 MMER 2 7502 BACKLITE Figure 10 21 PPI Block 1 07 19 A1 729 10 23 0 0 5 2 RESETP C DM ICSPPI2 8 RP608A 0602 37 won ONE Wass 31 DMO 30 29 0M2 28 DM3 27 9 4 26 DM5 25 DM6 24 DM7 n QN O0 O c QM 0 eT 43 OCCLSEL E x FF j e e e Q lt gt l lt lt lt OCCLSEL eu An Qe ole lt ec ac lt 32 RESETP ie ern ex lt uto 75 a O ON m rur 4 4 4 4 8 e gt ajaja a zjx 2 ajaja gt 14 1 PUMPSELI PUMPING2 PUMPSELI PUMPSEL2 PUMPING _ 2 CC LED MON LED TT NEXT CED CT TET TTT T C n NN YN
9. Nw lt GE c XE X O O 2 X X X OU wu m O Tu a x 55 e 5 wj mies a ml Ol E uu at wi ui aja min ell cl E 1 21 ed i NIN fou jN O Ol wj u gt lt gt lt ojoja a o ua OO ul RO O Sl gt oa TE NI aj a e jE ai 2 E 2 fs 1 uie ajajja aja TA RR O O Hoja 5 FF DD A ep ol fsa ce ee o alan c AYA uci c ajaja EOL gt zlzlajaja koond Lam kann kagad kand baad baad kand Kasa kasd gt 22 0 Cand laand kadd kon gt o gt ld exeun 4 XX OIE o E EE Sjn me me Ol ae gt Xa C o Siz an lt lt lt gt ovog E gt gt gt gt BATTERY CE INO gt lt Xuuuuc EEO oou a E X CE CO SEU ada DAL o POWER CONTROL P_CTRL MPA c doc N aaaa N m Ld NE ENN lt JN LAVAN lt 2 2 1 1 1 4 4 94 030 em
10. la a Exrro na low IO a gt gt a lt Ibe Ew jx wuwwxEZXEExe IZ W e lt lt gt gt gt gt gt C C C 0 lw p gt gt gt gt gt gt gt gt 1603 Voth LED OPTIONLED LITHIUM ALARMI OPTIONLED Cece LED CMON LED _____ NL 9t I NO 90 eL 00 t D D P 00 0 Qe L0 f MON m OAS mA n m 69 m 8901 040 1775 0 1 SEL DOUT CN901 3 2 1 538 ALARMI ALERTI OPTIONLED C LED 10 28 Figure 10 26 Display PCB 07 19 1 729 150 5612 R903 360K 0 1 1 SE 68 5663 SE SE 18 SEG 29 NO O NL 0 Fu ND D 60 OS 0 IN 00 THOR 00 CD m0 m TINO Q OQ 3E O3 03 6D QD A 4 14 A 0 08 v v uJ ul UJ lj UJ aj lal UJ uJ 6 40 0 QI OD CD RE RE RE RE RE RT OO OD OO OO 0 0 v vi wv v ua v v vo v UJ ul UJ UJ UJ UJ Ul GJ aJ UJ UU Ll GJ v v v5 vs v v uv ANN A vuv uuu uuu nm un N un Qe N Ou sss Rp 4 lt MJ UJ
11. 1 26 QFSB1220 A 5009425001 FUSE Main 0 8A 125V Slow Blow 2 27 QFSB1006 A 5009425007 4 FUSE Battery 3A 125V 1 28 QSOCA101 A 5009410002 BUNC Receptacle a 1 29 TLABZ108 B 07 26 01 085 Rev A LABEL Panel Lock amp Alarm Volume 1 30 TLABZ109 C 07 26 A1 201 w EABEL Battery 1 31 UBAT1008 A 5009480003 BATTERY Lead Acid 2 12 1 32 UBNDA100 A F042615001 s STRAP Power 1 8 8 07 19 1 729 Illustrated Parts Breakdown Figure 8 4 Rear Housing Assembly External 8 9 07 19 A1 729 Illustrated Parts Breakdown Item 8 10 Rear Housing Assembly External Figure 8 4 continued Sve Part XBBSD30P B XBBDS40P D XBPBN26P A XBPBN40P B XBPDS30P V XBSBN30P A XBSUW40P A XBTSN30P A XWHUZ400 A XXHUW40L A GCOVHIOI B QACCD761 D TCAUS102 A 07 26 A 1 244 TCAUS102 B Not Available Not Available TLABZ100 F F0498 10004 F0498 10005 TLABZ106 C TLABZ108 C TLABZ110 F XBBSD30P C Mfg Part 4009310010 4009310012 40093 10006 40093 10004 40093 10008 4009310013 4009310016 4009310017 4009330013 4009310022 F043624003 5009410001 07 26 B1 091 07 26 A1 244 07 26 01 090 07 26 01 098 F0498 10004 F0498 10005 07 27 01 018 07 26 01 086 07 26 01 100 4009310011 Description SCREW Binder Head M3X12 SCREW Binder Head M4X10 SCREW Pan Head M2 6X8 SCREW Pan Head 4 10 w washe
12. 0 7 2 E mx gt LOTA lt lt 2 lt 0 gt lt O X o lt lt A Ou lt lt a a x gue BuO Nn a Eom ee eH a e 2 mln yal xo Alo ix 2 jj gt ful 2 lt lt lt la o gt 553 ul ka z x joja lt 2 gxjo ojo cc AA aja lt 3 a gt 58 ae og gt gt lt lt to gt N w N N xx r waa mExoxum Aw lt EEN n o 2 gt gt ZN XAXOJML4 amp EX gt A gt tl ua 2 2 nad gt INN a lt OONN NANG be D D O rm
13. CN601 CN602 npp PMRSWI FRONT PANEL 00000000 lt lt lt lt lt 4 4 500300000 ON OFF CHARGE 2 HPNL 1026MC2Z CN602 Dour 0 7 0 7 DOUT 2 Dpour o DOUT 1 DOUT 5 DOUT 7 DOUT 4 DOUT 6 DOUT 3 Figure 10 38 Front Panel Key Assignments a In 07 19 A1 729 10 40 Appendix Data Sheet Flo Gard 6301 Volumetric Infusion Pump 2M8064 This data sheet should be used to record the results obtained when performing the Operational Checkout of the device The configuration option settings can also be recorded Device Serial Number Configuration Option Settings OCCLUSION 1 LEVEL 1 1 2 3 AUDIB SWI OFF AUTO RES DOOR OPEN OFF AIR SIZE NORM MIN ALERT INT 7 MAX RATE MAX VTBI FLOW CHECK OFF BAUD RATE COMP CONT 1 DISABLED DISABLED OFF W W ALRM CLOSE CLMP 2 ON OFF ON INS CLAMP 1 OFF OFF Note Alert or alarm option avail ON for software versions able only on pumps running soft earlier than 1 09 ware versions 1 09 or later ALERT for software versions 1 09 or later ALARM for software versions 1 09 or later 1 DISABLED DISABLED FIVE HOUR SEMI PERM TIME SET Central Standard Time DATE SET Current date for Central a Standard Time Signature Date
14. lt lt lt lt EA ANN O wie eee E UO VS rr lt lt Y ad Er X CO OG 0 C C6 a I I v m 327334 3000000000Nm gt Ar 5 5 gt gt gt lt lt Vn V V Umm 000 1 e e X EEEN NNN N OTHERS OTHERS MPA c ren ci eo en Ll m LS a 2 a e eI e e jN 2 lt e xiii iojajajaja jajaja jalo LOSE ST 2I 2 1 EA kk gt wv jojo jog vlvl ojojoj e 2i ame shee x 25 oci e nd HOO OO ww Lu jo HMM MOO OO lt gt ac ac eo ajajaj jaeja o ao ele 55 gt gt E gt o lt AO 3E xj ca c wm Iw ze aja gt ul e mm y gt 0 aaaa Ena a O
15. 20 MSPRP102 A 5048642 SPRING Flat Slide Shaft 21 NSFTD103 B 50440 SHAFT Slid i eda 22 LPiND101 D S048450 PIN Release 3 cy nap eR NC 23 NSFTD103 C 5048451 SHAFT Safety Latch 24 NSFTD103 D S048452 nn Safety Clamp 25 PSLDP100 B 048456 SEAL Safety Clamp P2 26 PZETL101 B 504444 FILM Insulation PCB 27 PZETL101 C S048463 FILM FPC Insulation P2 28 CPWBNI05 C 050046 PCB Slide Clamp Sensor 2 2 29 QPWBNIOS C 50441 FLXBL Slide Clamp Sensor 1 P2 30 XBPSD30P i 5048939 SCREW Pan Head M3X8 w washer assy 07 19 A1 729 8 33 Illustrated Parts Breakdown Safety Slide Clamp Assembly 2 Figure 8 14 continued Item Sve Part Mfg Part Description Qty 31 XBSSD30P B XBSSD30P10000 ti SCREW Upper 2 32 XBSUF20P C XBSUF20P06000 SCREW SCS1 Sensor housing 1 33 XJPSD30P A XJPSD30P06000 tl 5 1 34 XJPSF20P B XJPSF20P04000 SCREW FPC 4 oe Fede uw ue Mo da 2 35 XJPSF20P A XJPSF20P06000 SCREW SCS2 Sensor housing 2 8 34 07 19 1 729 Illustrated Parts Breakdown Figure 8 14 Clamp Assembly 2 8 35 07 19 1 729 Illustrated Parts Breakdown Item 8 36 Sve Part RDENC100 E 5
16. 5 6 5 3 7 Automatic Test Mode 7 Pumping Sensor Monitoring 5 6 5 3 8 Automatic Test Mode 8 Air Sensor Test Mode 5 6 5 3 9 Automatic Test Mode 9 Elapsed Time Test Mode 5 7 5 3 10 Automatic Test Mode 0 Downstream Occlusion Test Mode 5 7 5 4 Failure Identification Code Troubleshooting Table 5 8 5 5 Troubleshooting Chart 22210 Disassembly and 6 1 6 1 Introduction 6 2 Preparation for Maintenance E A Tet age i SA OL 6 2 1 Tools and Test Equipment iau at et die 6 2 2 Recording the Configuration Option Settings ba og a o 6 3 Disassembly Reassembly A id Se Ae a Ke 5059 6 3 1 Separation of Front and Reit Housings E O 2 6 3 2 Separation of Printed Circuit Boards 6 5 6 3 3 Replacement of Front Panel Film 2 2 2 2 2 2 67 6 3 4 Replacement of Pump Door Cover 6 7 6 3 5 Replacement of Pump Door Latch 6 3 6 Replacement of Pump Door or Pump Door Assembly RAE 6 8 6 3 7 Replacement of Door Latch Pin 6 9 6 3 8 Replacement of Pump Head Assembly 6 9 6 3 9 Replacement of Upstream Occlusion Sensor 2 6 10 6 3 10 Replacement of Downstream Occlusion Sensor Assembly gue 6 11 6 3 11 Installation of Air Sensor Assembly
17. from the power supply board d Disconnect the ground wire from the pump head mounting plate for Pump 2 Figure 8 2 item 7 6 Reassemble the housings in the following order a Connect the ground wire to the pump head mounting plate for Pump 2 b Make sure that the connector flange is unlocked and reconnect the flat cable connector on the CPU board Push in the flange to hold the ribbon cable in place c Replace CNI on the power supply board d Replace CN751 on the backup audible alarm board located in the rear housing Connect CN302 on the CPU PCB If the audible alarm is activated press both ON OFF CHARGE keys e Route the pump head harness and pump head ground wire in the front housing referring to Figure 8 2 so that they will not be pinched by internal components when the housings are closed f Stand the front housing up 5 Route the battery harness along the side of the battery compartment so that it is not pinched by the power transformer 6 4 07 19 A1 729 Disassembly and Calibration Note Route the flat cable so that it is not located above the pump head Route the ground wire above the stepper motor Be sure to make the orientation of the crimped terminals of the ground wire at the grounding plates as shown in Figure 8 2 item 14 and Figure 8 3 item 21 Reconnect CN301 and close the two housings by slightly lifting and moving the rear housing slowly toward the front housing Cau
18. ONCOLOGY no message OFF 0 1 2 3 4 5 OPER ROOM 6 7 8 9 1 2 ON 07 19 A1 729 ON General Description Table 1 1 Configuration Options Parameter Description 16 Insert Clamp Message Determines whether or not the slide clamp loading feature is enabled The spring retainer must re moved when this feature is enabled See Sections 6 3 14 and 6 3 15 Note The alarm option is available only on 17 Programmed Delivery Profile Determines the memory to store the programmed delivery profile pumps running software versions 1 09 or later 18 Time Setting Set the real time clock in hours and minutes military time 00 00 23 59 19 Date Setting Set the date using the Month Day Year format 1 16 Setting Options Factory Settings 1 OFF The spring retainer should OFF be installed 2 ON for software versions earlier than 1 09 or ALERT for 1 09 or later An audible alert occurs and the message INSERT SLIDE CLAMP is displayed The pump continues pumping 3 ALARM An audible alarm occurs and the message INSERT SLIDE CLAMP is displayed The pump will not operate 1 Disabled Disabled 2 5 hour memory 3 Semi permanent memory 4 Permanent memory Central Standard Time CST Current date CST 07 19 A1 729 General Description 1 6 Alarms
19. PUMP PERFORMANCE ACCEPTABLE TROUBLESHOOT IN ACCORDANCE WITH SECTION 5 REPAIR IN ACCORDANCE WITH SECTION 6 RECALIBRATE IN ACCORDANCE WITH SECTION 6 Figure 7 1 Maintenance Flowchart PLACE PUMP IN SERVICE 07 19 A1 729 Checkout 7 3 Operational Checkout 7 3 1 Administration Set Placement To avoid the possibility of fluids contacting the air sensor and pump mechanism the solution container should be spiked and the set primed before opening a pump door The container should also be placed low enough to permit a loop in the tubing to the side of the device Posi tion the container so that accidental spillage onto the device will be minimized Do not stretch the set when removing it from the packaging 7 3 2 Functional Testing Please become familiar with the device operating procedures in the Operator s Manual The pro cedures in this section are designed to check the ability of the device to pump primary and sec ondary infusions prior to testing the effectiveness of its alarms If either pump fails to perform as described or stops with a failure code alarm troubleshoot it in accordance with Section 5 and repair it in accordance with Section 6 before attempting to place the device in service 7 3 21 Preparation for Testing 1 Using a solution container distilled sterile water 0 9 sodium chloride or DSW and a Baxter s Continu Flo administration set with at least one Y site p
20. eG os OSI 6 3 12 Replacement of Force Sensing Resistor F SR Devices for Tube Misloading Sensors 6 12 6 3 13 Replacement of Pump Motor 0 14 6 3 14 Replacement of Safety Slide te 6 3 15 Spring Retainer Removal 6 17 6 3 16 Spring Retainer Installation 6 18 6 3 17 Replacement of Back Plate 618 6 3 18 Replacement of Battery 6 19 Interlink Electronics Interlink Electronics iv 7 19 A1 729 6 3 19 Replacement of Power Supply Board 6 3 20 Replacement of CPU Display Board 6 3 21 Replacement of Audible Alarm Alert Board 6 3 22 Replacement of Backup Audible Alarm Alert Board 6 3 23 Replacement of Terminal Board 6 3 24 Replacement of Power Transformer 6 3 25 Replacement of the PANEL LOCK Switch 6 3 26 Replacement of Lithium Backup Battery 6 3 27 Tube Guide Shim Installation 6 3 28 LCD Cushion Installation 6 3 29 Software Installation 6 4 Calibration 6 4 1 DC Line Voltages 6 4 2 Air Sensor Calibration 6 4 3 Downstream Occlusion Sensor Calibration 6 4 4 Upstream Occlusion Sensor Calibration 6 4 5 Slide Clamp Sensor Calibration 6 4 6 Slide Shaft Sensor Calibration 6 4 7 A D Convertor Reference Voltage Calibration Checkout r i A AAA 7 1 Introduction 2s 7 2 Maintenance Flowchart 7 3 Operational Checkout 7 3 1 Administration Set placement 7 3 2 Functional
21. pn N N Dornet n COM2 Figure 10 29 LCDs for Pump 1 10 31 07 19 A1 729 3 0 COM6 votre un vul NOUO AN NUO atest NUD mO NUJ mino QOEmM Cor vulc mer nnn corx oo Ma rm AU ima OE in US Mo MW f nuse Ma 5970 Ml Demet MN wo Mur mas EE f NO wo aimo QOO NWT NO we pr n NWOT Nt wo fas ARS Mun iy Dr ur Y a ee Muro AUST HO me o e emn OA ne NUI Ao mt et A vue ma 79 gt CD ci mer f Russ PN go 9 N PEE cow MID mt meu Oo Vul eoo MWUMOW E AWS meom VUGD f OOEx ous ECHO 00904 PROGRAMMING VYLF7696M MESSAGE VVLF7526M mo ao nuse mo TT POSO MN METE TT ISA uoo e NO PUNA me mua _ WON Py cuo Ne MUONS m uo Nw nuce cue Ns Tan woe N MONG e use Mw NN e nue To MUDO ko NUDY een Ne
22. Ge Mer et a EP Theory of Operation 4 1 CPU System 4 1 1 CPUs 4 1 2 Programmable Timer Module 4 1 3 Watchdog Function 4 1 4 Controllers 4 1 5 Multiplexer 4 1 6 Universal Pulse 4 1 7 Communication Controller 4 1 8 Air Sensor Circuit 4 1 9 Occlusion Sensors 4 1 10 Tube Misloading 4 1 11 Slide Clamp Detectors 4 1 12 Battery Low Alert Alarm Deteci t 4 1 13 Interlock Switches 4 1 14 Panel Lock Circuit 4 1 15 Keypad 4 1 16 Displays 4 1 17 Motor Driver 4 1 4 2 2 42 4 3 4 3 4 3 4 4 4 4 4 5 4 5 4 5 4 5 4 6 4 6 4 6 7 19 1 729 iii 4 1 18 Motor Rotation Detectors AC es ig GS ee S 4 2 DC Power Supply and Power Control Circuit Uo G usc eee xr som dre Troubleshooting noces x 9 9 9 UR e 5 1 5 1 Introduction ue erben E dp es SL 5 2 Failure Identification Codes ET 5 3 Automatic Test Modes A Sur 5 3 1 Automatic Test Mode j Calibration Model wei mon 5 2 5 3 2 Automatic Test Mode 2 Calibration Mode 2 5 4 5 3 3 Automatic Test Mode 3 Manufacturing Test Mode 29 5 m IW ere i 5 3 4 Automatic Test Mode 4 Aging Mode 5 5 5 3 5 Automatic Test Mode 5 Display Check Mode 5 6 5 3 6 Automatic Test Mode 6 Time Information Display Mode
23. OCBPZZ06 A OCBPKZOS A Power Supply Board Figure 8 15 Mfg Part F059130003 5009425013 5009420005 5009410040 Description Qty PCB ASSEMBLY POWER SUPPLY Ge ete he 1 54 HOLDER FUSE 1 S CONNECT 2 PIM es 4 07 19 1 729 Illustrated Parts Breakdown 315A L da FO59130003 1 1 02140 40018 wi T CMK 77X CMK 77X uS FB M ef 5 e C2 Ci qum 2 gt ika H AKA R3 WA En a THI ui 5 je Em MN n mae wm MW 14 03 a 1 RI3 MAL Ar Power Supply Board Component Side P T 3 E i EUN dio 02 P fu 02 OD IT alo C13 M dte A Figure 8 15 Power Supply Board Solder Side 07 19 A1 729 8 37 Illustrated Parts Breakdown Item 8 38 Svc Part CPWBNIO0S D PGUMS101 A PSEL1008 A PZETL100 A QCNCMI04 D QCNCW104 E RUNT1003 A RUNTI1004 A UBATLI00 A XUPSD26P A XUPSD26P C Display PCB Figure 8 16 Mfg Part F052130001 5009440001 3004090005 F044610001 5009410012 5009410037 5009492007 5009492008 5009480002 4009310019 4009310076 Description PCB ASSEMBLY Display STRIP Zebra SEAL DUST LCDs COVER LCD Insulation CONNECTR 3 Pin CN
24. 6 3 1 Separation of Front and Rear Housings 1 Turn the device off and place it face down on an anti static mat or work surface Take care not to lay the device face down on components such as screws which could dam age the front panel 2 Remove 10 screws that secure the rear housing to the front housing Figure 8 4 items 10 and 60 Caution Avoid stressing the device s internal cabling when separating the front and rear housings 3 Stand the device upright and separate the front and rear housings by slowly pulling the front half forward by about 10 16 cm 4 4 While the device is standing disconnect CN301 and CN302 from the CPU board Figure 8 2 item 3 The connectors are located in the center at the top in the front half of the de vice 07 19 A1 729 6 3 Disassembly and Calibration Note The backup audible alarm may be activated Continue with step 5 to disable the alarm 5 Lay the front case half down on its front surface Position it immediately in front of the rear half Disconnect the following to completely separate the two housings a 751 from the back up audible alarm board Figure 8 3 item 3 located at the top left of the rear housing to disable the back up audible alarm during the disassembly Note Be sure to unlock the connector flange by pulling it forward about 2mm 3 4 before disconnecting the cable b Disconnect the flat cable connector CNI F from the CPU board c Disconnect
25. HOUSING Lower Pl 1 3 LCHSM100 G 048643 o oul oyan HOUSING Slide Clamp Sensor 1 4 LCHSM100 D S048439 HOUSING Slide Clamp Sensor2 1 5 1005 S048638 CUAMP Safety Pl us 1 6 LPiNS101 B S048448 PIN Release lt a doa ne A eras E 1 7 LPiNSIOI F S048986 PIN Dowel Side A 1 8 LPLTP107 B 5048639 PLATE Motor Holding Pl 1 9 LXRZ1002 A 5048881 ESRING SS 3 10 100 8048632 ARM 1 11 MARMP100 D 5048631 ARM Right Retainer Pl 1 12 MARMP100 F 048642 ARM 1 1 13 MCAMP100 C S048640 LATCH Safety osx 1 14 MSLiZ100 A 048425 SLIDES 2 sau d Esto ee was 1 15 MSLiZ100 C S048633 LATCH Slide Plo uai ee eds 1 16 MSPRCIOI D 048500 SPRING Slide Latch 1 17 MSPRD102 B S048470 SPRING Retainer Arms 2 18 MSPRD102 C 5044722 SPRING Slide Shaft oo wx 1 19 MSPRD102 D 5048469 SPRING SafetyClamp 1 20 MSPRP102 A S048642 SPRING Flat Slide Shaft 1 21 NSFTD103 B 048449 SHAFT Slide a uu ey eR 1 22 LPiND101 D 504450 PIN Release eg h 1 23 NSFTD103 C 504451 SHAFT Safety Latch 1 24 NSFTD103
26. O nm gt aw ONNAN N A AER ls ll as u u ls ts as a a a a ss Hle gt 05 gt gt gt gt gt gt gt 9 N INN N HD61602R lt gt 8 NA un m mE bend el DEDE gt gt gt gt 00076 c910 0 1lu C911 lu C912 0 1u gt T Lal ei gt 2 gt 0 COM6 COM5 0 Figure 10 28 LCD Drivers for Pump 2 10 30 07 19 A1 729 0 3 C0M3 ce aaan NUMM mo NA mo No AWD Fin ke MUM hm nus ha nun Ho Muir mm Www mu wun num m NUDA pa vum p 515 GJG 313 8 9 4141414 4141313131313 3 3 3 8716 5 110 9 8 7 615 4 312 Yur mo ANCIEN oe Yamane ee Zax Ce COMI 3 1 3 5 2 wu umo ooro Vora NUII meo eom Vul D Musa zo MWCO AY rnm uo Qorm VOEN AWM VOZ oo Voznon MID emo MD mM 60 WWII OWA t PIED Uu eoo vulg eem NIHON MWe
27. zozx oa ec cc zm me tt gt ZEZE CAE x gt gt lt a lt gt mx lt 2 OVcpu Figure 10 20 CPU PCB Sensor Block 10 22 07 19 A1 729 0 15 gt A lt 9 7 RESETP i WRM gt I RDM gt 0 7 0501 Ycpu pouT 4 3 3 6 RP601C g RP607C 22K Noura DOUT 2 2 7 RP601B 2 22K 0001 3 6 11 1 8 601 4 2 22K IDEA 22K 2 7 RP6028B 22K 1 B RP602A 22K 3 6 RP602C 22K 4 5 RP602D 2 22K DouT o 7 gt y DOUTO 43 31 DMO E Hi 1 5 AER PO1 DL 00072 41 P02 D2 29 om2 y bours 00013 40 P03 D3 28 0M3 4 a va H H 5848 00 75 38 POS DS Y 00076 37 DE Pe PMB tt Tt ENE 80017 35 95 05 234 547 iseEL 1 3 SEL1 sett 14 jig b 15 12 15 211 WR E 16 A0 2 Lae AAA E 1 20 15 ts D 10058 21 P16 EYLO 22 P17 lt gt im lt lt lt lt us lt 1 gt tR S TALMNON
28. Disconnect and reconnect Perform steps in Section 6 4 5 Replace the safety slide clamp assembly 07 19 A1 729 5 19 Troubleshooting 5 20 07 19 A1 729 Section 6 Disassembly and Calibration 61 Introduction This section of the manual includes a list of tools and test equipment required for performing maintenance procedures for removing and replacing subassemblies once the cause of a malfunc tion has been determined and procedures for calibration after component or circuit board re placement Detailed exploded views of the device are provided in Section 8 6 2 Preparation for Maintenance 6 2 1 Tools and Test Equipment The following tools and test equipment are required to perform the procedures contained in this section Since all fasteners on this device are metric ensure that all tools used are for met ric fasteners Tightening torques on certain screws are specified in kgf cm and in Ib for your convenience The values in in Ib are approximate Note Reset the configuration options in accordance with Section 1 5 2 after performing any repairs This is especially important after replacing the EPROMs and after the occurrence of failure codes 49 or 94 07 19 A1 729 6 1 Disassembly and Calibration Test Equipment Digital Voltmeter DC Ammeter 5 ohm 20W resistor with variable load See Figure 6 4 Thickness gauge part number UKOG1013 B 0 3 mm flat feeler gauge Grounded wriststrap Anti
29. STOP ON OFF CHARGE Action Press and hold the LOCK key while simultaneously pressing the STOP and ON OFF CHARGE key then release all of the keys Multiple Key Combinations Sequence Alarm Log Failure ID Codes Key Combination Section SILENCE VOL STATUS Press CLR TOT VOL within 3 seconds The display will scroll backwards through the alarm codes and automatically exit at the end Flow Check 5 2 VOL STATUS When the keys are released the display will disappear 10 seconds later Configuration LOCK STOP ON OFF CHARGE TIME TOT VOL STATUS View Configuration Software Version Calibration Test Mode 1 Table 1 1 1 5 2 15 1 SILENCE ON OFF CHARGE CLR TOT VOL 1 ON OFF CHARGE Calibration Test Mode 2 Test Mode 3 CLR TOT VOL 2 ON OFF CHARGE CLR TOT VOL 3 ON OFF CHARGE Aging Test Mode 4 Display Check Test Mode 5 CLR TOT VOL 4 ON OFF CHARGE N A CLR TOT VOL 5 ON OFF CHARGE Time Information Test Mode 6 CLR TOT VOL 6 ON OFF CHARGE Pumping Sensor Monitoring Mode 7 Air Sensor Test Mode 8 CLR TOT VOL 7 ON OFF CHARGE CLR TOT VOL 8 ON OFF CHARGE Elapsed Time Test Mode 9 Downstream Occlusion Test Mode 0 CLR TOT VOL 9 ON OFF CHARGE CLR TOT VOL 0 ON OFF CHARGE 07 19 A1
30. e Insert the slide clamp Part no 030216490 and close the door Verify that the voltage at the appropriate test point is 0 25 V or less If the voltage is greater than 0 25 then attempt to adjust the voltage by turning the potentiometer VR805 for PUMP 1 or VR803 for PUMP 2 fully clockwise Replace the safety slide clamp assembly if it cannot be calibrated Section 6 3 14 f Without the slide clamp inserted and the door closed verify that the voltage at Pin 3 for PUMP and or Pin 1 for PUMP 2 is 4 2 V or greater Replace the safety slide clamp assembly if it cannot be calibrated Section 6 3 14 Repeat this procedure for the other pump Note Apply a thin film of red Glpt to the appropriate potentiometer to lock it in position 4 Perform the Operational Checkout procedures in Section 7 6 4 6 Slide Shaft Sensor Calibration Notes This calibration must be done after the slide clamp sensor has been calibrated Early production units may contain potentiometers VR804 and VR806 instead of jumper wires soldered across the holes If your unit contains these potentiometers you must perform this procedure oth erwise skip this procedure l Connect the device to 115 5 0 VAC 60 Hz power source Enter Automatic Test Mode 1 by pressing and holding the CLEAR TOT VOL and 1 keys while pressing the ON OFF CHARGE key 2 Insert the slide clamp and keep the pump door opened 3 Rotate potentiometer VR806 Pump 1 or VR804 Pump 2
31. nr t Lad leni amp 6 ja al Nun an lt zzu NAN rr w NNNN lt gt gt gt gt tX CPUPCB2 MPA w nexorramu IL gt Eee deere NO oo here 0 0 0 01 ee aa Saa zx gt 5 wena EN L e NNN gt NALALOLOALEFEFLEZIOOS gt gt 2 v PER P3 oe ae ar Se lt mala Load Ld tl mt D DP WO Oo gt gt lt gt QiO gt aw wj oe ej xwu ojo Ou Wl tN 6 a Aad ini vi O ojo On Lant Lam Lam Las Lam Lam gt gt E lt 160 CO gt Pr O O 2 9 2 gt ond busd wn jajajajajaja ETE a ajo a jojo lt lt aN aN gt lt lt gt LE X NL NLXUX mM NE Mm 9 gt gt lt wi Cea 23 25
32. 14 Place a 0 3mm flat feeler gauge between the motor bottom surface and the motor end plate If the flat feeler gauge cannot be inserted or the gap is wider than 3mm loosen the set screws Figure 8 8 or 8 13 item 27 to move the motor Ensure that the edge of the flat feeler gauge is touching the side of the motor shaft Press the motor against the plate and tighten the set screws to 5kgf cm 4 3 in Ib 15 Install the sensor 2 assembly using the two screws Figure 8 9 or 8 14 item 35 Tighten ing torque is 3 kgf cm 2 6 in 1b 16 Install the safety clamp arm cover Tightening torque for the arm cover securing screw Figure 8 7 or 8 12 item 2 is 1 kgf cm 0 9 in Ib Remove the thickness gauge 17 Install pump head assembly into the case in accordance with Section 6 3 8 18 Install the pump door cover in accordance with Section 6 3 4 19 Perform the Operational Checkout procedures in Section 7 6 3 15 Spring Retainer Removal The spring retainers are installed into the slide clamp slots at the factory to maintain proper ten sion on the springs within the assemblies They must be removed prior to use if the slide clamp feature is enabled l Openthe pump door See Figure 1 2 for the location of the spring retainer 07 19 A1 729 6 17 Disassembly and Calibration Press the safety clamp arm cover in until the safety clamp latches open Using E ring pliers insert the tips into the holes in the spring retainer Gently rem
33. 26 25 24 23 22 Figure 1 1 Front View 07 19 A1 729 1 5 General Description 9 Pump 1 ALERT LED 10 BACKLIGHT key 11 SILENCE Key 12 TOT VOL STATUS Key 13 CLEAR TOT VOL Key 14 TIME Key 15 PRI RATE Key 16 PRI VTBI Key 17 PRI START Key 18 PLUG Icon 19 MONITOR Legend 20 BATTERY Icon 1 6 Yellow LED which lights during Pump 1 alerts accompa nied by a message display and a repeated single beep An alert indicates that Pump 1 needs routine attention Provides backlighting of the displays when the device is used in darkened areas The key toggles the backlighting on and off If the device is operating on battery power the backlight remains on for 60 seconds and turns off automat ically to conserve battery power Temporarily silences an audible alarm or alert for two min utes visual alarm or alert information remains dis played Dual function key During operation this key causes total volume delivered and current settings to display when pressed It is also used to select a next step in Review Con figuration Modify Configuration and Programmed Deliv ery Profile modes The word NEXT above the key is illuminated when the key is functioning as a NEXT key Resets the total volume delivered to zero when the pump is stopped Enters desired time interval for an infusion during Volume Time or Rate Time programming Allows programming of the primary infusion rate Allows programming
34. Closed door Slide clamp is not loaded into the slide PRI or SEC slot although the set is loaded into START the pump EXT COMM ERROR Yellow No change or no flow No change PGM DELIV ENTER PGM Yellow No flow None Communication timeout period has elapsed No communication has occurred between the device and the host computer during the power up default time period 60 seconds or during the time period most recently specified by the host computer 1 300 seconds The computer and the device must maintain periodic and successful communication in order to avoid this timeout alert See the Programmer s Manual for further information The controlling or monitoring computer is sending multiple queries or commands to the device without waiting for the device s replies The condition has been caused by the computer not the device To clear the alert press OPTIONS to return the device to computer control if appropriate or press SILENCE or PUMP 1 or PUMP 2 to control the pump s manually Notify the technical personnel responsible for the computer the alert recurs disconnect the cable from the communications port Reprogram the pump s for manual operation PRI SEC attempt was made to start the PDP START before a program was entered Enter a program or press OPTIONS to leave the PDP mode None PGM DELIV REVIEW PGM Yello
35. M3X8 2 8 32 07 19 A1 729 Illustrated Parts Breakdown Safety Slide Clamp Assembly 2 Figure 8 14 Item Part Mfg Part Description 8 14 F049120020 F049120020 PUMP 2 HEAD ASSY CCRA1006 A 047875 CLAMP SAFETY SLIDE ASSEMBLY P2 LCHSM100 A 504428 HOUSING Upper P2 2 LCHSM100 B 048429 HOUSING Lower P2 3 LCHSM100 C S048438 HOUSING Slide Clamp Sensor 1 2 4 LCHSM100 D 5048439 HOUSING Slide Clamp Sensor2 P2 5 LCRA1006 A 504430 CLAMP Safety P2 6 LPiNS101 B S048448 PIN Release 7 LPiNS101 F S048986 uun PIN Dowel Slide A 8 LPLTP107 A 048434 PLATE Motor Holding P2 9 LXRZ1002 A S04888l na E RING Shaft 10 MARMP100 A S048023 ARM Right Retainer P2 11 MARMP100 B S048970 ARM Retainer P2 12 MARMP100 C 50434437 4 2 13 100 504435 LATCH Safety P2 14 MSLiZ100 A 5044425 SLIDE X 6 0 auae BE SUE 15 MSLiZ100 B 5044424 LATCH Slide B2 16 MSPRCIOI D S048500 SPRING Slide Latch 17 MSPRDIO2 B 504420 7 SPRING Retainer Arms 18 MSPRD102 C 50484727 4 SPRING Slide Shaft 19 MSPRD102 D 048469 SPRING Safety
36. R751 m p7seL_ Eh Li E A mime s ms R769 R756 E O c oo 55 p C104 0756 755 R768 c o lo ool C402 T Y o 25106 cis 825 Craig C405 R363 C 1 Ofen Maii eni em 109 C R05 20107 coz 0803 804 C004 E O C001 El 9 C809 C010 C005 a E reos 799 Ca C007 C821 past LOS do E 6 R158 R34 R823 1 C 1ce75 5098 ME 657 10 a tao 322 316 0307 8827 370 R37 D308 eO E EIE 907 ZL ce76 UC 8317 78316 p cr rs O 203 R869 7 534 3 cese L Co em 20 O R870 ee gm R219 R321 O g L3 R545 R501 R335 ES EE E c 2213 peer R701 R546 2722 R705 R712 El O Figure 8 17 Sheet 2 of 2 CPU PCB Solder Side 07 19 A1 729 zn Illustrated Parts Breakdown Terminal PCB Figure 8 18 Item Sve Part Mfg Part Description Qty CPWBN104 B F043130001 ASSEMBLY Terminal 1 1 QCNCM233 A 5009410014 7 Pin 701 1 2 QCNCM233 C 5009410016 9 Pin 401 1 3 QCNCW 142 5009410021 CN IF2 1 4 RRLYD321 A 5009450001 se RELAY e di i AAA 1 OTS 94vo R421 Ia 6003560081 GEN Geos CN701 Figur
37. SCREW Pan Head 3 20 7 XBSUF40P A 4009310015 SCREW Flat Head 4 18 10 GCOVA101 D 2053624003 1 11 GCOVA101 E F053624004 COVER PumpHead2 12 LRTNP100 B F044620002 SPRING RETAINER 13 XBSUF30P A 4009310014 SCREW Flat Head M3X12 8 2 07 19 A1 729 Illustrated Parts Breakdown Figure 8 1 Front Housing Assembly External 07 19 A1 729 Illustrated Parts Breakdown Front Housing Assembly Internal Figure 8 2 Description HOUSING FRONT SUB ASSEMBLY DISPLAY PCB ASSEMBLY See Figure 8 16 for details on item 2 PCB ASSEMBLY See Figure 8 17 for details on item 3 Part Mfg Part 2059120001 F059120001 CPWBNI105 D 2052130001 CPWBX105 A 051130002 104 2051624001 GLEGG100 D F044630001 LANGT103 B F042220001 LANGT103 C F052220001 PGUMM103 G 054630001 PSPAF103 A F044230001 PSPAF103 B F054230001 103 2049620013 QCNW 1043 B F044140001 XBPBN30P A 4009310001 4009310003 XBPSD30P G 40093 10038 XUPSD30P B 40093 10020 XWHSD300 C 4009330001 XEPSD30P A 4009310018 UBATL100 A 5009480002 PSEL1008 A 3004090005 HOUSING Front FOOT Rubber BRACKET Pump Head 2 Mounting BRACKET Pump Head 1 Mounting SEAL Rubber Housing SPACER Pump Head 2 SPACER Pump Head 1 Spacer Double Locking PCB WIRE Grounding SCREW Pan Head
38. The device has a number of built in safety features Should a situation occur which requires op erator attention or intervention the pump stops infusing and sounds an audible alarm The fol lowing are brief descriptions of these alarms AIR An ultrasonic sensor in each pump head detects air in the administration set Detection of an air bubble stops the infusion and illuminates the red ALARM LED AIR is displayed in the ap propriate Message Display and the audible alarm is activated OCCLUSION The downstream occlusion sensor senses an increase in back pressure between the patient and the pump indicating an occlusion or closed clamp When an occlusion is sensed the pump stops OCCLUSION is displayed in the appropriate Message Display the red ALARM LED is illuminated and the audible alarm is activated UPSTREAM OCCLUSION The upstream occlusion sensor senses a closed clamp or complete blockage upstream of the pump When sensed the pump stops UPSTREAM OCCLUSION is dis played in the Message Display the red ALARM LED is illuminated and the audible alarm is ac tivated BATTERY LOW When approximately 15 minutes of running time remains during battery opera tion BATTERY LOW is displayed in both Message Displays the yellow ALERT LEDs are illumi nated and the audible alert is activated After approximately 15 minutes the device stops BATTERY LOW is displayed on both Message Displays the red ALARM LEDs are illuminated and the audible alarm
39. awenn o vuse _ eee Lom ewes Fe mr 22222222222222222222 QOENOmM Ma Damos NUDNO eu goemt e mu vue viugems AWONMN NONN Mil MWA tr ron MID ra wo NWFN ru rre lt p Mi MD Vu DN et DN rm O Mid NUDNO NUJNO COENOO Qoxwotw Figure 10 30 LCDs for Pump 2 10 32 07 19 A1 729 ALARH ALERTI ALERTI PUNPTWGT gt PUMPING ALARNZ ACERT Z ALERT PUMPING gt PUNPING2 NEXT LED NEXT LED OPTIONLED OPTIONLED LED gt MON LEO Vcpu Q R930 3 3k LED LED914 DC non gt 06 La CHARGING i 20mA R 1 5k 3 2 Ju 19mA R 1 6k 3 3 0 a TA LT9002E Ycpu Q 9901 TALARM1 2504081 1 0901 AA 5H 0903 RT 25504081 09 GL5HY42 9905 1 2504081 LED905 AA GLSEG42 9902 25 4081 6L5HD4 9904 ALERT2 2504081 904 390 LED AA 918 R920 220 PUMPSELI PUMPSEL2 B
40. seconds Check that front panel is recurs replace front not damaged panel 36 Master CPU received an Check HIC302 on CPU board for Replace HIC302 or CPU abnormal power ON OFF proper function board signal Troubleshootin Table 5 1 Failure Identification Codes CODE CAUSE CHECKS CORRECTIVE ACTION 37 Either ON OFF CHARGE Check that the keys were not Replace front panel if key was pressed for inadvertently pressed for 5 necessary more than 5 seconds seconds Check that both keys are when device power was not damaged off 38 Malfunction in tube Check CN803 Pump 1 or CN804 Clean contacts on male misloading detection Pump 2 for proper connection connector Circuitry Repair or replace connec tor if necessary or replace FSR 41 Abnormal operation of Turn device off and back on If failure code recurs Master CPU replace CPU board Malfunction in alarm control circuit 42 Turn device off and back on If failure recurs replace CPU board 46 The PWRON1 signal is Turn device off and back on If failure recurs replace held low _ CPU board 47 PWRON1 signal is Turn device off and back on If failure recurs replace held high CPU board E 48 Malfunction in real time Turn device off and back on If failure recurs replace clock RTC does not 0506 or CPU board count time correctly 49 Malfun
41. 1 With the administration set loaded into the pump and the pump not running elevate the solution container to a head height of 0 7 meters 27 inches or higher as measured from the midpoint of the device to the level of solution in the container Open the roller clamp and close the pump door and observe the distal end of the set for 60 seconds after closing the door Verify that no more than 1 2 mL of fluid flows in the first 60 seconds and that no gravity flow occurs after 60 seconds Repeat steps 1 through 3 for the other pump Warning If either pump fails to prevent free flow remove the device from serv 7 10 ice Troubleshoot it in accordance with Section 5 and repair it in ac cordance with Section 6 07 19 A1 729 Checkout 7 3 11 Alarm Volume 1 Induce an alarm by any convenient means 2 Rotate the VOLUME knob on the rear of the unit Verify that the sound level increases as the control is rotated clockwise and decreases as the VOLUME knob is rotated coun terclockwise The alarm alert sound should be audible at any VOLUME knob position 3 Set the volume to maximum upon completion of this test 7 3 12 Slide Clamp Test The Slide Clamp Feature is an alert or alarm option software versions 1 09 and later enabled through the configuration utility When this option is enabled the slide clamp on the administra tion set must be loaded into the slide clamp slot When the infusion is complete the administra tio
42. 1 Vcpu MOTORIC MOTORIA wen L MOTOR 1 MOD1 6213 1 gt cpu CEDE D 0209 2 09 d ex STOP 1 11 0 Q TEC E for 0204 gt IPUMPIE 24 R219 C 74HC32F 22k i 74HC32F RP204A 1 0204 8 1 9 O RP203A 12 ants 99202 spe 5 gt LMTR1D 114 9 10051 7 s 10051 203 5 1 5 3 6 0211 IMTRIB lici diu BN il 10051 1 22K 7 P EN 0210 d J 8118 RP203B i AL Eee C IMTRIC v d EE S 22 10 RP203D UPA1522U 10202 RD20FB TRIA IMTRIA 22K 74HCO2F dei da IN o IM Vatr R216 T 1 5 CURRI 100u 35V CURRI ALUMINUM 0 01u 1 0k 0 22 1 28 C c204 10u 16v T TANTALUM 1 07938 R705 R721 R722 R706 1 390 390 390 100k 14 J P o 10 N U R pres lij PIREVI 136 T 3 REVIS lt TREVIS PISECTI 7 174HC109F 74HC14F 5 LRESUMELTURESUMET gt 1 74HC109F U701D IREVIM CIREVIM 74HC14F Figure 10 18 Motor Driver Circuit Pump 1 07 19 1 729 10 20 MOTOR 2 1 7 IMOD 2 212 c219 1 002 gt END 0 01 0 01u 92098 9 V 1209 4d STOF SIOP 94 5 5 GND for 0203 for 0209 TRUMPZE gt IPUMPZE 104 5 74HC32F 74HC32F Ycpu Q RP201C 6 3 92201 20 INTR2D SAGs 3 3 2
43. 16 Sheet 2 of 2 Display PCB Solder Side 8 40 07 19 A1 729 Item Sve Part CPWBX105 A QCNCM012 A 100 QCNCM100 B QCNCM100 D QCNCMIOI A 104 QCNCM104 C QCNCM233 B 233 QCNCM701 A QCNCWI100 A QCNCW103 A QCNCW142 A QFSH4330 A QFSH8300 A 07 19 1 729 Illustrated Parts Breakdown CPU PCB Figure 8 17 Mfg Part F051 130002 5009410003 50094 10004 50094 10005 5009410007 5009410029 5009410010 5009410011 5009410015 5009410016 5009410034 5009410031 5009410036 5009410021 5009425004 5009425005 6009590001 Description PCB ASSEMBLY CPU CONNECTR Test Point GND 2 Pin CN302 CONNECTR 3 Pin CN301 CONNECTR 6 Pin CN851 CN852 CONNECTR 5 Pin CNTEST2 CONNECTR 40 Pin CNDISP CONNECTR 11 Pin 201 202 CONNECTR 8 Pin CN811 CN812 CNTESTI CONNECTR 9 Pin CN803 804 CONNECTR 10 Pin CONNECTR 8 Pin CN 601 CN602 is CONNECTR 2 Pin 3254546 katte we oto CONNECTR CNIF we FUSE 1 5 A 125 V SB F201 FUSE 125 302 PROTECTR 600 mA ICP301 F15 Illustrated Parts Breakdown ENZO 5 82607 F202 Usa 5002560020 ooo O
44. 19 There is a separate motor driver circuit for each pump that func tions identically Each motor driver receives four separate motor drive signals from the slave CPU which are effectively ANDed with a pulse width modulation PWM signal from the pro grammable timer module The PWM signal controls the current level required for proper motor operation The motor current level is converted into digital signal by the UPP and monitored by the master CPU which activates an alarm and stops the pump if a motor overcurrent is detected The user defined rate is saved in two different memory locations which are compared against each other and the feedback from the motor rotation detectors to guard against any non pro grammed rate changes Snubbing diodes have been added to increase motor efficiency The motor is shut down when an alarm or a failure occurs The motor speed range permits infusions from 1 mL hr to 1999 mL hr 4 6 07 19 A1 729 Theory of Operation 4 1 18 Motor Rotation Detectors See Figures 10 11 10 16 10 18 10 19 10 36 and 10 37 The motor rotation detectors assure that pump drive rotation occurs or the motor shuts down The motor rotation signals are read by the master CPU via the UPP and slave CPU The sector signals are read by the slave CPU and utilized for controlling motor currents 4 2 DC Power Supply and Power Control Circuit See Figures 10 5 through 10 8 The DC power supply circuit is a switching type which pro vides
45. 6 07 19 A1 729 Illustrated Parts Breakdown Figure 8 6 Pmp 1 Bs Plt w Tube Misloading Detectrs 8 15 07 19 A1 729 Illustrated Parts Breakdown Item 8 7 Sve Part F059120015 LPLTC106 B LXBZ1020 A MSPR1001 C MSPR1002 B NSFTZ102 A OiCMP32T A 2 OiCMP32T J PCASD100 B PCOVP101 D PZETL102 E CCILZ100 A RCORF100 D 5048992 TLABH109 B XBSUF20P A Pump 1 Base Plate Assembly Rear Figure 8 7 Mfg Part 059120015 5048625 5048918 5048015 5048014 5048012 5048928 5048893 5048901 5048022 5048641 5048508 5048011 5048013 5048992 07 26 01 088 5048962 PUMP 1 HEAD ASSY SPRING Downstream Occl Sensor SPRING Upstream Occl Sensor ACTUATOR Occlusion Sensor SCREW Pan Head M1 7X4 5 WASHER MI 7 WASHER M2 HOUSING Occl Sensor SENSOR AIR ASSY P1 LABEL Safety Clamp Rev A SCREW Flat Head M2X10 07 19 A1 729 Illustrated Parts Breakdown W a rw 8 17 Figure 8 7 Pump 1 Base Plate Assembly Rear 07 19 A1 729 Illustrated Parts Breakdown Pump 1 Base Plate Assembly w Pump Mechanism Figure 8 8 Item Sve Part Mfg Part Description Qty 8 8 F059120015 F059120015 PUMP 1 HEAD ASSY 1 1 CCRA1005 A S047780 CLAMP SAFETY SLIDE ASSEMBLY1 1 Note See Figure 8 9 for details on item 1 2 LBRC1006 A 048426 RETAINER Motor Spring 1 3 LBSHZ101 D 048497 OPRPER ia tie e
46. 8 6 Item 8 6 8 14 Sve Part 2059120015 CPLTC106 A LBRC1007 A LBSHZ101 B LPiNS101 A LPiNS101 E LPLTC106 B LXWZ1003 A NROLP100 A PGiDM100 D PGiDM100 E QSWZ1010 B QSWZ1009 B TLABZ109 D TLABZ109 E TLABZ110 E Not used XBSSF20P B XBSUF30P C PZETL102 B PBOX1004 A OiCMP32T G XBPDS30P K Mfg Part F059120015 5050043 5048626 5048501 5048447 5048453 5048625 048873 5048455 048486 048487 5047932 5047931 5048650 5048651 07 26 1 202 4009310081 5048963 5050045 5048432 5048895 5048940 Description Qty PUMP 1 HEAD ASSY 1 PLATE SUB ASSY 1 S BLOCK Mounting Latch Pin P1 1 fat BUSHING DoorHinge 4 RIN Lateh gt a ea 1 PIN Latch Mounting Block 2 PLATE kn teens ete eles WASHER Latch Roller 1 ds ROLLER Latch 1 38 GUIDE Tubing Lower Channel bo de is ES GUIDE Tubing Upper Channel ASAS SENSOR Tube Misload IR 1 SENSOR Tube Misload 1L 1 DECAL Tubing Channel P1 1 DECAL Tubing Channel Pt 1 LABEL Slide Clamp Slot Rev A 1 SCREW Flat Head 2 5 2 SCREW Flat Head M3X8 1 TAPE Conductive Finger 2 BOX PIDSGE 1 se WASHER M3 2x S 6 SCREW Pan Head M3X8
47. A 1 Data Sheet Flo Gard 6301 Volumetric Infusion Pum Operational Checkout Section 7 Paragraph Test Results Pump 1 Pump 2 Self Test Pass Fail Pass Fail 3 2 Primary Infusion Test Pass Fail Pass Fail 7 3 3 DOOR OPEN message and audible alarm occur when Pass Fail Pass Fail door is opened during infusion 7 3 4 Pump alarms for air bubble NORM gt 110 ul or MIN gt 85 pl Pass Fail Pass Fail 7 3 5 Drive defect Occlusion check Fail Pass Fail 7 3 6 Downstream occlusion detected Pass Fail Pass Fail 7 3 6 Downstream Occlusion Sensor Calibration Value Pass Fail 2967 3039 with thickness gauge in place 7 3 7 Upstream occlusion detected Fail Pass Fail 7 83 7 Upstream Occlusion Sensor Calibration Value Fail Pass Fail 3242 3314 with thickness gauge in place 7 3 7 Upstream Occlusion Sensor Calibration Value Fail Pass Fail 163180 or less without thickness gauge installed 7 3 8 BATTERY appears when device is unplugged during Fail operation and the pump continues to operate while unplugged 7 3 8 2 BATTERY disappears when the device is plugged back Fail in 7 3 9 Loc message appears when PANEL LOCK switch is Fail Pass Fail pressed 7 3 9 Input from front panel keys is not accepted
48. AIRTX2 da q 5 NORMLVL2 d MINLVLZ d NY B8B XH A NORMLVL2 gt A GND Figure 10 24 Air Sensing Block 07 19 A1 729 10 26 lt en ejes ala lt x x ojo o min 1 di Sass pin xx v m gt gt gt 0 Voth NCALL DGND OG AO vaain BUPBZ ALARMBZ 98048 04 74 14 ni aja eo o 2 nx j 4 1 ol lt 1 Eai bad kas ka mal ejja lt gt El eye ejej ol 2020000000000 90 m CN I F SlP 15s 2 rom a eel eoi ojal 1 gt e QOoooooQooo i a Nal e 0 2 85 5 85 52 ANM 6 00 0 AD lt 00 NL eri io DAO 4 4 NNN 00 QD GJ 0 09 08 08 0 0 0 0 0 0 em wr 8911 040 1785 A les 2 le 1 epo 0o opas aja NOIR la 9 o aja aja ja pat bad aja 5 Lala 1 nia e jo lt z ho ojo a gt lt x x o ojo 2 gt gt ww ei ma f Nw lt n gt lt S o uu dui uw Due
49. CN E XU QUU DO QOOOOGGOOOUGGcC UG si VEG Gd qioimiewaoocooo aooOdOz o m xm 0p oOwwuwuuuuuwunuwnuu 38 39 5 63 39 SEG3 38 48 SEG 2 29 NODO e D em DA CO m NM iD 0 NM no Q 3E CD 3 D QD QD aan mA o 24 v vy o GJ uj UJ aj UJ UJ GJ CD CO CD C9 COD C9 OQ OD OG OU D Oo O O viii vivi wu v wv uu u u u tas u Ul t GJ GJ UJ li CU UJ LO Ku v v wu uv ww wu uuu uu NN WN IN lt C OQ OD r xo wh f 6 uu c4 04 m uo mom Mm co co c5 0 5 HD61602R gt lt e a gt Pje BOUTS 68 SEGi 9 G Q 59 SEGI 18 49 SE61 28 48 SEGI 29 cn UN Q m OL 00 dino m NL 00 m sri uo O3 QI Q3 Q3 4D Q3 QD QD Q3 24 4 eO NL UNI UL Lud GJ Ud Ld UJ AJ UJ CD CD QD QI QD 29 QD D 5952 D 6 0 0 0 O 0 0 vi wv Mn uu Y us Ll las ul GJ Uf C LU had tas Lal Lal dad La
50. CPU Because the tubing collapses somewhat during normal operation the software E looks for a collapse that is faster and or farther than expected If the rate of collapse is too fast or 4 4 07 19 A1 729 Theory of Operation too far the pump alarms There is a maximum tubing collapse beyond which the device will no longer permit operation The upstream occlusion sensor operates in a frequency range of 1 2 MHz to 1 35 MHz 4 1 10 Tube Misloading Detectors See Figures 10 11 10 25 10 36 and 10 37 Each pump head has a Force Sensing Resistor FSR device attached to each side of the tube loading channel If the tube is misloaded over the FSR its resistance decreases The two FSR output voltages of each pump are converted into digital signals by the UPP and monitored by the master CPU The CPU activates an alarm when the resistance reduces below a specified level 4 1 11 Slide Clamp Detectors See Figures 10 22 10 25 10 36 and 10 37 Each slide clamp detector consists of two opto inter rupters contained in the safety slide clamp assembly If the slide clamp option is selected via the configuration option settings the administration set slide clamps should be loaded into the slide clamp slots in order to avoid an alert or alarm condition If the slide clamps are not loaded into the slide clamp slots or are loaded improperly the opto interrupters do not receive reflection signals The interrupter output voltages are read and monitor
51. Ensure that the encoder disk is properly secured Check photointerrupter output for proper function Secure encoder disk Replace photointerrupters if necessary Replace CPU board 78 Drive defect overinfusion High motor rotation against the number of revolution counter interrupts 79 Drive defect underinfusion Low motor rotation against the number of revolution counter interrupts See Failure Identification Code 77 Ensure that pump head is clean and rotates freely Check coupling between pump mechanism and motor Check encoder disk for secure mounting Apply a trace of Loctite 211 or 222 to coupling screws and tighten Secure encoder disk Replace CPU board Turn device off and back on 82 No acknowledgment message from Slave CPU for three communication trials 83 Undefined message type received from Slave CPU Turn device off and back on If failure recurs replace CPU board If failure recurs replace CPU board 86 LVDT reading of downstream occlusion sensor is too high Check calibration of downstream occlusion sensors Loctite Inc See Failure Identification Code 2 5 14 07 19 A1 729 Troubleshootin Table 5 1 Failure Identification Codes Check calibration of upstream occlusion sensors CORRECTIVE ACTION See Failure Identification Code 4 Turn device
52. Head 3 6 7 27 XBSUZ30P F 5048966 SCREW Flat Head M3X10 1 28 XBSUF30P A 4009310014 SCREW Flat Head M3X12 5 29 XXXSP30L B 504880 SCREW Set M3X4 2 8 24 07 19 A 1 729 Illustrated Parts Breakdown Figure 8 10 Pump Head 2 Door Assembly 07 19 A1 729 8 25 Illustrated Parts Breakdown Pump 2 Base Plate Assembly w Tube Misloading Detectors Figure 8 11 Item 8 11 8 26 Part F049120020 CPLTC106 A LBRC1008 A LBSHZ101 B LPiNS101 A LPiNS101 E LPLTC106 A LXWZ1003 A NROLP100 A PGiDM100 D PGiDM100 E QSWZ1011 B QSWZ1012 B TLABZ109 A TLABZ109 B TLABZI10 E Not used XBSSF20P B XBSUF30P C PZETL102 B PBOX1004 A OiCMP32T G XBPSD30P K Mfg Part F049120020 050044 048018 048501 5048447 5048453 5048017 5048873 048455 048486 048487 5047933 5047934 5048465 5048466 07 26 1 202 4009310081 5048963 5050045 5048432 5048895 5048940 e Description PUMP 2 HEAD ASSY PLATE BASE SUB ASSY P2 BLOCK Mounting Latch Pin P2 BUSHING Door Hinge PIN Latch ROLLER Latch GUIDE Tubing Lower Channel GUIDE Tubing Upper Channel SENSOR Tube Misload 2L SENSOR Tube Misload 2R DECAL Tubing Channel P2 DECAL Tubing Channel P2 LABEL Slide Clamp Slot Rev A SCREW Flat Head 2 5 SCRE
53. Mode Warning This is an automatic test mode for testing the device during manufac turing only This mode must not be used on patients because the downstream occlusion upstream occlusion and air sensors are dis abled The initial display in this automatic mode is for a PRI RATE of 1999 mL hr PRI VTBI of 3998 mL SEC RATE of 500 m hr and SEC VTBI of 100 mL Each press of the TIME key changes the primary settings as follows PRI RATE PRI VTBI SEC RATE SEC VTBI 999 1998 100 499 998 250 500 125 250 10 20 500 In each combination the primary and secondary rates and VTBIs can be manually altered 100 100 100 The device automatically stops one hour after the PRI START key was pressed While the de vice is running the air sensors and the upstream and downstream occlusion detectors are dis abled 5 3 4 Automatic Test Mode 4 Aging Mode Warning This is an automatic test mode for testing the device during manufac turing only This mode must not be used on patients because the rates and VTBIs cannot be altered 07 19 A1 729 5 5 Troubleshooting While the device is stopped pressing any numbered key 0 6 programs preset rate VTBI com bination as follows Key Number PRI RATE PRI VTBI SEC RATE SEC VTBI 0 500 3000 999 6000 1 499 0 999 1 2 3 0 0 0 3 250 0 0 0 4 499 100 0 0 5
54. Reassemble the case halves Perform the Operational Checkout procedures in Section 7 6 3 13 Replacement of Pump Motor 1 10 6 14 Remove pump door cover in accordance with Section 6 3 4 Separate the front and rear housings completely Section 6 3 1 Remove pump head assembly in accordance with Section 6 3 8 Close the pump door Carefully place the pump head assembly face down on the work surface Carefully remove the two springs Figure 8 8 or 8 13 item 9 above the motor coupling Perform this step carefully to avoid losing springs Remove two screws that secure the motor holding plate to the safety slide clamp assem bly Figure 8 9 or 8 14 item 30 Remove two screws washers and spring washers Figure 8 8 or 8 13 items 22 14 and 25 securing the encoder cover Figure 8 8 item 16 and finger box cover to the finger box Do not lose the short nut bar Figure 8 8 item 31 Remove two screws washers and spring washers Figure 8 8 items 22 14 and 25 secur ing the finger box cover to the finger box above the motor coupling Do not lose the long nut bar item 32 Remove the finger box cover 07 19 A1 729 Disassembly and Calibration Note Slide the encoder cover toward the encoder to prevent it from stick 11 12 13 14 15 16 17 18 19 20 ing to the encoder screw head Carefully lift and remove the motor and its associated assembly from the pump head base plate T
55. Replace Display board Replace Sensor Board The backlight does not light The backlight cannot be turned off Replace Display board Replace Display board Replace CPU board The device or a pump turns off or stops with audible alarm for no apparent reason Check ICP301 Check CN601 and CN602 for proper connection and continuity Check front panel cables for short circuits Replace ICP301 Repair or replace connectors if necessary Replace front panel film Replace Display board ALARM LED s is are always lit Turn device off and back on If problem recurs charge or replace battery Replace CPU board Replace Display board ALARM LED does not light Check CNDISP for proper connection and continuity ALERT LED 1 always lit Turn device off and back on Check CNDISP for proper connection and continuity Replace CPU board Replace Display board If problem recurs charge or replace battery Replace CPU board Replace Display board ALERT LED does not light ALARM and ALERT LEDs are lit but the pump will not operate PUMPING LED s is always lit PUMPING LED s does not light Check CNDISP for proper connection and continuity Replace CPU board Replace Display board Check backup battery voltage in accordance with Section 5 3 1 Sometimes this condition is followed by a F49 and or F94 code Recharge or
56. S050052 5050052 DOOR PUMP HEAD PI 12 LBSHZ101 A S048489 BUMPER Door 2 13 LBSHZ101 C S048502 BUSHING Door Latch 1 14 LPiNS101 C 50474347 24 PIN Door Hinge 2 E oett ea 2 15 LPLTM106 A 504445 PLATE Safety Clamp 5299 1 16 LPLTM106 C 5048644 COVER Back Plaie P locas 1 17 LPLTM104 C S048493 PLATB BACK n te oa oe Baty SDN 1 18 MSPRC101 C S048499 SPRING Back Plate 5 19 PAJS1002 A 504444 STOP Occlusion Detector 2 20 PCUSGIOL A SO48504 BUMPER DOOD wd are he Bee 4 21 PZETE100 C 5048506 FILM Plate Insulation 1 22 TLABZ110 A 07 26 01 179 LABEL FIOW or edet 1 23 TLABZ110 G 504655 LABEL Tube Loading 1 24 TLABZ110 H 50486658 LABEL Tube Loading 1 25 XBPSD20P C S048033 SCREW Pan Head M2X8 w washer assy 2 26 XBSUZ30P A S048987 SCREW Flat Head M3X6 7 27 XBSUZ30P F S048966 a SCREW Flat Head M3X10 1 28 XBSUF30P A 4009310014 SCREW Flat Head 12 5 29 XXXSP30L B S048890 SCREW Set M3X4 Atak a a ds 2 8 12 07 19 A1 729 Illustrated Parts Breakdown Figure 8 5 Pump Head Door Assembly 8 13 07 19 A1 729 Illustrated Parts Breakdown Pump 1 Base Plate Assembly with Tube Misloading Detectors Figure
57. Sensors on Pumphead 1 07 19 A1 729 H2 on 202 NM D DH eo OUUUUUUUUUO DOUUUOUO OUUUUUUU OUUUUUUUO gt 5 jaj ea lel faja v ej IN ojoj ieiz e lt jojoju OF lt ajo pater al a aj bi had xj joja jajaj ac me ac bay i ajojo Paja v e lt lt lt a be lt ofaj a gt x ex ec us tl mr us eo co gt 2 c eo n n n n s 0 esl e este es mom a e a 2a mre XHP 11 CN852 XHP CN812 1 2 3 4 5 6 7 8 XHP 1 2 3 4 5 6 7 8 9 XHP NORM 2 MOTOR 2 ATH PISECT2 Gud UPOCCL 2 L2791 Ut2791 GRAY side side VIOLET Z26AWG _ upstream side downstream side WHITE OOO Kani kan Kee kan Can kani 2i gt gt EE YELLOW 011007 NER WIRE used for is used for 1 N I 15 used for TX is used for RX is tube ole gt lt gt x gt n lt lt e aja ola 24 NIN NIN
58. When the pump is stopped all displayed values return to normal 5 3 8 Automatic Test Mode 8 Air Sensor Test Mode Upon entering this mode the PRI RATE 30 PRI VTBI 100 SEC RATE 600 and SEC VTBI 100 Pressing the TIME key selects the device s air sensor sensitivity MIN or NORM without using the configuration option The air sensor selection is displayed in the message dis 5 6 07 19 A1 729 Troubleshooting play when a pump is started All other keys function normally except for the TIME key Rate and VTBI information for both primary and secondary mode may be changed 5 3 9 Automatic Test Mode 9 Elapsed Time Test Mode The elapsed pumping time is displayed in the first line of the message display in this test mode Momentarily pressing the TIME key selects two pre programmed primary mode test conditions The first is a PRI RATE of 125 mL hr with a VTBI of 100 mL The second is a PRI RATE of 499 mL hr with a VTBI of 100 mL The elapsed time counts only when a pump is running Stop ping a pump and then restarting it will reset the timer to zero All keys except the TIME key work normally When the VTBI has been delivered the pump will enter KVO mode 5 3 10 Automatic Test Mode 0 Downstream Occlusion Test Mode In this mode pressing the TIME key will allow you to select the device s downstream occlusion level sensitivity without entering the configuration mode The selected occlusion sensor level 1 2 or 3 is momentarily shown
59. a razor blade or similar tool Note All adhesive residues must be removed from the surface to ensure the successful attachment of the FSRs 9 Completely remove any adhesive residue from the base plate and clean the surface with an alcohol soaked cloth 10 Using a digital multimeter check that the resistance of the replacement tube misloading sensor is between 140 and 210 If it is not do not use it 11 Loosely attach a new tube misloading sensor to the pump head base plate Ensure that it fits within its recess and does not override the pump head area Do not attach the sen sor firmly to the pump head base plate yet 12 Check that the resistance of the tube misloading sensor is between 140 KQ and 210 KQ If not repeat steps 8 through 12 13 If the sensor resistance reading is normal press the tube misloading sensor firmly and en sure that it is securely attached to the pump head base plate with no gaps Interlink Electronics 07 19 A1 729 6 13 Disassembly and Calibration 14 15 16 17 18 Connect both sensors to the connectors at top rear of the pump head plate through the hole for the upstream occlusion sensor See Figure 8 6 or 8 11 Replace the upstream occlusion sensor on the pump head base plate and perform the cali bration checks in accordance with Section 6 4 1 and 6 4 4 Install the mounting block for the latch pin by replacing one screw Figure 8 6 or 8 11 item 17
60. a regulated 13 65 V output at 1 4A maximum The circuit will charge the battery as long as the device is connected to a specified AC outlet The design continues to supply useful output down to a 105 0 VAC input Two 500 mA slow blow replacement fuses are required for AC A 2 0A fuse is required in the battery circuit Whenever the supply is activated by AC voltage the Plug Icon on the front panel is lit The DC power supply has over voltage and over current pro tection The power supply circuit on the CPU board Figure 10 8 generates several DC sources from the 13 65 V output of the DC power supply board when the device is plugged into a specified AC source or from the internal battery The 5 VDC lines are shown below See Section 6 4 1 for voltage specification limits Vepu This line is the output of a DC to DC convertor HIC301 and is switched by the master CPU Vcpu is the main DC source voltage of the device Motor current does not flow while Vepu is off Vref This is the reference voltage regulated by a filter and a reference diode U502 LM336M 5 0 Figure 10 7 for the A D convertor in the UPP This voltage is generated from Voth which is switched by the master CPU Vkey This is generated either from the output of the DC power supply board or from the internal battery voltage and is used for monitoring the ON OFF CHARGE key This is the unswitched power source 07 19 A1 729 4 7 Theory of Operation Other DC voltages used
61. ae Uso pronos 0501 RPE RP602 8 0002 27 512 ACOQ 24 lt Ro 1 gt 01 014 O Quien O s2 Wis eO E 9315 0104 270010 2105 C eeie2 7 _ b 19 ACO2 ES o O RPOOS RP104 neon E ai S 5 e RPOTO 005 g Payee quss M o 109 1703 109204 a 32 RPOII Aco RP012 1 12 RP106 oe O AO pes 999 165 0754 O 4 204 02 0851 53 0852 HC4040 4006 0107 ACO2 ioe czo CIL UTSIHCOO 9306 pec TE at Ep 1p ep ee gl Hos3ts0cr 8 14 uso vat ad U108 ACO2 U753 HC00 U752 e m eas E X a sar Had ae yaaa 8 HCO 5 an 0755 _ 6 0079 C864 C05 aZ a 22 5 7722 W7508F E d C869 C863 858 C852 e 29806 diac L 0208 097 02 0205 i 1 L 1 1 0402 71080 us PP A sf 5 9 6 8 1 Laos 3 RP503 n gt 020 to VR803 Ls RP501 T1 5AP 8 sarl SIA 4 n CN202 40 0404 Figure 8 17 Sheet 1 2 CPU PCB Component Side 07 19 A1 729 8 42 Illustrated Parts Breakdown 503 2 R8 2 25 us 5 40 x CNDISP 338 C601 1 Gos E E cI C R338 7 R339 7426 521 R533 S C C520 R420 c R770 R755 R752 C755 R419 O 6752 co R771 6752 C 0752 C aoe C101
62. amp 3 E 5 AWWEEEE 2 O 222325252o0o0uu a2a23a32 C t Q O X X t0 uv vi v0 un AIRLVL AIR SENSING BLOCK AIR SEN MPA lt cn ANAN a 4 NN ex d gt e ZO dl Wed t O OWE Uee yN Rew VOW X 2 2 O uwadmoodotuug4EuwuwzzxzEcrxx OO Qe 2 2 gt gt gt 2 Qu ur QOO c ce C OQ QO uv a XC X Z c c O0 un uu 7 gt 37 IA SD eju j ajajaja mja EJ EEEE ef 2 e 1202 210 ainia 6 2 Ajoj ojo j ao gt lt 2 2 FEF ul xlejolo ol w 2 2 2 2 2j 2 ojejuju olo 9i 2 1 AJA e Ol ojo o ajajajaja j z c ON N a N a 064 ENAN a gt gt cCooooouoirco gt gt gt gt lt CEEE E E E HI on X z zocx
63. automatic test modes to aid in troubleshooting and manufacturing The ten modes are described briefly in the following paragraphs The procedure to access any of the automatic test modes is as follows 1 Turn off the device 2 Press and hold the CLEAR TOT VOL key and while pressing the numeric key corre sponding to the automatic test mode you wish to enter 1 through 0 3 While performing step 2 press either ON OFF CHARGE key 4 exit any automatic test mode press the ON OFF CHARGE key that was pressed in step 3 5 3 1 Automatic Test Mode 1 Calibration Mode 1 The purpose of this calibration mode is to check the calibration of the upstream and downstream occlusion sensors and to check the device s internal DC voltages from the power supply 1 Place the device on its back Enter Automatic Test Mode 1 2 Place the thickness gauge part no UKOG1013 B onto the downstream occlusion sen sor 3 Close the pump head door 4 Plug the device into a 115 5 0 VAC 60 Hz power source 5 2 07 19 A1 729 Troubleshooting 5 Check that the value displayed in the PRI VTBI window of the appropriate Main Display is between 2967 and 3039 No calibration is required if the values are within the specifi cation 6 If the value is out of specification perform Section 6 4 3 steps 2 and 3 7 Place the thickness gauge used in step 2 onto the upstream occlusion sensor 8 Close the pump door 9 Check that the value displayed in
64. device off and back on If failure recurs replace circuitry is too low the CPU board 68 Malfunction in A D Turn device off and back on If failure recurs replace converter circuitry A D 0501 or CPU board conversion for channels 8 and 9 did not complete in 72 15 69 Abnormal battery Check calibration of DC Power Recalibrate the board recharging voltage Supply board failure recurs replace 0501 or CPU board If failure recurs replace CPU board If failure recurs replace CPU board 07 19 A1 729 Troubleshooting Table 5 1 Failure Identification Codes CODE CAUSE CHECKS 72 Slave CPU received undefined data 4 times from Master CPU Turn device off and back on CORRECTIVE ACTION If failure recurs replace CPU board 73 Overcurrent to motor 74 Motor slipped even though at maximum current to motor Check for loose motor coupler Check that CN201 Pump 1 or CN202 Pump 2 is seated firmly Check CN201 Pump 1 and CN202 Pump 2 for proper connection and continuity Apply a trace of Loctite 211 or 222 to coupling set screws and tighten them to 5 kgf cm 4 3 in Ib Plug CN201 and CN202 in firmly Replace CPU board Plug CN201 and CN202 in firmly Check for blown fuse F201 Pump 1 or F251 Pump 2 77 Slave CPU received no revolution interrupt while motor is rotating Turn device off and back on
65. ej gt ot mr o ojo co gojo or ow ona gt gt Sc gt we v u a een pos ore gt L o 2 4 A i 2 eL rta es ras 49 o z E d M m to ws 2 wee x L x ul e lt mes E pr avr gt m gt E 24 lu w 24 gt nus uva RE vse uuo tnc gt lt lt xxx wee zzz Eb lt lt orno e m cman w 6 am m NN LEINN gt O Q0OOrOOO0 x 2000o0 uv _ AQ REEF gt w XxEXEXXEXEXDL002O0wv 5 xxmxxxx uu PISECT 2 MOTOR 2 MOTORZA MOTOR2B MOTOR2D DWNOCCL2 INTLOCK2 10 39 Figure 10 37 Sensors on Pumphead 2 07 19 A1 729 SEC SEC PRI PRI OPTIONS START RATE START DOT BACK CLEAR KEY1 TIME CLEAR SILENCE TOT VOL LIGHT VOL STATUS ON OFF CHARGE 1
66. fully counterclockwise and check the voltage at Pin 4 for PUMP 1 and or Pin 2 for PUMP 2 is 0 2 V or less 4 Close the door and check that the reading is 4 2 V or more Loctite Inc GC Electronics 07 19 A1 729 6 37 Disassembly and Calibration 5 Note 6 4 7 Insert the slide clamp and check that the reading is 0 6 V or less with the door opened Replace the safety slide clamp assembly if it cannot be calibrated Section 6 3 14 Re peat this procedure for the other pump Apply a thin film of red Glpt varnish to the appropriate potentiome ter to lock it in position A D Convertor Reference Voltage Calibration Separate the front and rear housings See Section 6 3 1 Connect a digital voltmeter between pin 1 and pin 8 of the CNTESTI connector Connect the AC plug of the device to a 115 5 0 VAC 60 Hz power source Adjust potentiometer VR501 until the meter reading is 5 000 0 050 Disconnect all test equipment Reassemble in reverse order GC Electronics 6 38 07 19 A1 729 Section 7 Checkout 7 1 Introduction The Operational Checkout procedures in this section determines if the device operates properly after it has been repaired If the device fails any part of the Operational Checkout the fault must be corrected prior to placing the device in service Please become familiar with all the checkout procedures before beginning The following test equipment is required to perform t
67. is activated Table 1 2 lists the alarms and the possible causes of each In all cases fluid infusion is halted See Section 5 for an explanation of how to troubleshoot the device 07 19 A1 729 1 17 General Description d START key was pressed with no set in pump a Closed distal clamp stopcock clogged filter kinked tubing or other blockage downstream of the pump b Ambient and or solution temperature is too low a Closed clamp or other blockage upstream of the pump b Pinched or kinked tube loaded in the pump Door must be fully closed with tubing properly loaded for the pump to operate The door latch must be pushed down Turn the pump power off and back on to reset If FAILURE does not clear the microprocessor has detected a pump malfunction After recording the code number remove the device from use and have it serviced See Section 5 for more Turn both pumps off and back on to reset If FAILURE does not Table 1 2 Alarm Messages Alarm Message Possible Cause AIR a Air bubble at sensor b Empty fluid container c Improper set loading OCCLUSION UPSTREAM OCCLUSION c Improper set loading DOOR OPEN completely FAILURE with code number detailed service instructions COMMON FAILURE with code number BATTERY LOW with rapid three beep alarm tone clear the microprocessor has detected a device malfunction After recor
68. is amplified rectified applied to the UPP and then con verted into a digital signal The master CPU monitors the signal and activates an AIR alarm if it detects the absence of a precise level of energy 4 1 9 Occlusion Sensors 4 1 9 1 Downstream Occlusion Sensor See Figures 10 10 10 23 10 36 and 10 37 The downstream occlusion sensor consists of a mov ing ferrite core inside a mechanically fixed oscillator coil The moving ferrite core is spring loaded against the IV set tubing When pressure downstream of the pump increases the core moves from its original position which in turn changes the frequency of the oscillator One of the two downstream occlusion sensor outputs is selected by the multiplexer applied to the master CPU and compared to the occlusion level selected in the configuration option If the occlusion is sufficient to cause a specific frequency change the CPU activates an alarm There is a maximum expansion of the tubing beyond which the pump will no longer permit operation The downstream occlusion sensor operates in a frequency range of 1 3 MHz to 1 45 MHz 4 1 9 2 Upstream Occlusion Sensor See Figures 10 10 10 23 10 36 and 10 37 The upstream occlusion sensor is similar to the downstream occlusion sensor except for the spring but is not tuned to the same frequency and is controlled by different software One of the two upstream occlusion sensor outputs is selected by the multiplexer and applied to the master
69. of the primary VTBI Starts the primary infusion Green LED always lit while the device is plugged in and the battery is charging Yellow LED which lights for at least 2 seconds each time the host computer communicates with the device when the device is in monitor mode Yellow LED always lit while the device is operating on battery power 07 19 A1 729 General Description 21 COMPUTER CONTROL Legend 22 CLR Key 23 SEC START Key 24 SEC VTBI Key 25 SEC RATE Key 26 Numerical Keyboard 27 OPTIONS Key Legend 07 19 A1 729 Yellow LED which flashes when the device is initiating communications with a host computer to enter the com puter control mode It is constantly illuminated when the device is in computer control mode Clears any locked in values and programming values cur rently being entered Starts the delivery of the secondary solution Allows programming of the secondary VTBI Allows programming of the secondary infusion rate The numerical values for rate VTBI and time are entered with these keys Enables the device to operate in special modes 1 7 General Description See Figure 1 2 for the location of the following items Note that this figure shows Pump 2 only Pump has identical features which function in the same manner 1 Upstream Occlusion Sensor Detects a complete tubing restriction upstream of the pump 2 Pump Mechanism Linear peristaltic pump mechanism 3 Tube Misloading Se
70. off and back on 31 Malfunction in air MIN detection circuitry Input to A D converter remains high 32 Malfunction in air NORM detection circuitry Input to A D converter remains high 33 Malfunction in air MIN detection circuitry Input to A D converter is not 0 V although the MIN air transducer is not oscillating Turn device off and back on Turn device off and back on Replace CPU board Clean contacts Charge or replace battery Repair or replace connector s if necessary Replace safety slide clamp assembly Repair or replace connector s if necessary Replace CPU board Repair or replace connector s if necessary If failure recurs replace CPU board If failure recurs replace CPU board If failure recurs replace CPU board Check tightness of CN811 Pump 1 or CN812 Pump 2 connectors on the CPU board Repair replace connectors if necessary Replace CPU board 34 Malfunction in air NORM detection circuitry Input to A D converter is not 0 V although the NORM air transducer is not Check tightness of CN811 Pump 1 or CN812 Pump 2 connectors on the CPU board Repair or replace connectors if necessary Replace CPU board 07 19 A1 729 oscillating 35 Front panel key was Check that key was not Turn the device off and pressed for more than 40 inadvertently pressed for 40 back on If failure code seconds
71. rear housings in accordance with Section 6 3 1 3 Disconnect CNI from the power supply board Figure 8 3 item 18 and the grounding wire of the board from the grounding plate item 7 4 Remove four screws item 22 securing the power supply board 5 Reassemble in reverse order Do not pinch the wire harness of CN401 on the terminal board item 2 between the power supply board and the bosses for it Tightening torque for the four screws item 22 securing the board is 7 kgf cm 6 1 in lb Be sure to recon nect CN1 6 Perform the Operational Checkout procedures in Section 7 6 20 07 19 A1 729 Disassembly and Calibration 6 3 20 Replacement of CPU Display Board Separate front and rear housings in accordance with Section 6 3 1 Separate boards in accordance with Section 6 3 2 Carefully squeeze the four board spacer tops Figure 8 2 item 11 with needle nose pli ers to release the CPU board item 3 from the display board item 2 Lift the Pump 1 side of the CPU board to disconnect CNDISP at the bottom of the board from the display board and pull it perpendicularly to the board Caution Be sure to place the CPU board on an insulated surface Avoid touching potentiometers on the CPU board and the LCDs on the display board during the disassembly assembly procedures Reassemble in reverse order Be sure to check that the Pump 2 side of the CPU board is in the slot of the white PCB holder on the display board and that
72. the PRI RATE window of the appropriate Main Dis play is between 3242 and 3314 Remove the thickness gauge close the door and check that the value is 3180 or less 10 If the value is out of specification perform Section 6 4 4 steps 2 and 3 11 Check that the voltage readings in the SEC RATE and SEC VTBI windows of Pump 1 Main Display are within specification Note The pump must be plugged in to obtain voltage readings within the specifications below Descriptor Window Displayed Specification Vmain MB SEC RATE Vmem BB SEC VTBI Note a Actual voltage Displayed data x 0 01953 b Actual voltage Displayed data x 0 00488 12 If the BB display is out of specification replace the lithium backup battery per Section 6 3 26 13 MB is a value related to the voltage of the charging circuit If the MB display is out of specification turn the device off and charge it for 8 hours Repeat steps 1 and 11 If the MB display is still out of specification perform the following procedure 14 Remove the battery cover by removing 4 screws Figure 8 4 item 34 on the battery cover located on the back of the device Disconnect the main battery at the battery termi nals and perform steps 1 and 11 15 If the MB display is out of specification the DC power supply must be calibrated per 6 4 1 07 19 A1 729 5 3 Troubleshooting 16 If the MB display is within specification as described in Step 11 the main ba
73. the connector CNDISP is seated firmly Be sure to remove any dirt or dust on the LCDs and the windows before tightening the CPU board to the front housing Tightening torque for board is 7 kgf cm 6 1 in Ib Calibrate in accordance with Sections 6 4 1 through 6 4 6 when the CPU board is re placed Perform the Operational Checkout procedures in Section 7 6 3 21 Replacement of Audible Alarm Alert Board l Separate the front and rear housings in accordance with Section 6 3 1 Remove one screw Figure 8 3 item 22 securing the audible alarm alert board item 4 to the rear housing Remove the board and unplug the connector CN753 Reassemble in reverse order Tightening torque for item 22 is 7 kgf cm 6 1 in 1b Perform the Operational Checkout procedures in Section 7 07 19 A1 729 6 21 Disassembly and Calibration 6 3 22 Replacement of Backup Audible Alarm Alert Board ES 1 Separate the front and rear housings in accordance with Section 6 3 1 2 Unplug connectors CN751 and CN752 3 Remove one screw Figure 8 3 item 22 securing the backup audible alarm alert board item 3 to the rear housing 4 Remove the board 5 Reassemble in reverse order Tightening torque for item 22 is 7 kgf cm 6 1 in Ib 6 Perform the Operational Checkout procedures in Section 7 6 3 23 Replacement of Terminal Board 1 Separate the front and rear housings in accordance with Section 6 3 1 Note Be sure to unlock the connector flange bef
74. the device The numbers at the upper left of each block refer to the number of the figure in Section 10 in which the major components of that block are shown in greater detail 4 1 CPU System 4 1 1 CPUs See Figures 10 9 through 10 16 The device uses two CPUs U101 and 0001 U101 always func tions as the master CPU and 0001 always functions as the slave The master CPU controls all device functions except motor control which is handled by the slave CPU The master CPU sends rate information and motor start stop messages to the slave CPU and also monitors the motor control by the slave CPU The master CPU gathers data from and or controls the interlock switches the power control cir cuit the communication controller two I O controllers the occlusion detection multiplexer the RAM the real time clock the air sensor the universal pulse processor and the alarm control cir cuit The master CPU also handles RS 232 serial communication with an external computer through the communication controller The slave CPU mainly controls the pump motors via the motor control circuit in three ways e Generates pulses to rotate the motors e Monitors motor skip steps by checking the signals from the motor rotation detectors e Controls the motor currents while minimizing current draw from the battery It also controls the alarm control circuit 07 19 1 729 4 1 Theory of Operation The slave CPU outputs an interrupt signal to the master
75. the maximum rate and or maximum VTBI setting through the configuration option 07 19 A1 729 Problem Checklist Table 3 1 Problem Checklist CORRECTIVE ACTION PROBLEM CHECKS An AIR alarm occurs with no Check the positioning and seating air in the tubing or when the of the tubing sensor pump door is closed and the Check the tubing for surface START key is pressed scratches and for tube roundness Check the administration set for type and code Position the tubing fully into the air Replace or reposition the tubing if surface scratches are significant or if the tubing has become flattened or oval in shape Replace with a Baxter s s suffix administration set Check for solution spills liquids or residues Clean the sensor with cotton swabs dampened with one of the agents listed in Table 2 1 Remove fibers or foreign particles Do not use hard instruments for cleaning An OCCLUSION alarm or an UPSTREAM OCCLUSION alarm occurs when the pump door is closed and the START key is pressed Check the positioning and seating of the tubing Check that there are no obstructions upstream or downstream of the pump Position the tubing properly into the sensor and safety clamp Correct any pinched or kinked tubing in the pump Remove obstructions and or open the roller clamp Check the administration set for type and code Replace with a Baxte
76. to the cover and dis connect the battery wires 6 Remove the EPROM s using the removal tool Note The Master EPROM is located below the Slave EPROM designated on the board Also note that the orientation of both EPROMs is with the notch pointed up 7 Use an IC insertion tool to install the new version EPROM s Make sure that all of the pins are seated in the socket correctly and that the notched ends of the EPROM s are pointed up 8 Replace the battery Section 6 3 18 Connect the battery wires to the battery check po larity and slide the battery carefully into the battery compartment Note If the secondary alarm is activated press the ON OFF CHARGE key to stop the alarm If a failure code appears perform steps 1 5 in the Set Configuration section 9 Set the configuration to its original settings per Section 1 5 2 10 Perform the Operational Checkout procedures in Section 7 6 28 07 19 A1 729 Disassembly and Calibration 6 4 Calibration Read all steps in this procedure prior to calibration of the device Be sure that all of the neces sary equipment is available before beginning calibration procedures During calibration it is important to keep the connectors clean The device should be powered off for at least two hours before beginning calibration All calibration procedures should be performed in ambient and solution temperatures of 22 C to 28 C 72 F to 82 F 6 4 1 DC Line Voltages Veri
77. while panel Fail Pass Fail lock is in effect 7 3 9 Loc message disappears when PANEL LOCK switch is Pass Fail Pass Fail pressed again and input from keypad is accepted 7 3 10 Safety clamp prevents free flow Pass Fail Pass Fail 7 3 11 Sound level increases as VOLUME 1 rotated Pass Fail Pass Fail clockwise and decreases as knob 15 rotated counterclockwise 7 3 11 Alarm alert sound audible at any VOLUME knob position Pass 7 3 12 Slide clamp enabled Yes 7 3 12 If the slide clamp option is enabled slide clamp operates Pass correctly 7 3 12 If the slide clamp option is disabled spring retainer Pass Fail Pass Fail occupies slide clamp slot 7 3 13 Leakage current is 50 microamps or less Pass Fail 7 9 13 Ground impedance is 0 15 ohm or less Pass Fail Air Sensor Calibration Values Section 5 3 2 Descriptor Window Displayed Acceptable Tubing Loaded Results Value Pump Door Closed Pump 1 Pump 2 NORM RATE and Pass Fail Pass Fail and MIN PRI VTBI NORM PRI RATE and Pass Fail Pass Fail and MIN PRI VTBI NORM PRI RATE 11 or less Pass Fail Pass Fail and MIN PHI VTBI Signature Date A 2 Appendix Multiple Key Combinations The following multiple key combinations can be used to initiate sequences on the pump See the appropriate sections for details regarding the proper use of these combinations An example of the standard convention used in this table is given below Key combination LOCK
78. with a Flashball device are not recommended in these applications The primary rate of infusion is selectable from 1 to 1 999 mL in 1 mL hr increments and 1 0 to 99 9 mL hr in 0 1 mL hr increments The secondary rate is selectable from 1 to 999 mL in mL hr increments 1 0 to 99 9 mL hr in 0 1 mL hr increments The volume to be infused VTBD is also selectable from 1 to 9 999 mL in 1 mL increments and 1 0 to 99 9 mL in 0 1 mL increments The total volumes infused from primary and secondary programs are added together and accu mulated and can be displayed on demand The primary and secondary VTBIs are independently decremented and displayed Upon completion of the primary VTBI the pump automatically switches to a keep vein open rate If the pump is started on a secondary rate and VTBI the pump will change to the primary rate when the secondary program is completed Either pump may be stopped at any time by depressing the STOP key unless the device is in the lock out mode 07 19 A1 729 1 1 General Description 1 2 2 Nurse Call The Nurse Call feature is enabled by installing a jumper wire to the Terminal Printed Circuit Board at the location labeled R421 on the board When the jumper is connected the Nurse Call relay will be energized only during an alarm condition and when the ALARM LED is lit The re lay contact points normally closed normally open and common are accessible from the COM MUNICATIONS PORT on the rear
79. 0 30 10 31 10 32 10 33 10 34 10 35 10 36 10 37 10 38 10 39 10 40 7 19 1 729 Section 1 General Description 11 Introduction This manual provides service information for the Flo Gard 6301 Dual Channel Volumetric In fusion Pump product code 2M8064 for qualified hospital biomedical engineers and Product Service personnel See the device s Operator s Manual for detailed operating instructions 1 2 Device Overview 1 2 1 Principal Features The Flo Gard 6301 Dual Channel Volumetric Infusion Pump is an electromechanical device used for the intravenous infusion of liquids at user selected rates The device contains two linear peristaltic pump heads allowing it to simultaneously infuse two different solutions Each pump head is independently programmable and permits infusion of primary and secondary medication programs The secondary program automatically switches over to the primary program when secondary infusion is complete automatic piggybacking The device operates on standard 115 VAC 60 Hz electrical power or on its self contained re chargeable battery It is portable and has a panel lock out feature to prevent patient tampering It is designed for use with Baxter s standard administration sets which contain an s as the last character of the code number for example 2C5537s When infusing solutions through a central line catheter sets with Luer lock adapter should be used Sets
80. 07 19 1 729 Service Manual Flo Gard 6301 Dual Channel Volumetric Infusion Pump Product Code 2M8064 Baxter Healthcare Corporation Deerfield IL 60015 USA Copyright 1993 1995 Baxter Healthcare Corporation All rights reserved Change Record Page Specification number 7 19 01 729 Original issue 04 93 Rev A 05 95 Page Revision gt Cover Back of cover blank Title Page Change Record Page iil 1 1 1 20 2 1 2 4 3 1 3 4 4 1 4 8 5 1 5 20 6 1 6 38 7 1 7 16 8 1 8 48 9 1 9 2 10 1 10 40 Backs of 10 3 10 40 blank A 1 2 A B 1 A Back of B1 blank Inside of Back cover blank Back cover A A zero in the revision column indicates original issue gt gt gt gt gt gt gt gt gt gt gt gt gt ii 7 19 A1 729 Table of Contents General Description ee cr rr ror o we tn y s 1 1 Introduction 1 2 Device Overview 1 2 1 Principal Features 1 2 2 Nurse Call 1 3 Technical Specifications 1 4 Controls and Indicators 1 5 Configuration Option Feature 1 5 1 Reviewing the Configuration Option 1 5 2 Option Settings 1 6 Alarms Rees de Be te HS ede 1 7 Alerts Hospital Service Procedures lt 2 1 Replacement Of Power Fuse 2 2 Cleaning 2 3 Battery Charging 2 4 Preventive Maintenance Problem Checklist
81. 0856 DHNOCCL2 gt 10k 2504081 0 0224 470 25K374 R864 5 10k C862 8865 R868 0 022u 2 2k 150k Va O NY NY 7 CN852 A GND A GND R GND A GNO A GND a I b b Bb PUMP 2 DOWNSTREAM OCCL Bb C870 R873 72 C869 360p 3 3k 0 1u 68 510 MICA DWNOCCL2 R GNO Va R869 MICA C871 R872 O INTLOCKZ 0857 E 18 iok 2504081 0220 470 25K374 R870 874 10k C868 R871 150k 0 022u 2 2k NY SY NY V4 A GNO R GND R GND R GND R GND lt OCCLCH OCCLSEL DECIS EL KOCCISEL d n OCCLCLR am enu 7 N U 4 6 N U 3 5 N U 3 N U En 2 N U 11 4 N U 12 13 N U 1315 12 N U 14 N U 15 N U 21 1 OCCLPLS O CCLPLS p 1 16 ___154 26 40F 74HC153F OCCU CHK Vcpu for U851 for U852 Va C876 9 14 NY V A GNO SS Figure 10 23 Occlusion Sensing Block 07 19 A1 729 10 25 AIRSEL SENSE 74ACOOF Va C809 Va 0 1u R805 220 C805 R809 C806 100 680 L 0 01 zh ALUM B GND R GNO R808 100 4803 2564081 C811 0 lu R812 C810 0 01u R GND Y A GNO A GND 11 AIRNORMI d AIRCOMI _ 1_ NORMLVLI 4 JAIRCOM2 AIRTX2 MINLVLI 6 3v INUM 888 if 1 CNB12 AiRNORM2 fi AIRCOM d 3
82. 1 XHP 6 NANI UPOCCLI INTLOCKI LIGHT GREEN YELLOW used for downstream side used for upstream side 24AWG 24AWG is is insulation tube insulation tube Red Blue 1 e o 245 Mi DOOR 6P3S25 77 1 UPSTREAM L2 LvpT DOWNSTREAM INTER LOCK cN811 BROWN UL2791 28AWG 28AWG 28AMWG 28AW6 e Ofo gt lt E o zx us ec ac ac 1 nm lt lt lt wj La bend gt ES XHP 8 o lil ivil MLVLI END MIN NOR GRAY 012791 TX side side RX tube is used for tube is used for 28AWG 28 6 insulation insulation Yellow Green FSR1 NOTE m o 9 i o NX ca 2 wee gt E a o o wo 3 eeu mo gt v zzz ad we z lt a mu n meo mao n aa waa Met E RATES A jr ON OG X X ce D X Caco 00Qorooo x Jo00o0o0 2 u OoOcoo0o0r wuwiuoox zocxu x co ooeao Qc OO QO O Hw E me eee Ome NM HY enn INTLOCKI es iz a E e 10 38 Figure 10 36
83. 1401 100 0 0 6 1999 100 0 0 The RATE VTBI keys and number keys 7 8 and 9 are not accepted Other specifications are the same as during normal operation 5 3 5 Automatic Test Mode 5 Display Check Mode All the LCD segments LEDs and icons turn on sequentially for a visual check each time the Pump 2 STOP key is pressed At any point in the sequence the SEC START key may be pressed to return to the beginning of the sequence 5 3 6 Automatic Test Mode 6 Time Information Display Mode In this test mode the cumulative time values are displayed sequentially each time the SEC RATE key is pressed The test mode first displays the cumulative Power On time then the time on battery and finally the time that each pump was actually pumping It should be noted that the first six digits from the left are the time in hours and the two digits on the right are the time in minutes Therefore the display 0001 02 21 represents 102 hours and 21 minutes 5 3 7 Automatic Test Mode 7 Pumping Sensor Monitoring Mode Warning This is an automatic test mode for testing the device during manufac turing only This mode must not be used on patients In this test mode the motor current and occlusion sensors may be monitored during pumping During pumping the motor current is displayed in the PRI VTBI location the upstream occlu sion detector reading in the SEC RATE location and the downstream occlusion sensor reading in the SEC VTBI location
84. 22u 0 22u 22K 2 2 9 1 mu i 2902 CLK R20 10K PWRSWI i 7 2 lt Tvtrwr C15 0 01u R17 10K 6 55 330p C16 19 gt 2 18 R9 UGA d 74HC02 748C05 Vepu O 0 lt IVMASRST gt 1 06 RB715F Q Vepu DE p R8 9 1 330K R22 R19 1 0K P vt R21 47K 1 0K T besos 74HC132 R7 1 0K id CXCCORT 8715 Ue 1 04 16V cig 74HCOS 74HC02 1 15 R23 10K 18 16 WCIVSUVRST gt 8 PURCUIN R13 330 74005 22K R28 1 0 13 ol TRESETM U6F 74HCOS olf__ lt 7Tresers 20 PWRCUTS USE x12 330p M NE iy a 7480132 7 5 22K Ycpu 7 32 748C132 R27 C11 12 1 0M 0 1u 0 1u Figure 10 8 Power Supply Control Hybrid Circuit 07 19 A1 729 10 10 7 r a Hs NN 2 No TI N Pom Uu O gt gt NX Qo TQ ort a ao Misa DA 5 Com undcux lt lt 1 gt lt lt LXZTALNXOO xx T EO oS lt ZE EE RO A lo AR NAAA lt lt gt exo o 2 a aA W a 5 2 2 WeEonacae 2 eermaane nae 11 lt x lt a sexz 222
85. 2K 0204 t 10051 RP201B 5 7 2 1 0 ETREZE gt 191828 IAE TD A 22K 7 92021 RP2010 6 10051 5 4 IMTRZE ara Ja 22K 8 10051 RP2014A PA1522H IMTR2A _ gt q 22K 7 2 1 5 FS H4330 11 6203 6 0 01 gt Q t q es lt TFEVRS TA Ti 74HC109F 5 LRESUMEZ TRESUMEZ gt 74HC109F LLEVA C IREVZW SECI2 74HC1AF on oo ro for 0701 Figure 10 19 Motor Driver Circuit Pump 2 07 19 A1 729 10 21 OVcpu YN a a OCCLCHK OCCLPLS OCCL SENSING BLOCK OCCL SEN m mm mn Mare eH ANO gt pr z ADO gt Peer iw 8 4 OQ x DOUT 0 217 DM LO did Sor Ma Wr oN m x e z ENS gt ar SORRY ux gt lt LODO gt OO 6 d 1 gt La BACKLITE MPA 1 2 lt Na MANN N DS ou amp 0 20 2
86. 3 3 1 2 3 Replacement of Front Panel Film Separate the front and rear housings completely except the ground wire Section 6 3 1 Separate the printed circuit boards Section 6 3 2 Remove one screw Figure 8 2 item 13 that grounds the front panel film Caution Do not damage the front housing or the EMI plating with the tool Do 6 3 4 not reuse the removed front panel Remove the front panel film and the silicon rubber around the panel from the front hous ing with a razor blade or similar tool Reassemble in reverse order Remove the adhesive backing from the new front panel film and apply it pressing firmly around the film edges to ensure that the film is securely attached to the device with no gaps Tighten the front panel film grounding screw item 13 to 3 kgf cm 2 6 in lb Perform the Operational Checkout procedure in Section 7 Seal the edges of the new front panel as follows a Place the device on its back and apply a strip of masking tape along the four edges and corners of the front panel approximately 38 to 64 mm 0 015 to 0 025 from the edges and corners of the panel b Using a dispenser with a small diameter tip apply a bead of Toray Dow Silicone SE 9189 L part no UPAS0002 A along the edges and corners of the panel Apply the bead uniformly within 40 to 50 seconds per edge c Remove the masking tape before the silicone starts to form a skin d Keep the device on its back for 30 45 mi
87. 304 CONNECTR 40 Pin CN901 BACKLIGHT Message LCD BACKLIGHT Programming LCD BATTERY Lithium SCREW Pan Hd Tapping M2 6X8 SCREW Pan Hd Tapping M2 6X10 07 19 A1 729 Illustrated Parts Breakdown MESSAGE MESSAGE LCD909 a LON 59 e E 1 440 1 4 LED901 NEXT ay ALARM LEDOOS PUMPING LEDS0S ALERT 24 jM 2 LEDS06 PUMPING2 LED902 ALARM2 27 4 O O N 8 a 1 19 O O O LCD902 IPROORAMING I 1 0904 LPROGRAMING T 3 a m LED908 a yo 4 PUMPSELZ vec 3 i LED9t3 BATTERY 25 LED910 OPTIONS 3 E 771 I xe RT tL COMPUTER CONTROL Go Cr oM pere ee Figure 8 16 Sheet 1 of 2 Display PCB Component Side 07 19 A1 729 8 39 Illustrated Parts Breakdown ss o iL nnn HO61602 L4 bend 190 82895 7 5 0906 2 amp 3 0902 0905 06 602 c905 931 0916 R930 ao 5 dh Dh 8929 9915 reza 994 Di h Dh Dh Dh dh C904 9906 H061602 eed 7068 HDB1602 c9oi E 9901 rr 0903 2 0905 8926 0902 061602 8 55 2 S U903 H061602 o o 1 o o 2 e 8 4 2 lt a a 6002560019 1 8924 C 1 BAXTER D 03 C914 R342 8s2 1993 oh Dh Dh Figure 8
88. 418 TRACE ONLY ed to RXRDY U401 pin38 er BEEPBZ gt 4 Y gt 2 D jx MO RESETP BUPBZ 0401 DAN202U NCALL Figure 10 14 Serial Communication Block 07 19 A1 729 10 16 e OW Oo gt Q c c c NNN 0 gt NNN lt 5 10 17 SLAVE CPU Ae eere a MOTOR CONTROL BLOCK 1 MOTOR CONTROL BLOCK 2 MOTOR1 MPA MOTOR2 MPA 00 lt N n 5 lt rrz z o uu lt 6 06 9 X gt 0 gt gt lt lt gt Cc X oorrrrrrrr vd E A a 3 244444444 gt 4 gt N lt A gt Lad Uu O minjuln elec mol 2 2 gt ac lt PUN Fey FU FO alec gt ex ac 2 oc az el x o
89. 44 ro ala to xix gt 2 Sa Q wor gt aja 212 z e Se 5 ao by ea gt gt ma no a ton lt o on L a ew a n es ui a wj E 4 5 eo eix x jw gt eo ojo e meg OU 1 un Land Las m win ain jajjj a ao gt gt gt ee oler SET mar i Miu un e lt ico D m _ 02000000 per wj MO gt ojo ee al2 ow lt e lt an NP THOR la aja e ica T X SLCSENSE CNDISP 10 27 Figure 10 25 Misload and Slide Clamp Sensors 07 19 A1 729 Vcpu RP614C RP615A RP615C RP6148 RP614D RP615B 6150 614 C603 0 1u U603 for PUMPL PUMP for e Q E 22K 3 3 gt gt 2 a gt gt gt 5 5 EX lt lt m m x N x gt a AN NOw 2 gt DIJU Ou o a NONE
90. 5 JKNBZ100 C F04962001 1 KNOB Volume Control 1 6 JKNBZ101 B F044620012 KNOB Pole Clamp 1 7 JKNBZ101 C 6009590024 KNOB Panel Lock Sw 1 8 LFiX1010 A F044220004 1 9 LPLTZ107 A F044630006 CUSHION Pole Clamp 1 10 LXBZ1004 A 40043 10023 SCREW Pan Head M4X63 8 11 LXBZ1019 A 40093 10024 SCREW WITH SNAP 4 8 1 12 LXNZ1003 A F049211002 z NUT Comm aaa 2 13 LXWZ1007 A 4004330003 WASHER Cord Strap M4 ROZET 1 14 NSFTT102 A F044211003 1 15 PCASB100 A F052620003 HOUSING Battery 1 16 PCUSS102 A F044630003 CUSHION Battery Side 1 17 PCUSS102 B F054630005 CUSHION Battery Surface 1 18 PCUSS103 A F054630006 CUSHION Fuse Holder amp Battery 2 19 PGUMM103 L F054630002 SEAL Battery Cover 1 20 PGUMM103 M F054630003 SEAL Batt Housing 55256585 1 21 PGUMM104 A F054630004 SEAL 1 22 QFSH5100 A 5009425014 MFUSE 01A 250V Sata Aug eru OP See 1 23 PZETL102 J 3004010010 FILM Battery Insulation 1 24 QCNWI1092 A F043140004 HARNESS Comm Port 1 25 QCNW1116 A F052 140002 HARNESS Battery
91. 7 8 19 8 23 8 25 8 27 8 29 8 31 8 35 8 37 8 39 8 40 8 42 8 43 8 44 8 45 8 46 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 Figure 10 10 Figure 10 11 Figure 10 12 Figure 10 13 Figure 10 14 Figure 10 15 Figure 10 16 Figure 10 17 Figure 10 18 Figure 10 19 Figure 10 20 Figure 10 21 Figure 10 22 Figure 10 23 Figure 10 24 Figure 10 25 Figure 10 26 Figure 10 27 Figure 10 28 Figure 10 29 Figure 10 30 Figure 10 31 Figure 10 32 Figure 10 33 Figure 10 34 Figure 10 35 Figure 10 36 Figure 10 37 Figure 10 38 Master CPU Schematic UPP RTC and SRAM Block P O CPU Board Alarm Control Circuit Address Decoder Serial Communication Block Slave CPU Block Diagram Slave CPU Schematic Slave RAM and Programmable Timer Module PTM 2 Motor Driver Circuit Pump 1 Motor Driver Circuit Pump 2 CPU PCB Sensor Block PPI Block 1 PPI Block 2 Occlusion Sensing Block Air Sensing Block Misload and Slide Clamp Sensors 4 Display PCB EM LCD Drivers for Pump 1 LCD Drivers for Pump 2 LCDs for Pump 1 LCDs for Pump 2 LED Lamps Audible Alarm PCB Backup Buzzer PCB Terminal PCB Accessories Sensors on Pumphead 1 Sensors on Pumphead 2 Front Panel Key Assignments 10 12 10 13 10 14 10 15 10 16 10 17 10 18 10 19 10 20 10 21 10 22 10 23 10 24 10 25 10 26 10 27 10 28 10 29 1
92. 7 A 5048473 HARNESS Tube Misload Detector 1 41 QCNW 1098 S048474 HARNESS Slide Clamp Sensor 1 OR2 1 42 QCNW1099 A S048475 HARNESS Slide Clamp Sensor 1 2 ext 1 43 QCNWI100 A S048476 HARNESS 1 44 QCNW1101 A 5048477 HARNESS Door Sw 2 1 45 QCNW1102 A S048478 HARNESS Upstream Occl 2 1 46 QCNW1103 A 048479 HARNESS Downstream Occl Sensor P2 1 47 QCNW1104 A 5048480 HARNESS Air Sensor Input P2 1 48 QCNW1105 A S048481 WIRE HARNESS Air Sensor Output P2 1 50 QPWBN103 B 5048492 i PCB Door Open Sw 1 51 QPWBNIO0S A 048459 PCB Tube Misload Terminal 1 52 CPWBN105 B S047877 PCB Flexible Prntd Crkt Terminal 1 53 QSWL1003 C 048513 5 WITCH Door Open 1 54 VRDRV2EY A S048521 RESISTOR 100 Ohms 2 55 XBBSD30P D 4003910075 SCREW Binder head 2 56 XBPBN30P C 048929 SCREW Pan Head M3X8 w washer 5 2 57 XBPBN4OP F 40093 10080 SCREW Pan Head M4X6 1 58 XBPSD20P A 5048923 SCREW Pan Head M2X3 2 59 XBPSD26P B 5048933 SCREW Head M2 5X8 1 60 Not used 61 XWHSD200 A S048891 WASHER Door Open Sw PCB Bracket 2 62 XBPSD30P i 5048939 SCREW Pan Head
93. 7 kHz signal for the door open detector and the signal for backlight dimming The UPP also interrupts the master CPU each time a pulse is received from the motor rotation detectors when an interrupt signal from slave CPU is received or when the device communi cates with an external PC The UPP is used to select the baud rate for external communications The baud rate is set at power up according to the configuration setting 07 19 A1 729 4 3 Theory of Operation 4 1 7 Communication Controller See Figures 10 11 and 10 14 The communication controller allows the device to communicate with an external computer through an RS 232C interface The baud rate is selectable and control led by the universal pulse processor 4 1 8 Air Sensor Circuit See Figures 10 11 10 22 10 24 10 36 and 10 37 The air sensor circuits for both pumps are identical Each circuit consists of an ultrasonic transmitter and receiver mounted on opposite sides of the tubing path The transmitter consists of a 500 kHz oscillator and a selector that trans fers the oscillator output to two of three transducers The transducers are selected by the air bub ble alarm size setting in the configuration option The receiver contains a selector that transfers the transducer outputs to the universal pulse processor through an amplifier The transducers operate on the principle that air in the tubing transmits ultrasonic energy much less effectively than fluid This energy
94. 729 Baxter Baxter Healthcare Corporation Deerfield IL 60015 Copyright 1993 1995 Baxter Healthcare Corporation All rights reserved 07 19 A1 729
95. 8510 oo MOTOR 5 5 2 dies ts oc 1 21 XBPSD30P D 4009310005 SCREW Pan Head M3X6 1 22 XBPSD30P U S048947 SCREW Pan Head M3X55 4 23 2 048955 SCREW Pan Head M2X6 4 24 XWSSD200 A 5048879 WASHER Spring Optocoupler 2 25 XWSSD300 B 5048899 Ec 5 4 26 XXXSP30L A 5048876 Se GREW M3X3 2 27 XXXSP30L B 5048890 sg SCREW 3 4 4 28 XBPSD30P W 40093 10042 SCREW Head M3X10 1 29 Not used 30 LANGTIO3 A 5048446 BRACKET Fixing Door Sw PCB 1 8 30 07 19 A1 729 Illustrated Parts Breakdown Figure 8 13 Pump 2 Bs Plt Assmbly w Pump Mechanism 8 31 07 19 A1 729 Illustrated Parts Breakdown Pump 2 Base Plate Assembly w Pump Mechanism Figure 8 13 continued Item Sve Part Mfg Part Description Qty 31 LFiX1011 A S048443 NUT BAR Finger Box 1 32 LFiX1012 A S048444 NUT BAR Finger Btm 1 33 Not used 34 PSPA1020 A S048746 SPACER Door Sw PCB d 35 PSPAZIOI A 5048490 RETAINER Rubber Bottom Bearing 1 36 PSPAZ101 B S048491 RETAINER Rubber Top Bearing 1 37 PZETL101 A S048462 FILM Door Switch PCB Insulation 1 Note The following wire harnesses are not shown 40 QCNWI09
96. ACKLITE gt PUMPSELI 615 42 Voth UNT 1003 1902 ZA R B RUNT 1004 81903 AA RUNT 1003 BL904 AA RUNT 1004 20901 trace only R915 MESSAGE PROGRAMMING MESSAGE PROGRAMMING Figure 10 31 LED Lamps 07 19 1 729 10 33 Vmain Figure 10 32 Audible Alarm PCB A A Oe 07 19 A1 729 10 34 Pin 1 of 751 is connected to GND via wire harness But true GND line is VBZ CN752 1 2 3 D B3B XH A BUPBZ BUPBZ GN D PGND 07 19 A1 729 R760 D754 ECIODSI C753 NO e Figure 10 33 Backup Buzzer PCB 10 35 gt A E Voth E 127 R421 G6bE 134P US I F JPWO2 Voth Voth Vmain Vmain Vot TRACE ONLY CN401 GND gt GND D NCA RY COM E GND 8 E 5H HH D Q 6 NCALL 5 9 A 1 RY NO d 4 TXD 5 GND 4 RTS TXO G2 RX p di DO MBZN E B98 XH A BUPBZ ALARMBZ w LOCK DOUT O Vmain P 15S 2 RY COM CN701 RY NO GND 47 RY NC ea BUPBZ d 6 l1 o 1 vmain _____ ___________ 3 ALARMBZ ds LOCK ds DOUT O Hs B7B XH A Figure 10 34 Terminal PCB 07 19 1 729 10 36 QCNW 1114MC ALARMBZ RY NC RY NO RY COM TXD RXD RTS CTS PANEL LOCK QCNW 1092MC M NO t wr Figure 10 35 Accessories 10 37 07 19 A1 729 201 11 CN85
97. C16 I 100 507 1 2 I 1 1 F B R N T T D 3 R12 R15 R13 33K 10k 470K C18 1000p VR2 1 20K 8 Figure 10 6 DC Power Supply 07 19 A1 729 10 8 lt TPWRONT R370 KETTOT Vkey HIC302 3 VKEY P TEZEN E BZEN cco PWRON2 VSivs QSTBY VOTHSW 254 15279 1 7 19 RESETM 13 OTALI4YU A Pig c321 p 5MRECUTN YsivesT pe 0 1u PWROFFM gt ro PMRCUTS VMASRST D KEYLOCK R316 5 1 YMAIN eno Look Vmain 5 0042 O Vkey R347 R346 R339 100k 3 18K 0 0330 104 16 8338 ALUMINUM R D307 1 0308 11 E RB717F 1 3 21 LITHIUM 0 4 6 DAN202U cirmium D s R337 Vmain 9305 10M 25 1580 10051 20301 DIODE ZEMER HIC301 18K D Vo th R335 1 0k C516 22 6 ALUMINUM 6319 10u 25 A GND ALUMINUM Ycpu 1CP301 _ F15 6315 330u 6 3Y ALUMINUM Voth R333 lt VCPULYVL 36 0 C338 C341 0 1 0 1u ACLINE LED Figure 10 7 Power Supply Control Hybrid Circuit 07 19 A1 729 10 9 038 5 816 10 4 22 lt 3 748002 ag R14 10K 22 6 155193 5 R15 10K lt 2 05 1 829 10K 4 PWREXOR 2 4 4538 R26 10K A oras 17 0
98. CLEAR TOT VOL key To read the total volume infused and review the infusion settings press the TOT VOL STATUS key VOLUME INFUSED will be displayed followed by the RATE and VTBI of both primary and secondary To stop an infusion press the appropriate STOP key To restart the pump press the appropriate PUMP select key and START key 7 When a pump has delivered the selected volume the pump activates an audible alert illu minates the ALERT LED and switches to a KVO Keep Vein Open rate 8 To stop the infusion press the appropriate STOP key 7 3 3 Door Open Alarm Testing The pumps are designed so that they will not operate if the associated pump door is open Per form the following steps to ensure proper operation of the DOOR OPEN alarm 1 Prime and load a Baxter s suffix standard administration set Refer to Section 7 3 2 1 steps 1 4 2 Program a primary rate of 100 mL hr and a primary VTBI of 10 mL 3 Close the door and press the PRI START key 4 Open the pump door The following should occur a DOOR OPENis displayed in the Message Display b The red ALARM LED flashes c The audible alarm is activated Warning If these indications do not occur remove the device from service Troubleshoot in accordance with Section 5 and repair in accordance with Section 6 07 19 A1 729 7 5 Checkout d Repeat the procedure for the other pump 7 3 4 Air Alarm Testing The air bubble size for air dete
99. CPU through the universal pulse proces sor after every one eighth of the liveband period to provide air bubble detection timing to the master CPU Both CPUs handle the watchdog function which is the periodic communication between the CPUs through two serial communication lines at 15 625 baud The CPUs utilize 16 address and 8 data lines and can access 64Kb The master CPU addresses 128K x 8 EPROMs through 2 bank address lines The master CPU addresses an EPROM RAM Real Time Clock universal pulse processor two controllers and the communication controller The slave CPU addresses an EPROM RAM and programmable timer module Note that the EPROMs cannot be swapped between the mas ter and the slave CPUs because the software in the master EPROM is different from that of the slave 4 1 2 Programmable Timer Module See Figure 10 12 The programmable timer module PTM divides the 8 MHz system clock into 500 kHz for the oscillation of air sensors and also generates a signal for pulse width modulation control of the motor drivers The slave CPU calculates and outputs motor drive signals based on the rate information from the master CPU It also sets motor current levels in the PTM from a reference table 4 1 3 Watchdog Function The watchdog function is performed in two ways Both CPUs monitor each other s status The purpose of this watchdog is to detect a malfunction of either microprocessor and stop the pumps with an alarm S
100. D 048452 1 SHAFT Safety Clamp 1 25 PSLDP100 C S048645 SEAL Safety Clamp 1 26 PZETL101 B 048464 FILM Insulation 1 27 PZETL102 D 3004010007 FILM FPC Insulation Pl I 28 CPWBNIOS E S050074 PCB Slide Clamp Sensor 2 Pl 1 29 QPWBNIOS D 50486448 1 FLXBL PC Slide Clamp Sensor 1 P1 1 30 XBPSD30P i 50442395 SCREW Pan Head M3X8 w washer assy 2 07 19 A1 729 8 21 Illustrated Parts Breakdown Item 8 22 Safety Slide Clamp Assembly 1 Figure 8 9 continued Part XBSSD30P B XBSUF20P C XJPSD30P A XJPSF20P B XJPSF20P A Mfg Part 048960 5048967 5048953 048954 048955 TP Description SCREW Flat Head M2X6 SCREW Pan Head M2X6 SCREW Pan Head M2X4 SCREW Pan Head M2X6 07 19 A1 729 Illustrated Parts Breakdown 30 31 28 26 35 Figure 8 9 Safety Slide Clamp Assembly 1 07 19 A1 729 8 23 Illustrated Parts Breakdown Pump Head 2 Door Assembly Figure 8 10 Item Sve Part Mfg Part Description Qty 8 10 049120020 F049120020 PUMP 2 HEAD ASSY 1 1 2049120021 F049120021 DOOR ASSEMBLY P2 1 2 CHNDP100 F 5044944 LATCH Door 55 2 1 3 JHNDP100 B 5048401 LATCH Door P2 1 4 LPLTP106 A 5048440 PLATE Door Latch Label 1 5 LXRZ1003 A S048882
101. D LED SWITCH ALARMS PUMP HEADI amp PUMP HEAD 2 Figure 10 1 System Block Diagram 07 19 A1 729 10 3 POWER CORD SET CN301 115 5273 18 6 POWER SUPPLY YEL d TO FRONT PCB RED d HOUSING 60 Hz 22446 1015 22446 1015 F059130003 20AWG6 1007 YHR 3N 22AWG 1015 BRACKET GROUNDING PLATE 19AWG 1015 0 8A 58 250Y 14AWG 1015 1444G 1015 TO FRONT HOUSING 14AWG 1015 TO POLE CLAMP 103 MAIN GND PLATE 2 RED 20AW6 1015 o o RED d TO FRONT 2OAWG 1015 HOUSING SB 1257 BLK COMMUNICATIONS PORT RAMA PTE ES VHR 2N CN401 CNI F 2896 FFC WHT Q GROUNDING STRAP QS un 0 wv CN401 CNI F TO FRONT 98 SLEMISS 2 HOUSING TERMINAL PCB LOCKOUT SW F043130001 CN701 B7B XH A 26AWG 1007 3 754 BACK UP BUZZER 043130003 Note Dotted lines are green yellow green wires or grounding strap BATTERY 12 Y 3 2 Ah Figure 10 2 Rear Housing Wiring Diagram 07 19 A1 729 19 4 FROM 1 2 REAR HOUSING 245 PUMPHEADI PUMPHEAD2 CN302 1 CN201 CN202 YEL 01 CN202 GRN MOTOR 1 MOTOR 2 di MOTORIA MOTORZA WHT MOTORIC MOTOR2C ds PN MOTORI MOTOR2 d 4 MOTORIB MOTORZB ds 24446 3265 OTORZ d BLU GND GND 97 RED P1 1 P1 2 ds YEL PIREVI PIREV2 d 9 WHT PISECTI PISECT2 d
102. E RING Door 1 6 MSPRC101 D S048500 SPRING Door Latch 1 7 OiCMP32T H S048896 a WASHER 4 08 1 8 OiCMP32T L S048897 WASHER M4 2 0 1T 2 o 2 9 PMAGT100 B 504448 MAGNET Door Latch 1 10 109 07 26 06 029 7 LABEL Push 57 aus gd 1 11 5050051 S050051 DOOR PUMP HEAD P2 1 12 LBSHZ101 A 048489 7 7 BUMPER Door 2 13 LBSHZ101 C 8048502 1 BUSHING Door latch 1 14 LPiNS101 C 8047417 PIN Door Hinge uva ee We RG IE 2 15 106 S048445 PLATE Safety Clamp 1 16 LPLTM106 B 5048441 COVER Back 2 1 17 LPLTM104 C 504843 PLATE BACK Reg uds nex 1 18 MSPRC101 C 048499 SPRING Back Plate 5 19 PAJS1002 A 5044244 STOP Occlusion Detector 2 20 PCUSGIOI A S048504 BUMPER ema at a as 5 4 21 PZETE100 C 504506 FILM Plate Insulation 1 22 TLABZ110 A 07 26 01 179 LABEL x uh CERE 312 1 23 TLABZ110 B 5047920 LABEL Tube Loading P2 1 24 TLABZ110 C 80479030 LABEL Tube Loading P2 1 25 XBPSD20P C S048033 SCREW Head M2X8 w washer assy 2 26 XBSUZ30P A 048987 SCREW Flat
103. Hysan Corp __ Huntington Labs Hi Tor Plus Huntington Labs 10 bleach and water Soapy water z i Isopropyl alcohol up to 95 Caution Attempts to clean or disinfect internal parts autoclaving or steriliza tion by ethylene oxide gas will damage the device and void the war ranty Caution The following chemicals may damage the plastic front panel and tube misloading sensors Acetoldehyde Acetone Ammonia Benzene Hy droxytoluene Methylene Chloride n Alkyl Dimethyl Ethyl Benzyl Ammonium Chloride and Ozone For a device that has been in an Isolation Area select those agents from Table 2 1 that both clean and disinfect Only external parts of the device should be disinfected The following are procedures for cleaning accessible areas of the device Do not use hard instruments for clean ing 1 Lift the door latch to the open position Open the door and pus the safety clamp latch until it locks in the open position 2 Using a cotton swab dampened with one of the agents listed in Table 2 1 clean all tub ing guides and tubing channels from the top of the pump to the exit point below the safety clamp Clean all surfaces in the pump head which may contact the tubing 3 Clean all surfaces of the air sensor located just above the safety clamp This area must be completely dry and free of foreign matter prior to reuse 2 2 07 19 A1 729 Hospital Service Procedures 2 3 Battery Charging The battery
104. IONLEO 063803 TAACOZE Y cLK lt A gt A lt AM O 151 PAAA Figure 10 10 Master CPU Schematic 07 19 A1 729 10 12 DAS M5M5165FP 18 mmm mau eoocvcecoz gt gt gt a oan mu ajo w e CANN ENON DAWA lt lt lt RTC62421A lt lo E HD63140CP gt SANMPENION aS lt lt lt lt lt lt lt lt lt me z x o lej e lt lt ellas w a ww 0 5 4 A R GND lu ROU lt gt 504 0 HON CHUM 4 44 NANANANN OO lt lt lt lt lt lt lt lt anaaanan AMIN gt lt 9 3 jojeja rne colmo e ojelojejolniojnind eje aja ain aja e 23 col ales ala aja ee E alo E ojal 2 puc lt gt NIN gt kad kod gt gt gt gt 4 af ans tas 3 gt gt m vo ac a alu o mpe jowe lt gt lt El O w
105. If both the NORM and MIN air sensor values are within the speci fied ranges continue to the next step If these ranges cannot be achieved replace the air sensor per Section 6 3 11 After the air sensor is replaced start this section with step 2 Remove the fluid filled tubing from the pump head Load an air filled piece of calibra tion tubing into the pump head and close the door Open and close the door two more times and wait two minutes Proceed to the next step if the values are 5 or less If the values are greater than 5 adjust VR801 for Pump 1 and VR802 for Pump 2 so that the higher of the NORM and MIN val ues is 4 If adjustment was required load the fluid filled calibration tubing into the pump head and close the door Open and close the pump door two more times and wait two minutes Verify that both NORM and MIN values are between 410 and 470 Apply red Glpt to VR801 Repeat steps 1 8 for the other pump head Exit Test Mode 2 by pressing the ON OFF CHARGE key that was pressed in step 3 gt Prime and load a Baxter s 5 suffix standard administration set See Section 7 3 2 1 steps 1 4 Using the precision syringe introduce an air bubble 25 uL for MIN setting or 50 uL for NORM setting into tubing just above the pump head door Press and hold the safety clamp arm cover slightly and allow the air bubble to travel to just above the air sensor Then release the safety clamp arm cover and close the pump door Turn o
106. M3X6 SCREW Pan Head M4X8 SCREW Pump Head M3X6 SCREW Pan Hd Tapping M3X8 WASHER Rubber Foot SCREW Pan Head M3X8 BATTERY Lithium SEAL Dust LCDs 07 19 A1 729 Illustrated Parts Breakdown Figure 8 2 Front Housing Assembly Internal 8 5 07 19 1 729 Illustrated Parts Breakdown Item 2 Note 3 Note 4 Note 8 6 Rear Housing Assembly Internal Figure 8 3 Part Mfg Part Description Qty DUNT1275 A F059120008 HOUSING REAR SUB ASSEMBLY 1 CPWBN104 B F043130001 PCB ASSEMBLY Terminal 1 See Figure 8 18 for details on item 2 CPWBN104 D F043 130003 PCB ASSEMBLY Backup Aud 1 See Figure 8 19 for details on item 3 CPWBNI05 A F043130004 PCB ASSEMBLY Audible Alarm 1 See Figure 8 20 for details on item 4 GCABB104 D 2051624002 a HOUSING RedE ai as oy v haee desee 1 GLEGG100 D F044630001 FOOT Rubber 2 LANGQ103 A F044211001 PLATE Main Ground LANGQ103 B F044220003 ss PLATE Grounding 1 LANGT103 D F054220002 BRACKET XFORMER 1 PGUMM103 D F044620003 BOOT Rubber Main Buzzer 1 PGUMM103 E F044620004 BOOT Rubber Backup Buzzer 1 1043 2044140001 GND WIRE Front Housing 2 QCNWI1052 B F044140003 GND WIRE XFORMER 1 QCNWI1058 A F044140002 G
107. ME and TOT VOL STATUS du again or press the Pump 2 STOP key 6 2 07 19 A1 729 Disassembly and Calibration 4 Record the contents of the alarm log by pressing the SILENCE and TOT VOL STATUS keys simultaneously while both pumps are on Within one second press the CLEAR TOT VOL key to bring up the rest of the failure codes for each pump 6 3 Disassembly Reassembly Disassembly of the Flo Gard 6301 Dual Channel Volumetric Infusion Pump is limited to the mechanical components and printed circuit boards PCBs It is recommended that electrical problems be corrected by replacing entire PCBs unless circumstances warrant component repair Use only approved replacement parts provided by Baxter Healthcare Corporation and listed in Section 8 Please read all steps in the procedure before beginning The procedures are given in order of dis assembly Disassemble the device only as far as required to complete repair All fastening com ponents such as screws washers and nuts used in the device are metric Be sure to use metric tools and replace only with metric components Caution The device is sensitive to electrostatic discharge damage ESD Al ways wear a grounded wriststrap when performing maintenance on the device to prevent damage to components Warning Always make sure that the device is unplugged and that both pumps are turned off before disassembling Failure to do so can result in per sonal injury and or damage to the device
108. MID mom Mi LD 4 NN Ch vu m der CD m mA VJ e mu AWS ed gp mm Ulo otn vul mmo 60 NUG Mulet y ur Om VsOnon May Dn O NWDU OO 00902 00901 PROGRAMMING VVLF7696M MESSAGE VVLF7526M no mo Vulg mu vorm COEN Vora voze SS anes E Pomo Ne uen me TTT cen owen Pan we Ne ao aus na ze awom WF ee Tan ne Tan __ re uae me a o RA uem Le orm vem He ree m eom rr or Lc Ee PU __ mr Mi 22222222222222222222 m _ NN ETELIION PN VN po VOENOM VOENON Mist Deen AWN uium WwNmmu OWONN N NWONNS NWN MUDO e co VWDNOn AWUNOS PWINOM NUJNO NVuJNOO
109. ND WIRE Pwr Receptacle 1 QCNW1114 A F052140001 ss HARNESS Buzzer 1 QCNW1118 A 5009415002 CABLE Flat Ribbon 1 QSWP1008 A 5009470002 WITCH Panel Lock 1 RDENC100 E 2059130003 BOARD ASSEMBLY POWER SUPPLY 1 See Figure 8 15 for details on item 18 RTRNP100 F 5009462002 XFORMER Power 117V 60Hz 1 RVRC1350 A 2501003200 POT Volume Control 1 4009310003 SCREW 4 4 8 w washer assy 7 XUPSD30P B 4009310020 SCREW Hd Tapping M3X8 9 XUPSD40P A 4009310021 SCREW Pan Hd Tapping M4X8 4 XWHSD300 C 4009330001 WASHER Rubber Foot M3 4 PZETL102 1 3004010009 FILM Power Trans Insulation 1 XEPSD30P A 4009310018 SCREW Hd M3X8 4 07 19 A1 729 Illustrated Parts Breakdown ls 12 2112 26 Figure 8 3 Rear Housing Assembly Internal AA A rae gt qua 07 19 1 729 8 7 Illustrated Parts Breakdown Rear Housing Assembly External Figure 8 4 Item Sve Part Mfg Part Description Qty 1 DUNT1275 A F059120008 HOUSING REAR SUB ASSY 1 2 GCASP101 A 042624007 2 BODY Pole Clamp 1 3 GCOVH100 C 4009390001 COVER Comm Port 1 4 101 052624005 COVER Batt Comprtmnt 1
110. NESS Upstream Sensor P1 1 46 QCNW1121 A 5048654 HARNESS Downstream Sensor Pl 1 47 QCNW1122 A S048655 HARNESS Air Sensor Input Pl 1 48 QCNW1123 A 5048656 HARNESS Sensor Output PL 1 50 QPWBN103 B 5048492 PCB Door Open Sw 1 51 QPWBNIOS A 048459 PCB Tube Misload Terminal 1 52 CPWBNI106 A S048624 PCB Flexible Prntd Crkt Terminal 1 53 QSWL1003 C 5048513 SWITCH Door Open 1 54 VRDRV2EY A S048521 RESISTOR 100 Ohms 2 55 XBBSD30P D 4003910075 SCREW Binder Head M3X8 2 56 XBPBN30P C S048929 SCREW Pan Head M3X8 2 57 4009310080 SCREW Pan Head M4X6 1 58 XBPSD20P A 5048923 SCREW Pan Head 2 5 2 59 XBPSD26P B 5048933 SCREW Pan Head M2 5X8 1 60 Not used 61 XWHSD200 A 048891 WASHER Door Open Sw PCB Bracket 2 62 XBPSD30P i 048939 Screw Pan Hd M3 X8 2 8 20 07 19 A1 729 Illustrated Parts Breakdown Safety Slide Clamp Assembly 1 Figure 8 9 Item Part Mfg Part Description Qty 8 9 2059120015 2059120015 PUMP 1 HEAD ASSY coda 1 1005 5047780 CLAMP SAFETY SLIDE ASSEMBLY 1 1 LCHSM100 E S048636 1111 HOUSING Upper Pl 1 2 LCHSM100 F S048637
111. RECTIVE ACTION Expel air in tubing Replace or reposition set if tubing is flattened or scratched Clean air sensor in accordance with Section 2 if dirty Perform Section 5 3 2 steps 1 through 5 If values are not within specification recalibrate or replace the air sensor Check for scratched or deformed tubing Verify that solution and ambient temperatures are between 60 and 100 F 15 5 and 37 7 C Ensure set is correct type and is properly loaded Check for spilled solution in sensor region Remove downstream occlusion and reposition the tubing Clean occlusion sensors in accordance with Section 2 if dirty Raise or lower temperatures if necessary Perform Section 5 3 1 steps 1 through 6 Downstream occlusion was detected The sensor output increased to an absolute value See Failure Identification Code 2 07 19 A1 729 Troubleshooting Table 5 1 Failure Identification Codes CODE CAUSE CHECKS 4 Upstream occlusion was detected The sensor output decreased by a specified value Check for spilled solution in sensor region Ensure set is proper type and is properly loaded CORRECTIVE ACTION Remove upstream occlusion and reposition tubing Clean the sensor with cotton swabs dampened with one of the agents listed in Table 2 1 Remove fibers or foreign particles Do not use hard instrum
112. Testing 7 3 3 Door Open Alarm Testing 7 3 4 Air Alarm Testing 7 3 5 Drive Defect Occlusion Check 7 3 6 Downstream Occlusion Testing 7 3 7 Upstream Occlusion Testing 7 3 8 Battery Check 7 3 9 Panel Lock Test 7 3 10 Safety Clamp Test 7 3 11 Alarm Volume 7 3 12 Slide Clamp Test 7 3 13 Electrical Safety Tests 7 3 14 Accuracy Tests Illustrated Parts Breakdown 4 2 Warranty Service Information ra a 9 1 Warranty Information 9 2 Service Information 9 3 General Information 6 20 6 21 6 21 6 22 6 22 6 22 6 23 6 24 6 24 6 26 6 27 6 29 6 29 6 32 6 34 6 35 6 36 6 37 6 38 7 1 7 1 7 1 7 3 7 3 7 5 7 6 7 1 7 7 7 8 7 9 7 10 7 10 7 11 7 11 7 12 7 13 8 1 9 1 9 1 9 1 9 2 7 19 1 729 DIAS VANS Su uod A AAA A 10 1 Data Sheet Flo Gard 6301 Volumetric Infusion Pump 2M8064 1 Multiple Key Combinations 0 0 0 0 1 vi 7 19 A1 729 Figure 1 1 Figure 1 2 Figure 1 3 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 7 1 Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 8 5 Figure 8 6 Figure 8 7 Figure 8 8 Figure 8 9 List of Illustrations Front View of Pump Pump with Door Open Rear View of Pump Adhesive Application Pressure Application Points LCD Cushion Placeme
113. VDC 8 Verify the lithium backup battery voltage at pin 7 It should be 3 0 to 3 4 VDC 9 Press the ON OFF CHARGE key to turn off the device Disconnect all test equipment 07 19 A1 729 6 29 Disassembly and Calibration 10 Replace the battery cover 11 Ifthe values are outside of specifications calibrate the voltages as follows 12 Connect the calibration circuit shown in Figure 6 4 Variable transformer 100 135 VAC minimum 50 VA Digital voltmeter 4 5 digits with 0 1 accuracy at 20 VDC range and 3 accuracy at 100 135 VAC range DC ammeter 2 ADC in 0 01 A increments Power transformer RTRNP100 F Resistive load consisting of a 5 Q 20 watt resistor in series with a 5 Q 20 watt potentiometer See Figure 6 4 VARIABLE FLO GARD 6301 PUMP EXTERNAL CIRCUIT TRANSFORMER O 0 5 SB DC POWER SUPPLY BOARD 5 OHM 20W 5 3 E E e 2 5 5 20 W POWER ____ ACIN TRANSFORMER Figure 6 4 Calibration Equipment Setup 13 Calibration Set Up a Separate the front and rear housings completely in accordance with Section 6 3 1 b Disconnect the power supply connector CN301 from the CPU board Figure 8 2 item 3 and connect it to the electronic load c Connect the circuit as illustrated in Figure 6 4 with the positive lead connected to pin 2 and the negative lead connected to pin 3 d Plug all calibration equipment
114. W Flat Head M3X8 TAPE Conductive Finger BOX Finger WASHER M3 SCREW Pan Head M3X8 t 9 t e asopo ooo o a e abo o 07 19 1 729 Illustrated Parts Breakdown Figure 8 11 Pmp 2 Bs Plt w Tube Misloading Detectrs 8 27 07 19 A1 729 Illustrated Parts Breakdown Item 8 12 8 28 Pump 2 Base Plate Assembly Rear Figure 8 12 Sve Part F049 120020 LPLTC106 A LXBZ1020 A MSPR1001 C MSPR1002 B NSFTZ102 A OiCMP32T A 2 2 PCASD100 B PCOVP101 C PZETL102 E CCILZ100 A RCORF100 D 5048993 109 XBSUF20P A Mfg Part F049 120020 048017 5048918 5048015 5048014 5048012 5048928 5048893 5048901 5048022 5048436 5048508 5048011 5048013 5048993 07 26 01 088 5048962 PUMP 2 HEAD ASSY PUMP 2 BASE PLATE ASSEMBLY REAR 1 PLATE Base P2 SCREW Flat Head M1 7X6 SPRING Downstream Occl Sensor SCREW Pan Head M1 7X4 5 WASHER 1 7 HOUSING Occl Sensor COVER Safety Clamp Arm P2 PLATE Ground Upstrm Occl Sensor COIL Occl Sensor Assy CORE Occl Sensor SENSOR AIR ASSY P2 LABEL Safety Clamp Rev A SCREWS Flat Head M2X10 07 19 A1 729 Illustrated Parts Breakdown A DA c o ig SD HGS I dn S Figure 8 12 Pump 2 Base Plate Assembly Rear 8 29 07 19 A1 729 Illust
115. ake care not to deform the encoder or damage the fingers Keep the fin ger box and the fingers away from dirt or dust Remove the motor holding plate Figure 8 9 or 8 14 item 8 from the motor shaft bot tom and carefully place on the work surface Remove two set screws Figure 8 8 or 8 13 item 27 closest to the motor To install the motor push motor shaft into motor coupling item 8 Install set screws item 27 Do not tighten them at this time Attach the spring retainer item 2 to the re placement motor as necessary Place the motor holding plate Figure 8 9 or 8 14 item 8 onto the motor shaft bottom such that the plate protrudes from the motor housing on the side with the wires Figure 8 8 or 8 13 Install the motor and the assembly into the pump head base plate ensuring that a The motor is positioned such that the wires go out the back of the base plate Figure 8 8 or 8 13 b The fingers are in the finger box and the motor holding plate is properly installed in the hole on top of the safety slide clamp assembly item 1 Check that the bearings item 10 are properly seated on the finger box and install the fin ger box cover using the four screws washers and spring washers items 22 14 and 25 Before tightening these screws rotate the motor coupling by hand to ensure smooth rota tion of the motor shaft and the encoder Tighten the screws to 6 kgf cm 5 2 in Ib Install the motor holding plate onto the safety
116. as been used Important NOT reuse a tubing segment that has already been used to con duct an accuracy test Note The accuracy specifications included in these tests account for an ex tensive list of variables over a short term test cycle A more precise measurement of flow rate requires longer test times including statisti cal trials However this is not necessary to demonstrate proper func tion of the pump 7 3 14 1 Measurement by weight per time 1 Program a PRI VTBI of at least 500 mL and start the pump at 200 mL hr 2 Collect the solution in a container of known weight for 10 minutes and 30 seconds 3 seconds 3 Use calibrated scale with a resolution of 0 1 grams or better to weigh the container and solution Then divide the solution weight by the specific gravity of the solution water s specific gravity is 1 g mL 4 The solution collected should be between 32 5 mL and 37 5 mL 7 3 14 2 Measurement by volume per time 1 Program a PRI VTBI of 20 mL and start the pump at 200 mL hr 2 Collect the solution in an ASTM Class A 25 mL graduated cylinder with a resolution of 0 2 mL or better for 6 minutes 3 seconds or until the pump switches to the KVO mode 07 19 A1 729 7 13 Checkout Important Stop the pump within 10 seconds after the KVO alert since fluid de livered after the KVO alert adds to the test error 3 solution collected should be between 18 6 mL and 21 4 mL 7 3 14 3 Measuremen
117. ation of the switch Check CN701 and CNI F for proper connection and continuity Turn the device off and back on Check CN751 CN701 and CNI F for proper connection and continuity Replace PANEL LOCK switch If problem recurs replace CPU board Repair or replace the connectors Replace speaker The device does not run on AC but runs on internal battery Check CNAC and CN301 for proper connection and continuity Check that the AC power cord is firmly connected The Battery Icon is lit while the device is running on AC Check AC fuse Check connectors CNAC and CN301 for proper connection and continuity Repair or replace the connectors if necessary Replace CPU board Repair or replace power cord Replace AC fuse s with same type and rating if it has failed Replace CPU board 5 16 07 19 A1 729 Troubleshootin SYMPTOM The Battery Icon is off while the device is running on internal battery The LCDs are blank have missing segments or indicate an irrational display Table 5 2 Troubleshooting Chart 1 CHECKS CORRECTIVE ACTION m device off and back Check ICP301 and CNDISP for proper connection and continuity using Test Mode 5 Section 5 3 5 If failure recurs Replace Display board Replace CPU board Install LCD Cushions if necessary See Section 6 3 28 Replace CPU board
118. battery for 24 hours with the device turned off check the battery charging voltage MB per Section 5 3 1 No check required Replace the fuse s if it has failed and recharge the battery the desired volume is obtained If the voltage is below 105 VAC connect the device to the correct supply voltage Connect the power terminals of the power plug to an ohmmeter The ohmmeter should indicate continuity If the battery charge voltage is normal and the problem still persists replace the battery See Section 6 3 18 Recharge the battery Turn the VOLUME knob on the rear of the device clockwise until The interval between audible alarm tones is too long Change the interval for alert and or alarm tones to the desired value through the configuration option 07 19 A1 729 Problem Checklist Table 3 1 Problem Checklist PROBLEM close smoothly The pump door will not open or CHECKS CORRECTIVE ACTION Check the positioning and seating of the administration set tubing and the slide clamp type and code Check for solution spills liquids or residues Check the administration set for Position the tubing and slide clamp properly and make certain the tubing is seated in the guides and channels with the safety clamp open and the slide clamp is in the slot Close the pump door Replace with a Baxter
119. be a ews 4 26 XXXSP30L A S048876 Ge SCREW M3 X3 lots Og ee ade 2 27 XXXSP30L B 5048890 Set 3 4 4 28 XBPSD30P W 4009310042 SCREW Pan Head M3X10 w washer assy 4 29 Not used 30 LANGTIO3 A 048446 BRACKET Fixing Door Sw 1 8 18 07 19 1 729 Illustrated Parts Breakdown Figure 8 8 Pump 1 Bs Plt Assmbly w Pump Mechanism 8 19 07 19 A1 729 Illustrated Parts Breakdown Pump 1 Base Plate Assembly w Pump Mechanism Figure 8 8 continued Item Sve Part Mfg Part 31 LFiX1011 A 5048443 32 LFiX1012 A S048444 33 Not used 34 PSPA1020 A S048746 35 5 7101 5048490 36 5 7101 5048491 27 PZETL101 A S048462 The following wire harnesses are not shown SPACER Door Sw PCB RETAINER Rubber Bottom Bearing 1 RETAINER Rubber Top Bearing 1 FILM Door Switch PCB Insulation Description Qty NUT BAR Finger box 1 NUT BAR Finger box 1 40 QCNW 1097 5048473 HARNESS Tube Misload Detector 1 41 QCNW 1098 A 048474 HARNESS Slide Clamp Sensor 1 42 QCNW1099 A 5048475 HARNESS Slide Clamp Sensor lext 1 43 QCNWI100 A S048476 HARNESS Optocoupler 1 44 QCNW1119 A 048652 HARNESS Door Sw PCB P1 1 45 QCNW1120 A S048653 HAR
120. between the bracket and the rear housing Be sure to secure the two ground wires by the screw item 21 on the right side of the power transformer item 19 to the mounting bracket item 9 Align the power transformer so that the 2 pin connector is on top Perform the Operational Checkout procedures in Section 7 6 3 25 Replacement of the PANEL LOCK Switch 1 Separate front and rear housings in accordance with Section 6 3 1 Pull out the black pushbutton cover Figure 8 4 item 7 on the back of the device while holding the rear housing Desolder the pink and brown wires from the switch Remove hex nut and lock washer securing the switch and remove it Reassemble in reverse order Perform the Operational Checkout procedures in Section 7 07 19 A1 729 6 23 Disassembly and Calibration 6 3 26 Replacement of Lithium Backup Battery The lithium backup battery provides backup voltage to the device s memory when the main bat tery is disconnected To avoid loss of configuration option settings record the settings See Section 1 5 1 and ensure that the main battery is connected before beginning this proce dure 1 Separate front and rear housings in accordance with Section 6 3 1 2 Separate boards in accordance with Section 6 3 2 3 Separate display board in accordance with Section 6 3 19 4 Cut the tie wrap holding the lithium battery on the display board Figure 8 2 item 2 5 Disconnect connector CN304 and remove
121. ble which lists each failure code its cause and ways of correcting it e A table which describes how to correct problems not represented by failure codes Once the cause of a failure has been determined perform the corrective action given in the table All disassembly reassembly and calibration procedures for the device are in Section 6 To verify the effectiveness of repairs after they are completed perform the Operational Checkout proce dures given in Section 7 5 2 Failure Identification Codes Specific errors which may occur during device operation are represented by failure identifica tion codes When the alarm message FAILURE or COMMON FAILURE occurs it is accompanied by a two digit code number This code is the failure identification code The last 10 failure iden tification codes including alarms for each pump except DOOR OPEN and AIR alarms occurring in the stopped mode are stored in the device s memory along with the date and time at which the alarm occurred The failure identification codes can be used to determine the nature of a de vice failure and to troubleshoot its cause To view the stored failure identification codes press the STOP key s Press and hold the SI LENCE and TOT VOL STATUS keys The most recent failure identification code s will be dis played in the lower right corner of the appropriate Main Display The time at which the failure occurred will be displayed in the upper right corner of the appropriate Main D
122. ction 6 5 Turn the pump off and remove the tubing Check the calibration of the downstream oc clusion sensor per Section 5 3 1 steps 1 through 6 6 Exit calibration mode 1 by pressing the ON OFF CHARGE key that was pressed in step 2 of Section 5 3 1 07 19 A1 729 7 7 Checkout 7 3 7 Upstream Occlusion Testing The device is designed to detect a closed clamp upstream of the pump head Perform the follow ing steps to ensure the performance of the upstream occlusion sensor 1 Prime and load 5 s suffix standard administration set See Section 7 3 2 1 steps 1 4 Pinch off the tubing with a set clamp or hemostat above the pump head Set a rate of 125 mL hr and start the pump Within three minutes of starting the following should occur a The pump stops b The red ALARM LED flashes c UPSTREAM OCCLUSION is displayed in the Message Display d The audible alarm is activated Warning If these indications do not occur remove the device from service Troubleshoot in accordance with Section 5 and repair in accordance with Section 6 Turn the pump off and remove the tubing Check the calibration of the upstream occlu sion sensor per Section 5 3 1 steps 1 and 7 through 10 Repeat step 5 without the thickness gauge installed Check that the value displayed in the PRI RATE window of the Main Display is 3180 or less If the value displayed is out of specification ensure that the occlusion s
123. ction in real time Turn device off and back on If failure recurs charge or clock Abnormal RTC Check backup battery voltage in replace battery data accordance with Section 5 3 1 Reset all configuration option Replace U506 or CPU settings in accordance with Section board 1 5 2 50 Master CPU received Turn device off and back on If failure recurs replace TRAP interrupt the software EPROMs Replace CPU board 51 Master CPU received a Turn device off and back on If failure recurs replace CMI interrupt CPU board 52 Master CPU received a Turn device off and back on If failure recurs replace SWI interrupt CPU board 53 Master CPU received Turn device off and back on If failure recurs replace NMI interrupt CPU board 54 Master CPU received an Turn device off and back on If failure recurs replace interrupt CPU board 55 Master CPU received an Turn device off and back on If failure recurs replace IRQ2 interrupt CPU board 58 Master CPU s TIMER 1 Turn device off and back on If failure recurs replace interrupt does not occur CPU board 59 Program stuck in block 1 Turn device off and back on If failure recurs replace routine CPU board Interlink Electronics 5 12 07 19 A1 729 Troubleshooting Table 5 1 Failure Identification Codes CHECKS Malfunction in battery voltage detection circuitry Input t
124. ction is selectable through the configuration option and is factory set to NORM See Section 1 5 for an explanation of the configuration option If a pump fails to detect air remove it from service and troubleshoot it in accordance with Section 5 Repair and calibrate in accordance with Section 6 Check the air sensor calibration values per Section 5 3 2 steps 1 through 5 66 99 S Prime and load a Baxter s suffix standard administration set with one Y site above the device See Section 7 3 2 1 steps 1 4 Using a precision gas tight syringe part no S9662 81 or equivalent introduce an air bubble into the administration set through the Y site above the pump If the air sensor is set to NORM the bubble should be greater than 110 microliters If the air sensor is set to MIN the bubble should be greater than 85 microliters Open the pump door and slightly press the safety clamp arm cover to position the air bub ble below the pump fingers and above the air sensor Close the door and start the pump When the intact air bubble reaches the air sensor the following should occur a AIR is displayed in the Message Display b The red ALARM LED flashes c The audible alarm is activated d The pump stops e Ifthe pump does not alarm verify that the bubble did not break up before reaching the sensor and repeat the test Open the pump door press the safety clamp arm cover and purge the air from the tube Close the pump door and pre
125. ctly external computer Correct problems with PC software 07 19 A1 729 5 9 Troubleshooting Table 5 1 Failure Identification Codes CHECKS CODE CAUSE 8 Communication time out alarm was detected No communication between the device and an external PC for a given period 9 Slide Clamp Alarm software versions 1 09 and later See Failure Identification Code 7 CORRECTIVE ACTION Place pump into computer control mode Ensure communication cable 1 plugged in and or the cable is wired correctly Correct problems with PC software Slide clamp 15 not inserted 15 improperly inserted in the slide clamp slot Insert slide clamp properly Clean the slide clamp sensor with a cotton tipped swab dampened with water alarm recurs after cleaning the sensor perform the slide clamp test in Section 7 Interlink Electronics 5 10 10 Misloaded tubing was Check set loading in the pump Load the tubing in the detected mechanism Check any damage guides and channels on the tube misloading sensors correctly Repair or replace the FSR s 12 Upstream occlusion was See Failure Identification Code 4 detected in Revolution Counter Interrupt 20 Malfunction in Door Open Check that magnet in pump door Replace pump door latch detection circuitry P54 latch is present if magnet is missing Pum
126. ding the code number remove the device from use and have it serviced Battery power has been exhausted Plug device into AC outlet immediately to restore operation CHECK SET LOADING COM TIMEOUT EXT COMM ERROR The tubing is pinched between the pump head door and base plate Load set properly in the IV set loading path There has been no communication between the device and the computer for the specified time period Check for a disconnected cable or computer problem To clear this alarm press the OPTIONS key to return the device to computer control or press SILENCE or PUMP 1 or PUMP 2 to use the pump s without the computer The controlling computer is sending multiple queries or commands to the device without waiting for the device s replies The condition has been caused by the computer not the device To clear the alarm press the OPTIONS key to return the device to computer control or press SILENCE or PUMP 1 or PUMP 2 to control the pump s manually Notify the technical personnel responsible for the computer If the alarm recurs disconnect the cable from the communications port Reprogram the pump s for manual operation INSERT SLIDE CLAMP Note This alarm option is available only on pumps running software versions 1 09 or later 1 18 The slide clamp loading option is enabled and the slide clamp is not loaded in the slide clamp slot To clear thi
127. e 8 18 Terminal PCB 8 44 07 19 A1 729 Sve Part CPWBN104 D QCNCM100 C QCNCM100 E RALMB100 C Illustrated Parts Breakdown Backup Buzzer Board Figure 8 19 Mfg Part F043 130003 50094 10006 5009410008 5009490001 Description Qty PCB ASSEMBLY Backup Aud 1 CONNECTR 3 Pin 752 1 2 Pin CN751 1 BUZZER Back Up 7752 1 0754 Je CNTSI 87752 C753 3 zo BAXTER T 6003560002 GTS il 9470 AL Figure 8 19 Backup Buzzer Board 07 19 A1 729 8 45 Illustrated Parts Breakdown Audible Alarm PCB Figure 8 20 Item Sve Part Mfg Part Description Qty CPWBNIOS A F043130004 PCB ASSEMBLY Audible Alam 1 1 105 5009410013 4 Pin 753 1 2 100 5009490002 BUZZER 8275 1 82751 GMB 12 753 548 8275 GMB I2 Figure 8 20 Audible Alarm PCB 8 46 07 19 A1 729 Item Svc Part 070581530 0705C1719 SPAKA129 B 129 SSAKH002 A TiNSE111 B TLABZ110 E SSAKA124 A TTAG1003 A 07 19 1 729 Illustrated Parts Breakdown Parts list for Packaging Materials Mfg Part 07 05 B 1 530 07 05 C1 719 052720001 F052720002 3004035007 07 19 B1 564 07 26 A1 202 3004035002 07 26 06 030 Description Qty CARTON Individual Japan
128. e dy b 1 4 LPLTM104 D S048488 WHEEL Encoder 1 5 LPLTP104 A 5048484 so FINGER 1 2 7 8 a 4 6 LPLTP104 B S048485 FINGER bad a ors ae 4 7 MCAMP100 A S048483 CAME aa IAS ee Ress 8 8 MJNTM100 B 5048454 is COUPLING Motor 1 9 MSPRD102 A 048471 s SPRING Motor ir 2 10 100 5048511 BEARING Pumping Finger 9 11 NBRGY100 C S048512 BEARING Finger Box 1 12 NSFTD103 A S048433 so SHAFE Finger 1220 nt a as Gur d 1 13 OiCMP32T F 5048894 WASHER Optocoplr 2 14 OiCMP32T G 5048895 6 3 4 15 1005 5048431 2 COVER Finger 1 16 PCOVP101 B S048427 25 COVER Encoder Wheel 1 17 PSPAB102 A 048496 SPACER Encoder Wheel 1 18 CPBWM105 B 047876 PCB ASSEMBLY Optocoupler 1 19 VHPGP32S B S048016 uun OPTOCOPER ilg 1 20 100 5048510 S MOTOR govt a ale 1 21 XBPSD30P D 40093 10005 SCREW Head M3X6 1 22 XBPSD30P U 5048947 SCREW Pan Hd M3X55 4 23 XJPSF20P A S048955 SCREW Pan Hd 2 6 4 24 XWSSD200 A 5048879 WASHER Spring OptocouplerPCB 2 25 XWSSD300 B 5048899 ies WASHER M3
129. e the sensor assembly 6 Remove the two screws Figure 8 9 or 8 14 item 30 on the bottom of the safety slide clamp assembly to release the motor holding plate item 8 7 Remove the six screws Figure 8 8 8 13 item 60 on the finger box and lift the finger and motor assembly off of the base plate 8 Remove the flexible cable at the back of the safety slide clamp assembly from the con nector on the terminal board Be sure to pull the white part so as not to damage the flexible cable 9 Remove four screws Figure 8 8 or 8 13 items 28 and 55 securing the safety slide clamp assembly and remove it from the pump head base plate 6 16 07 19 A 1 729 Disassembly and Calibration 10 Press the safety clamp pin Figure 8 9 or 8 14 item 6 to close the safety clamp install replacement safety slide clamp assembly into rear of the pump head base plate and se cure with four screws Figure 8 8 or 8 13 items 28 and 55 Make sure safety clamp seal Figure 8 9 or 8 14 item 25 is in place Tightening torque for the four screws is 6 kgf cm 5 2 1n Ib 11 Connect the flexible cable Figure 8 9 or 8 14 item 29 to the connector in the terminal board 12 Install the finger and motor assembly with the motor holding plate using the six screws Figure 8 8 or 8 13 item 60 Tightening torque is 6 kgf cm 5 2 in Ib 13 Install the two motor holding plate screws Figure 8 9 or 8 14 item 30 Tightening torque is 4 kgf cm 3 5 in Ib
130. e the sensor to the pump head base plate 2 Pull and rotate the sensor 45 clockwise and take it out of the pump head base plate 3 Desolder the black and white wires from sensor Use caution to avoid contacting any plastic parts with the soldering iron 4 Remove the screw Figure 8 7 or 8 12 item 6 grounding wire and star washer item 8 Do not lose the washer and screw 5 Install replacement sensor and reassemble in reverse order Tightening torque for item 16 is 3 kgf cm 2 6 in 1b Tightening torque for item 6 is 1 5 kgf cm 1 3 in Ib 6 Calibrate in accordance with Section 6 4 1 and 6 4 3 7 Perform the Operational Checkout procedures in Section 7 6 3 11 Installation of Air Sensor Assembly Caution The pump should be unplugged with the power turned off before be ginning this procedure 1 Remove ten screws from the back of the pump and carefully separate the case halves in accordance with Section 6 3 1 if necessary Install a new air sensor assembly if it has not been replaced 07 19 A1 729 6 11 Disassembly and Calibration 2 Separate connector CN811 for PUMP 1 and or CN812 for PUMP 2 middle left of the CPU board as viewed from the rear Carefully lift and remove the pump head wire as semblies from PUMP 2 if they are routed between the hybrid circuits HIC301 and HIC302 Note Note the location of the wire ties restraining the cable leading to CN811 and or CN812 for later replacement and carefully cu
131. e x momo are o L A E S Re lt lt a B 5 a o gt nan aN coo ooo n wn A NNN Wook lt lt gt gt AN re e uu an oooo wz v gt lt oo RRR Re erre aa 2 N EE meee 0000 gt gt EN lt DAN oo x A xL x x 5 a po gt gt lt A xl lali Jo A n ojo ui e lt gt un Figure 10 15 Slave CPU Block Diagram OVcpu Vmtr Vmtr 07 19 1 729 002 224 6 3 ALUMINUM Ycpu for 0003 0005 BE 0001 007 C008 0 1u 0 1u V 014 1 12 GND 1 8 27 515 FA 5 12 n 10K lt lt loo RPOIZC 00058 4 511 4 0120 5 10K 5 RPOIID 10k ES 1 74 RPO11C 4 5 RPOOLS RPOIIB lt TRESUNET LA 2 3 6 RPOOIC 1 SIRPOLIA 22 3 34 58 MTM 7 2 RPOOIB RPO10D ss as p TESTAS soso 17 RPOOIA aa ase EOE 22 L n TERCOOF as ass O T RR RPOIOA O Re 8 0090 ass 009 EET ES
132. ecification perform the procedure in Section 6 4 2 6 Follow steps 7 through 11 to check that the tube misloading sensor outputs in SEC RATE and SEC VTBI windows are within specification 7 Load a Baxter s 5 suffix standard administration set and prime it with fluid 8 With the pump door open check the FSRR value at SEC RATE window and the FSRL value at SEC VTBI window Both values should be between 500 and 820 9 Repeat above step with the pump door closed Both values should be between 500 and 820 557 5 4 07 19 1 729 Troubleshooting 10 Open the door and intentionally load the tubing over the tube misloading sensor 1L and or 2L Figure 8 6 item 11 and or Figure 8 11 item 10 Close the door Do not load hard components on the administration set between the door and the base plate The FSRL value at SEC VTBI window should be 450 or less 11 Repeat above step on the tube misloading sensor 1R and or 2R Figure 8 6 item 10 and or Figure 8 11 item 11 The FSRR value at SEC RATE window should be 450 or less Note The sensors are normal if the values in steps 8 through 11 are within specification If any of these values are out of specification replace the tube misloading sensor per Section 6 3 12 12 Press the TIME key and check that the voltage reading in the Pump 1 SEC RATE win dow is within 472 579 Actual voltage displayed data x 0 00976 5 3 3 Automatic Test Mode 3 Manufacturing Test
133. ed by the master CPU via the I O controller The CPU activates an alert or an alarm software versions 1 09 or later when the slide clamps are not loaded and the option has been selected 4 1 12 Battery Low Alert Alarm Detector See Figures 10 7 and 10 11 The battery voltage is converted into a digital signal by the UPP and monitored by the master CPU The CPU activates the alert or alarm if the battery charge state falls too low The BATTERY LOW alert is triggered if the battery voltage drops below 11 4 VDC which will permit approximately 15 minutes of operation The BATTERY LOW alarm is triggered when bat tery voltage drops below 10 4 VDC which stops the pumps with alarms to prevent the battery from being damaged 4 1 13 Interlock Switches See Figures 10 10 10 36 and 10 37 The interlock switches are reed type activated by a magnet attached to each pump door latch The switch opens the circuit when a pump door is opened The master CPU monitors the interlock switches activates the DOOR OPEN alarm and stops the appropriate pump when its door is opened Electronics Interlink Electronics 07 19 A1 729 4 5 Theory of Operation 4 1 14 Panel Lock Circuit See Figures 10 3 10 21 10 34 and 10 35 The panel lock circuit is initiated by the PANEL LOCK pushbutton switch located on the rear of the device The switch is connected to an I O controller The purpose of this circuit is to prevent patient tampering A
134. ed in the Pump 2 Message Display To move on to the next parameter press the NEXT key or SEC START key 6 To exit press the ON OFF CHARGE key pressed in step 2 07 19 A1 729 1 13 General Description Table 1 1 Conliguration Options Parameter Description Setting Options 1 Alarm Log N A Clear alarm failure codes of Pump 1 or Pump 2 2 Occlusion Alarm Level 1 LEVEL 1 approx 7 psi The increase in pressure required to trigger a 2 LEVEL 2 approx 12 psi downstream occlusion alarm 3 LEVEL 3 approx 17 psi Select 1 or 2 to clear the corresponding pump s alarm log Factory Settings N A LEVEL 1 3 Audible Switchover 1 OFF Determines whether or not an audible alert tone will 2 ON be generated when either pump switches from the secondary program to the primary program 4 Number of Automatic Restarts 0 9 Determines whether or not the pump will automatically restart after a downstream occlusion and if so how many restarts can occur before the pump will remain in alarm If this parameter is set to anything other than 0 it is enabled The selected number corresponds to the number of automatic restarts If set to 0 the feature is disabled 5 Door Open Required 1 OFF Determines if the pump door must be opened after 2 ON a downstream occlusion alarm If the door is not opened and the pump is started within two minutes of the alarm the pump uses the pressure at which the alarm
135. ee Figures 10 10 and 10 16 Both CPUs communicate through the two serial communication lines Tx and Rx Each CPU has a communication counter which is initialized to a predetermined value by a signal from the other CPU The counter is then decremented by one count every 32 768 mS The counters are nor mally initialized again by the signal from the other CPU before they decrement to zero If a counter reaches zero it indicates that the watchdog signal from the other CPU was never re ceived This indicates a problem with the other CPU The remaining functional CPU then stops the pumps with visual and audible alarms If communication between the CPUs cannot occur both CPUs stop the pumps with visual and audible alarms Should both CPUs fail at the same time this watchdog function does not work The alarm con trol circuit is provided as a backup watchdog function See Figure 10 12 Alarm signals ALARMM ALARMS from each CPU are the inputs to the alarm control circuit 4 2 07 19 A1 729 When both CPUs functioning normally the signals change their state periodically The ware to control the signals is divided into several parts and located in different portions of the main program The state changes of the signals are considered normal only when all the individ ual parts of the program are executed according to an expected sequence If either or both signals fail the alarm control circuit is
136. en description of the problem should be attached to the instrument when it is returned for service Baxter Healthcare Corporation will not be responsible for unauthorized returns or for units dam aged in shipment due to improper packing 07 19 A1 729 9 1 Warranty and Service Information 9 3 General Information For general information concerning this product call Baxter Product Information at 1 800 933 0303 Baxter Healthcare Corporation reserves the right to change the design without notice 9 2 07 19 A1 729 Section 10 Diagrams This section contains all of the schematic and wiring diagrams for the Flo Gard 6301 Dual Channel Volumetric Infusion Pump These diagrams are intended only to assist the reader in un derstanding the theory of operation The diagrams are listed below Figure 10 1 System Block Diagram Figure 10 2 Rear Housing Wiring Diagram Figure 10 3 Front Housing Wiring Diagram Figure 10 4 CPU Board Block Diagram Figure 10 5 Power Supply Section Figure 10 6 DC Power Supply Figure 10 7 Power Supply Control Figure 10 8 Power Supply Control Hybrid Circuit Figure 10 9 Master CPU Block Diagram Figure 10 10 Master CPU Schematic Figure 10 11 UPP RTC and SRAM Block P O CPU Board Figure 10 12 Alarm Control Circuit Figure 10 13 Address Decoder Figure 10 14 Serial Communication Block Figure 10 15 Slave CPU Block Diagram Figure 10 16 Slave CPU Schematic Figure 10 17 Slave RAM and Progra
137. ensor button is moving freely If so repeat Section 6 4 4 steps 2 and 3 If not replace the Upstream Oc clusion Sensor per Section 6 3 9 Exit calibration mode 1 by pressing the ON OFF CHARGE key that was pressed in Sec tion 5 3 1 07 19 A1 729 Checkout 7 3 8 Battery Check Disconnect the device from AC Load a primed Baxter s s suffix standard administration set such as 2C5545s into both pumps and start them at 125 mL hr with a VTBI of 10 mL Verify that BATTERY is displayed and that the unit runs for at least five minutes or pumps 10 mL Plug the pump into AC and verify that BATTERY disappears from the message display 1 Battery Test Optional Note a Charge the battery for at least 16 hours before conducting this test Load a primed set into each pump such as 2C5545s into the pump Set the PRI RATE to 1901 mL hr and PRI VTBI to 4800 mL and start each pump Unplug the device while it is running No change in pumping should occur but BATTERY should be displayed on the message display within a few seconds The battery requires charging when BATTERY LOW is displayed the audible alarm or alert is activated and the appropriate LED is illuminated Operate the device on battery power for 2 5 hours Make sure that the pump does not initiate a LOW BATTERY alert before the KVO alert occurs If the unit fails this test perform the Battery Charging Voltage Check If the device operates satisfactorily on battery power
138. ents for cleaning Ensure ambient and solution Raise or lower temperatures are between 60 and temperatures 100 F 15 5 and 37 7 Perform the steps in Section 5 3 1 Reading displayed in the related to upstream occlusion appropriate PRI RATE window must be between 3242 and 3314 If not recalibrate or replace the sensor 5 Upstream occlusion was See Failure Identification Code 4 detected The sensor output decreased to an absolute value 1 6 Low battery voltage 10 4 If BATTERY LOW alarm is and V or less was detected CHARGING LED is off check a tightness of AC plug a Plug in firmly b AC voltage source b If AC voltage is below 105 VAC connect device to a correct voltage source power fuse c Replace if it has failed d battery fuse d Replace if it has failed Turn device off and recharge for 8 If alarm recurs after hours recharging check and repair loose connections at battery terminals If problem persists replace battery 7 Communication alarm Check that the device is in Place the device into was detected A framing computer control mode computer control mode error overrun error or Check for the loss of the Ensure communication parity error occurred communications link cable is plugged in during the Verify that computer software is and or the cable is wired communication with an correctly loaded onto PC corre
139. er sonnel to inspect and or modify certain device operating parameters to suit customer require ments These parameters and their setting options are shown in Table 1 1 The factory settings made at the time of manufacture are also shown in the table Note Although the configuration option data is stored in battery backed up it may be lost if the main battery connector CN302 is discon nected from the CPU board without turning off the device The con figuration option data is also lost if the lithium backup battery connector CN304 is disconnected while the main battery is discon nected Therefore we advise that the configuration options be re corded before beginning repair procedures and reset when repairs are complete 1 5 1 Reviewing the Configuration Option Settings To view the configuration option settings both pumps must be on and stopped Press TIME and TOT VOL STATUS simultaneously for one second The message REVIEW CONFIG will be dis played in the Pump 1 Message Display The option description will be displayed in the first line of the Pump 2 Message Display when the NEXT or SEC START key is pressed beginning with OCCLUSION The current setting will be displayed on the second line To view the next setting press the NEXT or SEC START key Each press of the NEXT or SEC START key will cause the device to advance to the next setting in the order shown in Table 1 1 starting with Occlusion Alarm Level To exit the in
140. ess gauge and place the device upright Turn the device off 3 The following procedure confirms that the calibration is correct a Load a Baxter s s suffix standard administration set prime it with fluid and close the pump door Ambient and liquid temperatures should be between 72 and 82 F 22 and 28 C b Occlude the tubing downstream of the pump c Turn the pump on and set the Primary Rate to 125 mL hr and Primary VTBI to 50 mL d Start the pump and ensure that a downstream occlusion alarm occurs e Press and hold the SILENCE and TOT VOL STATUS keys until an Alarm Code appears in the lower right corner of the Main Display The Alarm Code should be 2 or 3 4 Turn off the device and reassemble the pump door cover Loctite Inc 6 34 07 19 A1 729 Disassembly and Calibration 6 4 4 Upstream Occlusion Sensor Calibration 1 Loctite Inc Connect the AC plug of the device to a 115 5 0 VAC 60 Hz power source Enter Auto matic Test Mode 1 and check the calibration as described in Section 5 3 1 steps 7 through 9 If the value is out of specification calibrate the sensor using the following procedure Remove the pump head door cover as described in Section 6 3 4 Loosen and remove the occlusion sensor stop Figures 8 5 or 8 10 item 19 If it is stuck apply a small amount of isopropyl alcohol to the threads Wipe the threads clean Lay the pump on its rear and place the thickness gauge on the
141. ew and Phillips screw at the top and bottom of the pump head assembly Figure 8 1 items 6 and 7 Close the door and remove two black flat head screws Figure 8 1 item 7 on the door hinge side that secure the pump head assembly to the front housing These screws are ac cessible only when the door is closed Do not open the door before removing the two screws from the pump head assembly 07 19 A1 729 6 9 Disassembly and Calibration 7 Push the pump head assembly from the back and take it out of the front housing A Caution Do not pull out the two flexible cables Figures 8 6 and 8 11 items 10 and 11 from their associated connector housings This action could open the circuit Do not remove the gasket Figure 8 1 item 5 If resistance is felt check for pinched wires between the pump head assembly and the mounting plate or remove tangled wiring harness Do not force the assembly out Insulation of pump head wire harness can be damaged 8 Reassemble the pump head assembly in reverse order Caution sure not to pinch wires and gasket between the front housing and the pump head assembly when reinstalling the pump head assembly The three black screws Figure 8 1 item 7 and one Phillips screw item 6 must be torqued to 9 kgf cm 7 8 in Ib The screw Figure 8 2 item 14 for the two grounding wires must be torqued to 7 kgf cm 6 1 in Ib Route the pump head wiring harnesses as close as possible to the side of t
142. extends only to the original purchaser and is not assignable or transferable and shall not apply to auxiliary equipment or disposable accessories THERE ARE NO OTHER WARRANTIES INCLUDING ANY IMPLIED WARRANTY AND ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PUR POSE WHICH EXTEND BEYOND THE DESCRIPTION OF THE PRODUCT AND THOSE EXPRESSLY SET FORTH IN ITS LABELING UNLESS USED ACCORDING TO THE DI RECTIONS ACCOMPANYING THE PRODUCT ALL WARRANTIES ARE SPECIFI CALLY EXCLUDED In no event shall Baxter be responsible for incidental consequential or exemplary damages Modification alteration recalibration or abuse and service by other than a Baxter authorized representative may void the warranty 9 2 Service Information While under Baxter Healthcare Corporation Warranty Service Agreement optional or lease agreement the instrument must not be opened by unauthorized personnel Call 1 800 THE PUMP for service and repair information for all instruments Shipping costs for all units returned to Baxter shall be paid by the customer The unit must be packed in its original container or in another Baxter approved container that will provide ade quate protection during shipment Before shipping any unit for repair call 1 800 THE PUMP and notify a Customer Service Representative to ensure prompt return of your device When call ing Product Service please be prepared to provide code number and serial number of the unit A brief writt
143. fter the PANEL LOCK switch has been pressed the message Loc is displayed in the unused rate window and no keys except TOT VOL STATUS and BACKLIGHT are accepted The panel lock out is released by pressing the PANEL LOCK switch again The switches are enabled only when the pumps are running 4 1 15 Keypad See Figures 10 21 and 10 38 The keypad is a multiplexed 8 x 4 array which is scanned by an I O controller One of eight select lines determines which four keys are read All normal keypad presses are decoded by this matrix except the ON OFF CHARGE keys which have special in puts to the power control circuit 4 1 16 Displays See Figures 10 26 through 10 31 The LCD displays are multiplexed by display drivers which apply a DC biased free running frequency AC voltage to the segments of the displays when in the ON state and no DC biased AC voltage when in the OFF state The display drivers are ad dressed by the master CPU through an I O controller The data is sent on the data bus and is coded to update the displays periodically Once addressed the display driver retains the data un til addressed again The entire display is updated every 128 msec The display backlight is toggled on or off by the BACKLIGHT key If the device is running on AC power the backlight stays on continuously If the device is running on the battery the back light shuts off after 60 seconds to conserve battery life 4 1 17 Motor Driver See Figures 10 18 and 10
144. fy DC line voltages prior to performing other calibrations Further calibrations will not be reliable if DC line voltages are out of specification If the DC voltages are not within specifica tion check the appropriate DC power supply circuit The following section may be used to verify various voltages and signals without disassembling the device Measurements should be made with the device on AC power 1 Remove the battery access cover Figure 8 4 item 4 by removing 4 securing screws Figure 8 4 item 34 and remove the battery compartment assembly from the rear hous ing 2 Locate connector CNTESTI at Pump 1 side on the CPU board Note Connections called out in the following steps refer to connector CNTESTI Pin 8 top pin of CNTESTI is signal ground 3 Connect a voltmeter to Vmain pin 6 With the device powered off the reading should be 13 65 0 15 VDC The ripple voltage should be measured using an oscilloscope or using a 0 1 capacitor with the lead connected in series and the voltmeter set to AC The ripple voltage should be lt 100 mVp p at 105 VAC 4 Connect the DC voltmeter to Vref pin 1 Power up the device While both pumps are in STOP mode the voltage should be 5 000 0 050 VDC 5 Measure the voltage at pin 3 The voltage should be 5 00 0 30 VDC 6 Verify the Vkey voltage at pin 5 The voltage should be 5 00 0 30 VDC 7 Verify the Voth voltage at pin 4 The voltage should be 12 90 to 13 90
145. g made to the entire Flo Gard 6301 Dual Channel Volumetric Infusion Pump Generally the word pump is used to refer to either Pump 1 or Pump 2 Each device s serial number is recorded on a label on the back of the device ITEM FUNCTION 1 Pump 1 ON OFF CHARGE Key Turns Pump 1 on and off The internal battery charger re mains on regardless of the ON OFF CHARGE key as long as the device is plugged in 2 Pump 1 Door Latch Opens and closes pump door 3 Pump 1 STOP Key Stops Pump 1 The message STOPPED appears when the key is pressed An alert will sound if Pump 1 is stopped for more than two minutes Clears all programming alerts while pump is running 4 PUMP Key and Indicator Allows the device to accept keystrokes and other controls common to both pumps for Pump 1 programming Yellow LED lights to indicate that Pump 1 is selected 5 Pump 1 Main Display Shows rate volume be infused VTBI and total volume infused for Pump 1 primary and secondary infusion pro grams 6 Pump 1 Message Display Shows all Pump 1 messages 7 Pump 1 ALARM LED Red LED that blinks on and off during a Pump 1 alarm ac companied by a visual message display and a repeated se quence of three beeps An alarm indicates that Pump 1 requires immediate attention 8 Pump 1 PUMPING LED Green LED which is constantly lit while Pump is pump ing 1 4 07 19 A1 729 General Description 15 5 4 16 17 3 2 1 18 27 19 21 20
146. he Operational Checkout procedures Baxter s Continu Flo administration set with at least one Y site Secondary administration set Solution containers distilled sterile water DSW 0 9 sodium chloride etc Precision 100 uL gas tight syringe part no 59662 81 or equivalent Precision 250 uL gas tight syringe part 59662 82 or equivalent Thickness gauge part no UKOG1013 B Tape measure or yardstick 7 2 Maintenance Flowchart Figure 7 1 is a flowchart illustrating the maintenance procedures for this device The Opera tional Checkout should be performed after any repairs are performed on the device Any prob lems discovered while performing the Operational Checkout should be corrected using the troubleshooting procedures given in Section 3 Problem Checklist and Section 5 Troubleshoot ing Once a problem has been isolated to a single assembly the assembly should be replaced in accordance with the disassembly procedures provided in Section 6 The device should then be calibrated as described in Section 6 After all maintenance procedures are complete perform the Operational Checkout in this section Appendix A contains a data sheet which may be reproduced and used to record the device s con figuration settings and the results of the Operational Checkout and calibration procedures 07 19 A1 729 7 1 Checkout RECEIVE PUMP WITH SUSPECTED PROBLEMS PERFORM OPERATIONAL CHECKOUT OF SECTION 7
147. he back plate item 17 Install the replacement back plate Ensure that the back plate is clean and not worn En sure that the notch in the back plate aligns with the tongue in the door Ensure that all 5 springs item 18 are in place and perpendicular to the back plate cover 6 18 07 19 A1 729 Disassembly and Calibration 5 Install the back plate cover item 16 in reverse order Apply pressure to the back plate cover and install the screws items 26 and 27 working from the outside edges to the cen ter That is install the top and bottom screws first followed by the screws in the center of the back plate cover Before tightening these screws press the back plate a few times from the inside of the door to ensure smooth operation Tighten these screws to 6 kgf cm 5 2 in 1b 6 Replace pump door cover in accordance with Section 6 3 4 7 Perform the Operational Checkout procedures in Section 7 6 3 18 Replacement of Battery 1 Turn off and unplug the device 2 Remove the 4 screws Figure 8 4 item 34 on the battery compartment cover item 4 3 Slide the battery assembly out of the rear housing and place it down on the cover Note Lead batteries must be recycled or disposed of properly Contact fed eral or state environmental agencies for information on recycling and disposal options 4 Remove the 4 screws item 34 securing the battery compartment item 15 to the cover item 4 5 Hold the cover and the batte
148. he pump head assembly so that wires are not pinched or damaged by internal components when the housings are closed 9 Calibrate in accordance with Sections 6 4 1 through 6 4 4 10 Perform the Operational Checkout procedures in Section 7 6 3 9 Replacement of Upstream Occlusion Sensor 1 Remove two Phillips screws Figure 8 7 or 8 12 item 16 which secure the sensor item 9 to the pump head base plate 2 Pulland rotate the sensor 45 clockwise and remove it from the pump head base plate Caution Do not scratch the ribbon connectors located above the sensor Scratches can damage the connectors 3 Desolder black and white wires from sensor Use caution to avoid contacting any plas tic parts with the soldering iron 6 10 07 19 A1 729 Disassembly and Calibration 4 Remove the screw Figure 8 7 or 8 12 item 6 securing grounding plate item 11 grounding wire and star washer item 8 Do not lose the plate washer and screw 5 Install replacement sensor and reassemble in reverse order Be sure to attach the grounding wire and plate to the sensor See Figure 8 7 or 8 12 Tightening torque for item 16 is 3 kgf cm 2 6 in lb Tightening torque for item 6 is 1 5 kgf cm 1 3 in 1b 6 Calibrate in accordance with Section 6 4 1 and 6 4 4 7 Perform the Operational Checkout procedures in Section 7 6 3 10 Replacement of Downstream Occlusion Sensor Assembly 1 Remove two Phillips screws Figure 8 7 or 8 12 item 16 which secur
149. he slide clamp slot and load the set into the pump mechanism 3 Close and latch the pump door 07 19 A1 729 7 11 Checkout Note If INSERT SLIDECLAMP appears on the display clean the slide clamp sensor with a cotton tipped swab dipped in water and check the cali bration Repair or replace as necessary 4 Open the door Press the red safety clamp arm with moderate force approximately 15 Ib 6 5kg and verify that the latch will not lock in the open position 5 Using one hand pull on the slide clamp with moderate force approximately 15 Ib 6 5kg perpendicular to the pump face Verify that the slide clamp cannot be removed 6 Push the slide clamp in fully Verify that the red safety clamp arm can be latched in the open position and verify that the slide clamp and tubing can be removed 7 Load the primed set again but do not insert the slide clamp into the mechanism Close the door Verify that the INSERT SLIDECLAMP message is displayed with the alert LED constantly lit and the audible tone alternately ON and OFF Note For pumps with software versions 1 09 or later the pump will start in the alert mode but the message remains displayed The alarm mode will not allow the pump to start 8 Then partially insert approximately one third of the way the slide clamp Close the door Verify that INSERT SLIDECLAMP is displayed 9 Open the pump door and remove the tubing from the device Note See the repair section Sect
150. i L1 L3 BLK GND GND di 26446 1007 ET18 XH A SLP 15 WHT UPSTREAM SHIELO WIRE 28AWG 1691 i CN CN851 CNB852 12 14 UPOCCLI UPOCCL d WHT gt SHIELD WIRE BLU DWNOCCLI DMNOCCL2 3 Z28AWG 1691 d 564 2 564 7 BRN TNTLOCKI INTLOCK2 ORG 26AWG 1007 6 B6B XH A CPU PCB INTER LOCK DOOR X1052MC CNDISP SHIELD WIRE YEL B11 CN812 1 WHT AIRNORMI AIRNORM2 di PNK AIRCOMI AIRCOM2 GRN ATRMINI ATRMIN2 3 DISPLAY BLU 2 da 302 28 6 2791 ds N1051MC GND GND pod an WIRE 3 MINLVLI NINLYL2 ied PNK NORWLEVLI NORMLVL2 WHT 40 8 28 6 2791 LITHIUM BATTERY TUBE MIS CN803 CN804 803 CNB04 FSR2 FSRA LEFT a a q q CONAN WHE ISLCSENSE ISLCSENSE 26AWG 1007 FRONT PANEL FILM 9 PUMPHEADI PUMPHEADZ R1 R3 MOUNTING MOUNTING BRACKET BRACKET HBLBOS 14AMG 14 1015 1015 REAR HOUSING 14 1015 Note The symbol denotes pump head body 14AWG 1015 Dotted lines indicate green or green yellow bonding wires and 18AWG 1007 if not specified Figure 10 3 Front Housing Wiring Diagram 07 19 A1 729 10 5 C CD X N HANNA ON nw lt zoo oe NEGO au
151. if required Replace worn parts as required Replace door latch in accordance with Section 6 3 5 5 18 07 19 A1 729 Troubleshooting SYMPTOM CHECKS Free flow occurs when the door is opened Table 5 2 Troubleshooting Chart CORRECTIVE ACTION Check administration set for proper type and code Check for solution spills on and around safety clamp Check position and seating of tubing in safety clamp Check that ambient and solution temperatures are between 60 and 100 F 15 5 and 37 7 C Check for broken safety clamp spring and or broken safety clamp Replace with Baxter s s suffix administration set if required Clean in accordance with Section 2 2 Position tubing properly and make certain it is seated in guides and channels Raise or lower the temperatures Replace broken parts if required Backup buzzer does not acti vate during self test INSERT SLIDE CLAMP alert or alarm is constantly on Note The alarm option is only available on pumps run ning software versions 1 9 or later uere Check that the buzzer wiring is connected Check for an open fuse on the battery wire harness Plug in connector Replace fuse Replace backup buzzer Ensure that the slide clamp sensor is clean Check connections Check calibration and operation Clean the slide clamp sensor
152. il DANZO2U 9755 75081 74AHCIAF 1BUPBZ TBUPBZ 751 trace 752 only trace only for 9751 for 0752 74HC14F ALARMBZ U754F 13 912 5 74 14 1 C754 0 022u yAM202U BZDET Figure 10 12 Alarm Control Circuit 07 19 A1 729 10 14 020050 bit 74ACOOF O 6 74 20 74AC04F 7 vcc 10 D Le 12 P13 V 4 515 AMA AM O 15 gt 01108 a q BANK DO SANT 5 i D N U 74ACO02F 104 110 Q 1CSBANK 2 1 4 gt 74AC02F 1 5 01116 gt lt Di nias DCLK M lt 9419 7 gt ao DARE DI A 74HC74F 3 07 19 A1 729 N U N U ICSRAMN ICSBANK 5 2 1 5 1 1CSSCU 1CSRTC 0 1u Figure 10 13 Address Decoder for for for for for for U103 0106 1107 0109 0110 0111 lt n n C877 R419 trace only C878 trace only for 0405 for 0404 7SUO4F R420 2 2k 6 3 5 N U i BAUDO BAUDI 151 5 407 0 1u Vcpu t C406 O K pM 0 7 15 00 18 0 19 02 0441 25 03 15 gt 151 25104 N 08i 27 05 2305 07 RESETP RE LE cL 4 9 ao gt HR II 546 UPD71051GB LT1080CS SIME 10 R
153. in the device are Vmtr This is the DC source for the motors It comes either from the DC power supply output or the internal battery voltage This is the unswitched power source Voth This is used for backlights icons and optional nurse call feature The voltage comes from the DC power supply output and is switched by the master CPU Vmem This is the output of the lithium backup battery for the backup memory in the RAM 0507 and for maintaining the time in real time clock U506 This is the unswitched power source All the voltages except unswitched power sources are turned on when the ON OFF CHARGE key is pressed while the device is off However turning these voltages off can only be accom plished by the master CPU through the power control circuit The master CPU saves necessary data in the backup memory in the RAM U507 and turns off the Vref and Voth voltages when both pumps are turned off The power control circuit is contained in a hybrid chip HIC302 which also includes a circuit to activate the backup audible alarm when the device is shut down by a failure The RAM U006 for the slave CPU is not backed up 4 8 07 19 A1 729 Section 5 Troubleshooting 5 1 Introduction This section describes how to find the cause of device malfunctions The section consists of the following A description of the device s failure identification codes A description of the device s automatic test modes e A ta
154. in the second line of the message display until the test mode is ex ited After exiting test mode the downstream occlusion sensor level will revert back to the origi nal configuration setting Rate and VTBI information may be programmed manually 07 19 A1 729 5 7 Troubleshooting 5 4 Failure Identification Code Troubleshooting Table Use Table 5 1 to determine the corrective action necessary to resolve failure codes The causes of each failure code are listed in the order in which they are most likely to occur Perform the corrective action items in the order in which they are listed and retest the device after each ac tion All replacement procedures are contained in Section 6 There are two types of failure identification codes Alarm codes 1 19 and Failure codes 20 and above Alarm codes report malfunctions generally correctable by the operator Failure codes may require servicing of the device A code of 0 indicates that less than 10 alarms failures have occurred since the log was cleared The time and date will also be 0 Table 5 1 Failure Identification Codes CHECKS CODE CAUSE 0 No alarms or failures No action necessary 1 Air bubble detected in a Run mode Downstream occlusion was detected The sensor output increased by a specified value Check for air in tubing Ensure set is correct type and is properly loaded Ensure set tubing is not scratched or deformed COR
155. ink permanent marker and mark box number 1 6 Assemble the pump by performing applicable previous steps in reverse order 7 Perform the Operational Checkout procedures in Section 7 6 3 29 Software Installation Equipment 2 Phillips Screwdriver LC Removal Tool Insertion Tool Parts EPROM with master software MAS as necessary 1 EPROM with slave software SLV as necessary Note There are two EPROMS available for replacement upgrade in this de vice Although the parts IC are the same it should be noted that the software code contained in each is different Therefore ensure that the correct part is installed into the correct location 07 19 A1 729 6 27 Disassembly and Calibration Note This device uses CMOS circuitry Therefore take steps to prevent damage caused by electrostatic discharge This includes the use of ground straps grounded work surfaces EPROM Installation 1l With the pump powered off press and hold the SILENCE key then press either ON OFF CHARGE key Record the software version number shown on the lower right corner of the main display of PUMP 2 2 Power off the device and make sure it is disconnected from AC power 3 Remove the 4 corner screws Figure 8 4 item 34 that hold the battery access cover item 4 in place 4 Tilt the device back and carefully pull out the battery compartment item 31 and cover 5 Remove the 4 screws item 34 which hold the battery compartment
156. into a 115 5 0 VAC 60 Hz power source with the following settings Variable transformer 0 V or minimum setting Minimum current setting constant current mode 6 30 07 19 A1 729 Disassembly and Calibration e Turn both potentiometers VR1 and VR2 on the DC power supply board Figure 8 3 18 fully clockwise f Set the DC ammeter to the appropriate range and the DC voltmeter to 20 VDC range Do not use autorange 14 Calibration of Output Voltage by VR2 a Ensure the AC power plug of the device 15 connected to the variable transformer b Adjust the variable transformer output to 120 VAC The voltage may be checked with an ordinary tester with 3 accuracy Connect the resistive load and adjust the potentiometer until the output current is 1 40 A d Slowly turn VR2 counterclockwise until the voltage between pin 2 red and pin 3 black 1 13 65 0 05 0 To maintain this VR2 value while still maintaining the output current of 1 40 A minute adjustments may need to be made to both the potentiometer on the load and VR2 e Check that the voltage between pin 1 yellow and pin 3 black is between 13 8 and 14 5 V f Disconnect the resistive load and check that the voltage between pins 2 and 3 at no load is 13 7 0 1 V 15 Calibration of Output Current Limit by VR a Adjust the variable transformer output to 100 VAC and adjust the resistive load for an output current of 1 5 A b Slowl
157. ion 6 if the pump fails any of these tests 7 3 13 Electrical Safety Tests 1 Test the device s leakage current and ground impedance in accordance with UL 544 Leakage current should not exceed 50 microamps Measure the ground impedance at the mounting nut of the LOCKOUT switch on the rear of the pump It should not exceed 0 15 Q using a 25 amp UL specified test circuit or 0 15 Q using an NFPA 99 or equiva lent test circuits Warning If the device fails to meet these requirements remove it from service troubleshoot it in accordance with Section 5 and repair it in accord ance with Section 6 2 Thoroughly inspect the power cord for signs of wear or damage Replace it if any pins are broken or the insulation is damaged 7 12 07 19 A1 729 Checkout 7 3 14 Accuracy Tests Any one of the tests described in this section can be used to test the accuracy of the pump s You can perform just the One Hour Accuracy Test 7 3 14 5 or one of the shorter tests 7 3 14 1 through 7 3 14 4 but the One Hour Accuracy Test should be performed additionally if any of the shorter tests fail Repeat test as needed for additional pumps 1 Before proceeding with the selected test perform steps 1 4 of Section 7 3 2 1 Note An unused section of a Baxter s s suffix administration set or cali bration tubing Part no 3 2 92 479 can also be used for these tests 2 Mark the section of the tubing in the pump to indicate that the segment h
158. is recharged whenever the device is plugged in regardless of whether the pumps are on or off However for optimal charging turn the pumps off The Plug Icon is illuminated when ever the battery is charging The battery must be stored in a charged condition and should be re charged at least once a month To charge the battery plug the device into a 115 VAC outlet 2 4 Preventive Maintenance Table 2 2 lists preventive maintenance for the device which should be performed at the inter vals shown CHECK Schedule As required but recommended after every use Table 2 2 Preventive Maintenance Procedures ACTION Rear panel connector comm port Clean with an agent listed in Table 2 1 Replace the connector if its shell is damaged Check that plastic cover is in place Pump mechanism Clean with an agent listed in Table 2 1 Case Clean with an agent listed in Table 2 1 Loose or missing Replace in accordance with Section 6 hardware Main battery Recharge by plugging into a 115 VAC outlet for at least 8 hours Check that the Plug Icon is illuminated during this time Back plate and safety Power cord Schedule Every 12 months or as required clamp with Section 6 3 17 Pole clamp If operation is not smooth apply one drop of high grade general purpose machine oil to the screw threads Replace the power cord if the pins are bent or the insulation is damaged If the back plate d
159. isplay The date when the failure occurred will be displayed in the appropriate Message Display for as long as the keys are held plus one second To exit from the failure identification code viewing mode re lease the SILENCE and TOT VOL STATUS keys One second later the display of the RATE s and VTBI s data resumes To scroll back through the previous nine codes that occurred press the CLEAR TOT VOL key before the one second period elapses Each failure code along with the time and date will be displayed for one second with a one second off interval after each 07 19 1 729 gt 5 1 Troubleshooting code After the last failure code for the pump s has been displayed for 1 second the display s return to normal To exit press the appropriate STOP key s See Table 5 1 for descriptions of all failure identification codes and instructions on how to cor rect each failure Disassembly reassembly and calibration procedures are located in Section 6 During operation a pump specific failure is indicated by the message FAILURE and the failure code number in the format F_nn in the appropriate Message and Main Displays A device spe cific failure is indicated by COMMON FAILURE in the Pump 1 Message Display and the failure code number in the Pump 2 Main Display 5 3 Automatic Test Modes Warning The automatic test modes are for servicing the device only and must not be used while the device is connected to a patient The device has ten
160. l end of the infusion set into a container of known weight 4 Simultaneously start a timer and press the START key 5 Stop the pump 1 hour 20 seconds later Use a calibrated scale with a resolution of 0 1 grams or better to weigh the container and solution Then divide the solution weight by the specific gravity of the solution water s specific gravity is 1 g mL 6 The collected solution should be between 116 25 and 133 75 mL 7 Ifthe volume of the collected solution is NOT between 116 25 and 133 75 mL e verify proper test technique e check for a loose belt e check for a properly moving backplate or damaged backplate springs or e replace the pump head assembly as necessary Important Do NOT run this test again to improve results unless there is reason to believe that the test technique was in error Replace any pump head that fails this test and be sure to clearly identify it as having failed the One Hour Accuracy Test 07 19 A1 729 7 15 Checkout 7 16 07 19 1 729 Section 8 Illustrated Parts Breakdown This section includes illustrations and parts lists required to identify any replaceable part in the Flo Gard 6301 Dual Channel Volumetric Infusion Pump Each illustration is keyed to a parts list which lists each component shown in the figure by part number and description The quan tity per assembly is also shown The level of assembly is indicated by the number of dots preced ing the description For example o
161. mmable Timer Module PTM Figure 10 18 Motor Driver Circuit Pump 1 Figure 10 19 Motor Driver Circuit Pump 2 Figure 10 20 CPU PCB Sensor Block Figure 10 21 PPI Block 1 Figure 10 22 PPI Block 2 Figure 10 23 Occlusion Sensing Block Figure 10 24 Air Sensing Block Figure 10 25 Misload and Slide Clamp Sensors 07 19 A1 729 10 1 Diagrams Figure 10 26 Display PCB Figure 10 27 LCD Drivers for Pump 1 Figure 10 28 LCD Drivers for Pump 2 Figure 10 29 LCDs for Pump Figure 10 30 LCDs for Pump 2 Figure 10 31 LED Lamps Figure 10 32 Audible Alarm PCB Figure 10 33 Backup Buzzer PCB Figure 10 34 Terminal PCB Figure 10 35 Accessories Figure 10 36 Sensors on Pump head 1 Figure 10 37 Sensors on Pump head 2 Figure 10 38 Front Panel Key Assignments 10 2 07 19 A1 729 PWROFFS RS232C INTERFACE 12 BAUD RATE MAIN 12v GENERATOR MASTER BATTERY DC POWER SUPPLY 13 65v gt PO COMMUNICATION CONTROLLER PLUG ICON READ ONLY LED RANDOM MEMORY ACCESS MEMORY BATTERY SYMBOL ICON LEO PROGRAMMABLE TIMER MODULE NURSE CALL CIRCUIT CIRCUIT D AUDIBLE V V V 5 8 MULTE MULTI PLEXER PLEXER AMPLIFIER V V V V 16 LCD COMPUTER MONITOR NEXT OPTIONS 0 S CONTROL DRIVER S LED LED LED LED Y 16 15 V 14 V LCD s ALARM ALERT PUMPING PANEL KEYBOARD LOCK BACKLIGHT LED LE
162. n set cannot be easily removed from the pump without first pushing the slide clamp all the way into the slide clamp slot thus occluding the tubing in the slide clamp This test verifies that the Slide Clamp Feature is functioning properly Note If the Slide Clamp Feature is enabled the administration set slide clamp must be loaded into the assembly In the alert mode the pump gp operates if the slide clamp is not loaded In the alarm mode software versions 1 09 or later the pump will NOT start and an alarm tone sounds if the slide clamp is not loaded Use of the Slide Clamp Fea ture is selected as part of the configuration option before the pump is placed into service Note Spring retainers are loaded into the slide clamp slots at the factory to prevent damage during shipment The spring retainers must be re moved before operating the device with the Slide Clamp Feature en abled If the feature is not going to be used by your hospital it is recommended that the spring retainers remain in the slots to help pre vent spilled solutions from entering the slide clamp slots Contact Product Service at 1 800 THE PUMP for additional spring retain ers 1 If your hospital does not have the slide clamp feature enabled ensure that the spring re tainers occupy the slide clamp slots and proceed directly to Section 7 3 13 2 With the device ON fully insert the slide clamp of a primed Baxter s s suffix standard administration set into t
163. n the pump set the Primary Rate to 125mL hr and Primary VTBI to 1000 mL and start the pump Ensure that this air bubble is allowed to pass with no alarm If the air bubble is detected repeat the calibration procedure If the air sensor cannot be calibrated turn off the pump Replace the sensor in accordance with Section 6 3 11 Repeat steps 10 14 for the other pump head Perform the Operational Checkout procedures in Section 7 You may wish to perform the Air Alarm Test Section 7 3 4 prior to the other tests GC Electronics 07 19 A1 729 6 33 Disassembly and Calibration 6 4 3 Downstream Occlusion Sensor Calibration 1 Check calibration as described in Section 5 3 1 steps 1 through 5 2 If the value is out of specification calibrate the sensor as follows a Remove the pump door cover as described in Section 6 3 4 Loosen and remove the occlusion sensor stop Figures 8 5 or 8 10 item 19 If the stop is stuck apply a small amount of isopropyl alcohol to the threads Wipe the threads clean b Apply Loctite 211 or 222 to the screw threads of the stop c Repeat Section 5 3 1 steps 1 through 5 Reassemble the stop into the pump head door and slowly turn it with a screwdriver until the value displayed in the PRI VTBI window of the appropriate Main Display is between 2998 and 3002 Knock on the center of the door and check that the reading does not change more than 2 counts Allow the threadlock to set d Remove the thickn
164. ne dot indicates a top level assembly two dots indicate a second level subassembly three dots the third level of subassembly and so on To obtain replacement parts contact Product Service The first column shows the item number of each part The second column is the Product Service part number The third column is the manufacturer s part number and the last column is the quantity per assembly The last two dig its of each part number indicate the supplier s revision level and are needed when ordering so that a database search for equivalent parts can be conducted Orders will be filled with equiva lent parts however the last two digits of the replacement part number may vary depending upon the currently available revision level If replacement part number digits other than the last two digits vary please contact Product Service toll free at 1 800 THE PUMP to check compatibil ity 07 19 A1 729 8 1 Illustrated Parts Breakdown Front Housing Assembly External Figure 8 1 Item Sve Part Mfg Part Description 1 2059120001 2059120001 HOUSING FRONT SUB ASSY 2 2059120015 F059120015 PUMP 1 HEAD Note See Figures 8 5 through 8 9 for details on items 1 and 2 3 2049120020 2049120020 PUMP 2 HEAD ASSEMBLY Note See Figures 8 10 through 8 14 for details on item 3 4 HPNL1026 A 5001474005 PANEL Front 5 PGUMM103 K F044630004 wi SEAL Rubber 4224 yes 6 XBPUF30P A 40093 10009
165. nsor Detects misloaded tubing out of the channel guide slot 7 Figure 1 2 Pump With Door Open 1 8 07 19 A1 729 General Description 4 Downstream Occlusion Sensor Detects complete tubing restrictions downstream of the pump 5 Air Sensor Detects air bubbles in the IV set 6 Safety Clamp Prevents accidental fluid flow when the IV set is properly loaded and the pump door is opened 7 Slide Clamp Feature Provides an additional means of preventing accidental gravity fluid flow by occluding the tubing in the admini stration set with the slide clamp before the set can be re moved from the pump The use of this feature is optional when used the slide clamp must be loaded in the slide clamp slot The feature is selectable through the pump s configuration options If alert mode is enabled the pump will operate without the slide clamp inserted and the INSERT SLIDE CLAMP message displayed An alert tone will sound to notify the user that the slide clamp should be inserted If the alarm mode is enabled software versions 1 09 or later the pump will NOT start and an alarm tone will sound if the slide clamp is not loaded 8 Spring Retainer Insert The pump is shipped from the factory with this plastic in sert in the slide clamp slot It prevents damage to the mechanism during shipment and maintains the proper spring tension If your hospital does not plan on using the slide clamp feature Baxter recommends that this plastic in
166. nt Calibration Equipment Setup Maintenance Flowchart Front Housing Assembly External Front Housing Assembly Internal Rear Housing Assembly Internal Rear Housing Assembly External Pump Head Door Assembly ios Pump 1 Base Plate Assembly with FSRs Pump 1 Base Plate Assembly Rear Pump 1 Base Plate Assembly with Pump Mechanism Safety Slide Clamp Assembly 1 Figure 8 10 Pump Head 2 Door Assembly Figure 8 11 Figure 8 12 Figure 8 13 Figure 8 14 Figure 8 15 Figure 8 16 Figure 8 16 Figure 8 17 Figure 8 17 Figure 8 18 Figure 8 19 Figure 8 20 Figure 10 1 Figure 10 2 Figure 10 3 Figure 10 4 Figure 10 5 Figure 10 6 Figure 10 7 Figure 10 8 Figure 10 9 7 19 A1 729 Pump 2 Base Plate Assembly with FSRs Pump 2 Base Plate Assembly Rear Pump 2 Base Plate Assembly with Pump Nechanisn Safety Slide Clamp Assembly 2 Power Supply Board Component and Solder Sides Display PCB Component Side Display PCB Solder Side CPU PCB Component Side CPU PCB Solder Side Terminal PCB Backup Buzzer Board Audible Alarm PCB System Block Diagram Rear Housing Wiring Diagram Front Housing Wiring Diagram CPU Board Block Diagram Power Supply Section DC Power Supply Power Supply Control Power Supply Control Hybrid Circuit Master CPU Block Diagram 1 5 1 8 1 10 6 25 6 25 6 27 6 30 7 2 8 3 8 5 8 7 8 9 8 13 8 15 8 1
167. nutes Replacement of Pump Door Cover Open the pump head door Remove five screws that secure the pump door cover to the pump door Figure 8 1 item 13 Do not remove the screw affixing the metal plate in the recess at the bottom of the door Figures 8 5 and 8 10 item 27 Toray Dow Coming 07 19 A1 729 6 7 Disassembly and Calibration 6 3 5 10 11 12 13 6 3 6 6 8 Reassemble the cover in reverse order Tighten each of the five screws to 4 kgf cm 3 5 in lb with a torque screwdriver Replacement of Pump Door Latch Remove the pump door cover in accordance with Section 6 3 4 Close the pump door Remove the E ring Figures 8 5 or 8 10 item 5 that secures the door latch Lift the door latch and carefully pull it out of the pump door Use caution to avoid los ing the associated parts on the door latch pin To replace the latch lay the device on its back Place one thin washer Figure 8 5 or 8 10 item 8 the spring item 6 and the other thin washer item 8 on the door latch pin Insert the pin into the hole in the pump door Open the pump door slightly Press the door latch in toward the pump door so that the spring is compressed Install 4 mm washer item 7 on the pin Install the E ring item 5 on the pin Calibrate in accordance with Sections 6 4 2 through 6 4 4 Perform the Operational Checkout procedure in Section 7 Replacement of Pump Door or Pump Door Assembly Remove the door co
168. o HD61602R 906 gt gt 65 0 gt gt gt gt gt SF gt Q QQto iu 99 93 93 58 SEGS 19 e M cm LO Bu 0 0 00 un SD 0m DADO mio 3E QD oom nn 0 8L 6 60 64 NL QJ 09 9 0 0 0 m 0 Lad UJ Ld AJ UJ CO D RE RE RE RE RE RO 0 C00 9 O wv wv wv uv wv wu wv uu uiu IJ das Lal Ul UJ UJ Gf Ud GJ Lad laf LUI UJ GJ CJ wv v ww 99 WM wv gt N a CQ e 08 09 ax ur yr HE XXE OG QD 40 0 QD QD D D QD 42 Q3 Q0 0 D gt miot miuwuwoconlocom OoOOOmwoem mewaem IOQOQOQOwuutwwv tu Y NI Mn 0 0 r wo uy 0515028 00074 10 e NL Q Q cm UON 0 99 uU WD P L0 8f i0 4D P O0 O08 e NL 0 fF 9 O 89 0 OOZ U U e e e 24 0 v v UJ UJ tas UJ Ul Ul LJ UJ Ld CD CD QD CD D CD CD CD COD CD XD QD GO QD GOD QI CD D QD QD OD 0 UD O Q wv vi M ws qui Y UN Y YU qu u las hal tad uj las uj AJ LJ las Lad f GJ UJ dad UJ tad KJ la Lay tal KJ did Lal Lj Lad De v uv wv v vu uuu A A A YA IN YN Un N 00 t 0
169. o 030216490 Screwdriver with flat tip 2 5 to 3 mm width ceramic or insulated type preferred for po tentiometer calibration Cotton tipped swabs Preparation a Turn off the device b Press the safety clamp arm cover in until the safety clamp latches open c Use aC or E ring tool to remove the spring retainer from the slide clamp slot if one is present d Use a cotton tipped swab dampened with water to clean the safety clamp sensor This sensor is located approximately 1 4 in at the upper left of the slide clamp slot Repeat with a second dampened swab Allow to dry before proceeding e Separate the front and rear housings in accordance with Section 6 3 1 Slide Clamp Sensor Calibration a Connect the device to a 115 VAC 60 Hz AC power source b Disconnect and reconnect the slide clamp sensor connector CN803 for PUMP 1 and or CN804 for PUMP 2 Tocalibrate connect a voltmeter to Pin 3 of CNTEST2 and Pin 5 for ground Use Pin 1 for PUMP 2 d Enter Automatic Test Mode 1 by pressing and holding the CLEAR TOT VOL and 1 keys while pressing either ON OFF CHARGE key 07 19 A1 729 Disassembly and Calibration Important If the potentiometer s step e cannot easily be moved from their present settings they have been sealed with Loctite 211 or 222 To loosen the varnish apply one two drops of isopropyl alcohol to the affected potentiometer s and wait one minute before trying to move them again
170. o A D converter remains high CORRECTIVE ACTION Turn device off and back on 61 Malfunction in battery voltage detection circuitry Input to A D converter remains low Malfunction in memory backup battery voltage detection circuitry Input to A D converter remains Turn device off and back on Turn device off and back on If failure recurs replace CPU board If failure recurs replace CPU board If failure recurs replace CPU board Data in duplicate memory Turn device off and back on 70 areas does not agree 71 Slave CPU received no data from Master CPU Turn device off and back on high 63 Lithium backup battery Check connector CN304 for proper Plug CN304 in firmly voltage is too low to back connection and continuity Replace lithium backup up the memories battery Replace CPU board 64 Malfunction in A D Turn device off and back on If failure recurs replace converter circuitry A D CPU board conversion for 0 through 3 channels did not complete in 144 uS 65 Malfunction in A D Turn device off and back on If failure recurs replace converter circuitry A D CPU board conversion for 4 through 7 channels did not complete in 144 uS 66 Supply voltage of CPU Turn device off and back on If failure recurs replace circuitry is too high the CPU board 67 Supply voltage of CPU Turn
171. oard Pump operation is louder than normal Check administration set for proper type and code Check for solution spills on the pumping fingers and around the back plate Check the tightness of the motor mounting bracket screws Check for a PC board or other assembly vibrating against the inside of the case The rear clamp fails to hold the device on the IV pole Free flow occurs when the door is closed Check for worn or missing friction pad Check the clamp for worn threads and other worn or defective parts Replace with Baxter s s suffix administration set if required Clean in accordance with Section 2 Tighten as required Ensure all internal assemblies are securely fastened Replace worn or defective parts on the clamp as necessary Check administration set for proper type and code Check position and seating of the tubing Check that ambient and solution temperatures are between 60 and 100 F 15 5 and 37 7 C Check for cracks in the door hinges Check for deformation of the coil springs of the back plate Check for worn cams and pumping fingers Check for damaged or deformed door latch Replace with Baxter s s suffix administration set if required Position tubing properly without stretching or slack Raise or lower the temperatures Replace the pump head in accordance with Section 6 3 8 Replace the springs
172. occurred as the baseline for the next alarm You may wish to set this option to force the user to open the pump door This action resets the baseline and encourages the user to relieve the downstream pressure thereby lowering the alarm threshold Example Suppose the initial pressure is approximately 1 p s i and the occlusion alarm is set to LEVEL 1 or approximately 7 p s i The first alarm will occur at approximately 1 7 or 8 p s i This value represents the baseline pressure that will be used to caiculate the next alarm unless the door is opened the downstream pressure is relieved and a new baseline is set 6 Air Bubble Alarm Size 1 MIN average 50 uL Determines the air bubble size which will cause 2 NORM average 75 uL AIR alarm OFF OFF NORM 7 Alarm Off Interval 1 7 Sets the number of seconds between each occurrence of the three beep alarm tone 07 19 1 729 Description Table 1 1 Configuration Options Parameter Description 8 Alert Off Interval 9 Maximum Rate of Infusion primary rate 10 Maximum VTBI The maximum volume that either pump can be programmed to infuse Sets the number of seconds between each occurrence of the one beep alert tone Sets the maximum programmable primary infusion rate of both pumps When the maximum primary rate is 999 or higher the maxim
173. oes not operate smoothly clean or replace in accordance Preventive maintenance tests Perform the appropriate tests as detailed in Section 7 3 Operational Checkout 07 19 A1 729 Hospital Service Procedures 2 4 07 19 A1 729 Section 3 Problem Checklist Table 3 1 is a list of problems checks and corrections to aid in the diagnosis of possible pump malfunctions Corrections contained in the table can be performed without opening the device housing Review this list whenever a condition exists that does not appear to be normal Perform the specified checks and corrections If the problem cannot be corrected remove the device from service Troubleshoot it in accordance with Section 5 and repair it in accordance with Sec tion 6 PROBLEM The plug icon is not lit when the device is plugged in or the battery icon is lit when the device is plugged in The device fails to run on the internal battery No LCD dis plays appear A pump stops with BATTERY LOW alarm The audible alarm volume is not loud enough Table 3 1 Problem Checklist CHECKS CORRECTIVE ACTION Check the tightness of the power lug into the AC outlet Press the power plug firmly into the grounded AC outlet p Check the rear power fuses under the power cord cap Check the AC outlet for proper voltage Check the line cord for continuity After recharging the
174. of the device pins 1 4 and 9 respectively The Nurse Call feature may be used when the device is connected to a computer however provisions must be made at the communications port to connect both options simultaneously Specifications for the 9 pin D connector are listed under Technical Specifications 1 2 07 19 A1 729 General Description 1 3 Technical Specifications Catalog Code Number Description Administration Set Characteristic Dual channel linear peristaltic volumetric infusion pump Baxter s standard administration set with 5 suffix 5 mL hr or programmed rate whichever is less Battery 12 Volt 3 2 Ah sealed lead acid Battery Life Approximately 6 hours with one pump running at a rate from 1 to 1400 mL hr using a fully charged battery Approximately 4 hours with both pumps running at a rate from 1 to 1400 mL hr using a fully charged battery Battery Recharge 8 hours for 80 recharge AC Power Requirements Power Cord Leakage Current 110 120V 60 Hz 2 75 m 9 0 ft long with Hospital Grade plug Typically less than 50 microamps using UL 544 specified test methods Power Consumption 50 watts Weight Dimensions Flow Rate Range 8 2 kg 18 Ibs 33 W x 13 cm D x 29 H 13 W x 5 1 D x 11 4 H Prima
175. off and back on Turn device off and back on Reset all of PDP Programmed Delivery Profile working data Reset all of PDP CODE CAUSE 87 LVDT reading of upstream occlusion sensor is too high _ 89 Bank switching control circuit failure 90 Checksum error of RATE VTBI and VI data Checksum is not 0 91 Checksum error of Programmed Delivery Profile stored data 92 Checksum error of If failure recurs replace CPU board If failure recurs replace CPU board If failure recurs replace CPU board If failure recurs replace CPU board Turn device off and back on If failure recurs replace CPU board 93 Write data and read data of M5M5165 do not agree 94 Configuration option settings checksum is not 0 Reset all of the configuration option settings in accordance with Section 1 Turn device off and back on Check battery voltage in accordance with Section 5 3 1 Checksum error of alarm log data Checksum error of ROM code Undefined failure code was received from Slave CPU Turn device off and back on Clear the alarm log via the modify configuration mode If failure recurs charge or replace battery Replace CPU board If failure recurs replace CPU board Turn device off and back on Turn device off and back on If failure recurs replace CPU board If failure recurs
176. ore disconnecting the cable 2 Unplug connectors CN401 CN701 and ribbon cable connector CNI F2 Figure 8 3 item 2 from the terminal board 3 Remove three screws Figure 8 3 item 22 securing the terminal board to the rear hous ing 4 Remove the board Note Be sure to unlock the connector flange before connecting the cable and then push it in to lock 5 Reassemble in reverse order Tightening torque for item 22 is 7 kgf cm 6 1 in 1b 6 Perform the Operational Checkout procedures in Section 7 6 3 24 Replacement of Power Transformer 1 Separate the front and rear housings completely in accordance with Section 6 3 1 2 Desolder the black and white wires from the transformer at the fuse holders Figure 8 4 item 28 6 22 07 19 A1 729 Disassembly and Calibration Disconnect 2 pin connector CN1 from the power supply board Figure 8 3 item 18 Remove the transformer by removing two securing screws item 21 Remove the transformer mounting bracket item 9 by removing four securing screws item 23 Reassemble in reverse order Tightening torque for item 21 is 9 kgf cm 7 8 in Ib and for item 23 is 5 kgf cm 4 3 in 1b Caution Be sure to match the color of the wire when resoldering the black and 7 white wires to the fuse holders Route the wires underneath the trans former mounting bracket Figure 8 3 item 9 and the insulation film item 25 under it before replacing the bracket Do not pinch the wires
177. ouching the LCD Equipment 2 Phillips Screwdriver or power screwdriver Indelible ink permanent marker Parts 1 ea LCD cushion Part no PCUSU101 A 1 ea Upgrade Label Part no 072601047 1 Turn off the device and make sure it is disconnected from AC power 2 Separate the case halves as described in Section 6 3 1 the ground wire does not have to be removed Note Carefully lift and remove the pump head wire assemblies on the CPU board if they are routed between the hybrid circuits HIC301 and HIC302 3 Remove the circuit boards from the case Section 6 3 2 Note It is not necessary to disconnect CN201 and CN803 The CPU Display board assembly can be placed beside PUMP 1 6 26 07 19 A1 729 Disassembly and Calibration Figure 6 3 LCD Cushion Placement Inside View Important The LCD cushion is installed on the inside of the front case housing NOT on the LCD 4 Peel off the adhesive backing and install the LCD cushion across the bottom edge of the inset recessed area for the LCD See Figure 6 3 If properly positioned you should be able to feel a ridge the inset edge in the center of the LCD cushion The cushion should also be centered from left to right Ensure that the cushion is not visible in the display window when looking at the outside of the case 5 Remove the adhesive backing from the upgrade label Part no 072601047 and install it between the feet on the front case half Use indelible
178. ource SEC PRO Green No change SECRATE Secondary piggyback information is being GRAM Yellow or SEC VTBI programmed into a pump while it is running Pump will not exit this alert condition until SEC START is pressed 4 SEC RATE 0 Yellow No flow SEC START secondary piggyback infusion cannot be started unless a secondary flow rate is input SEC VTBI 0 Yellow No flow SEC START secondary piggyback infusion cannot be started unless a secondary volume to be infused has been input td 21 A SEC COM Yellow No change None The pump has completed infusing the PLETE secondary and has switched over to the primary infusion settings Pump will not exit this alert condition until any enabled key is pressed FLOW RATE v Yellow No flow PRI Enter a rate within the range selected START through the configuration option The pump cannot be started when Hi Lois displayed in a rate display CHECK Yellow No flow PRI or pump cannot be started when is START displayed in a VTBI display Enter a VTBI within the range selected through the configuration option 07 19 A 1 729 1 19 General Description INSERT SLIDE Table 1 3 Alert Messages No flow or flow if started Flow Status Key Alert Condition Pressed
179. ove the spring retainer Store the removed spring retainers in a safe place in case they are needed in the future Close the pump door to release the latched mechanism 6 3 16 Spring Retainer Installation The spring retainers are installed into the slide clamp slots at the factory to maintain proper ten sion on the springs within the assemblies as well as to help prevent the ingress of fluids into the mechanisms If the spring retainers have been removed you will need to reinstall them prior to operating the device with the Slide Clamp feature off Open the pump door and insert the Slide Clamp Resetting Tool into the slide clamp mechanism until it stops this tool cannot be pushed in fully See Figure 1 2 for the loca tion of the slide clamp slot Press the safety clamp pin to release the slide mechanism This pushes out the tool slightly Carefully remove the tool If the slide clamp mechanism was activated properly the ridges on both sides of the tool should rub against the claws of the mechanism Insert the spring retainer until it locks in place 6 3 17 Replacement of Back Plate 1 Remove the pump door cover in accordance with Section 6 3 4 Remove the back plate cover Figure 8 5 item 16 by removing the screw inside the door item 27 Then remove the 7 screws Figure 8 5 or 8 10 item 26 from the outside of the door Perform this step carefully to avoid losing springs item 18 Remove the 5 springs item 18 and t
180. p 1 or P55 Pump Repair or replace CPU 2 of the Master CPU board remains low 21 Malfunction in frequency Check CN851 Pump 1 or CN852 Repair or replace converter circuitry for Pump 2 for proper connection connectors if necessary occlusion detection P20 and continuity Replace CPU board of Master CPU remains high 22 Malfunction in frequency See Failure Identification Code 21 converter circuitry for occlusion detection P20 of Master CPU remains low 23 P50 IRQ interrupt port Check U101 pin 10 for a high If signal is always high remains high 5 VDC signal replace CPU board 25 Failure in occlusion None Replace CPU board circuit 07 19 A 1 729 Troubleshooting Table 5 1 Failure Identification Codes CODE CAUSE CHECKS CORRECTIVE ACTION 27 Malfunction in slide clamp detection circuit 28 Four air sensors outputs NORM and MIN of both pumps cannot be Check battery voltage in accordance with section 5 3 1 Check CN803 Pump 1 or CN804 Pump 2 for proper connection and continuity Check CN811 Pump 1 or CN812 Pump 2 for proper connection and continuity converter circuitry for air detection A D conversion did not complete in 50 uS selected 29 Two occlusion sensors Check tightness of CN851 Pump UP and DOWN cannot 1 or CN852 Pump 2 for proper be selected connection and continuity 30 Malfunction in A D Turn device
181. p tested After calibration of the fifth pump discard the segments and replace them with new ones 2 Place the device upright If the case is not already opened separate the front and rear housings See Section 6 3 1 but do NOT remove any connectors Plug the pump into AC power Warning When working on an open pump an electrical hazard exists when the pump is plugged into AC power 3 Set the device to Test Mode 2 Press and hold the CLEAR TOT VOL and 2 keys then press either ON OFF CHARGE key Release the ON OFF CHARGE key without releas ing the CLEAR TOT VOL and 2 keys for at least three seconds The pump is in Test Mode 2 when NORM and MIN are displayed on the left side of the message upper dis play If the pump is not in Test Mode 2 turn it off and repeat this step 4 Using the set assembled in step 1 load the fluid filled calibration tubing segment into the pump head and close the door Open and close the pump door two more times and wait two minutes 6 32 07 19 A1 729 Disassembly and Calibration Note 10 11 12 13 14 15 Adjust the NORM value PRI RATE window and the MIN value PRI VTBI window ing VR801 for PUMP 1 or VR802 for PUMP 2 Take the greater of the NORM and MIN values and calibrate to 450 20 430 470 If the lesser value is less than 410 adjust it up so that it is just above 410 Recheck that the greater of the NORM and MIN values is still within 430 470
182. pital Area Designator is displayed for 3 seconds in Pump 1 Message Display if the configuration option is selected The occlusion detection level is momentarily dis played in the message display LEVEL 1 2 or 3 followed by AUDIBLE SWITCHOVER if the Audible Switchover option is enabled If both Auto Restart and Flow Check are selected through the configuration option the message AUTO RESTART appears for one second in Pump 1 Message FLOW CHECK message is displayed when the pump is running Three distinct audible tones sound PRI RATE s and PRI VTBI s are then displayed SEC RATE s and SEC 5 are also displayed if they are not both zero 7 3 2 3 Primary Infusion Test 7 4 Press the PUMP 1 or PUMP 2 key as appropriate to select the desired pump Press the PRI RATE key and enter a flow rate of 100 mL hr on the keyboard Press the PRI VTBI key and enter a volume to be infused VTBI of 10 mL on the board Open the flow control clamp on the administration set Start infusion by pressing the PRI START key If the pump stops with an alarm refer to Section 3 Problem Checklist Let the pump continue to run and proceed to the next step 07 19 A1 729 Checkout 6 While the pump is running check for normal operation without upstream or downstream occlusion alarms and that no air bubbles are seen in the tubing To reset the volume previously infused press the appropriate STOP key PUMP select key and
183. plug it back in Operation should continue without interruption and the BATTERY message should turn off Recharge the battery by allowing the device to remain connected to AC power for a minimum of 16 hours 2 Battery Charging Voltage Check Optional a Perform this check to determine if the charging voltage is correct Disconnect and remove the battery from the device Connect a voltmeter to the pump leads and measure the charging voltage while both pumps are in the KVO mode It should be between 13 7 and 13 9 VDC If it is and the device failed the battery test replace the battery in accordance with Section 6 3 18 If the charging voltage is NOT between 13 7 V and 13 9 VDC check the other power supply voltages as described in Section 6 4 1 and repair and or calibrate the device as necessary 07 19 A 1 729 7 9 Checkout 7 3 9 Panel Lock Test With a pump s running without alerts press the PANEL LOCK pushbutton on the rear of the device for one second Verify that Loc is displayed in the Main Display of the powered on pump s Verify that input from the front panel keys is not accepted except from BACKLIGHT and TOT VOL STATUS Press PANEL LOCK again The Loe message should disappear and input from the front panel keys should be accepted Warning If any of these indications fail to occur troubleshoot the device in ac cordance with Section 5 and repair it in accordance with Section 6 7 3 10 Safety Clamp Test
184. r assy 3 SCREW Pan Head M3X14 SCREW Flat Head M3X10 SCREW Flat Head M4X8 SCREW Truss M3X8 WASHER Pole Clamp Shaft M4 5 SCREW Allen M4X8 COVER Power Cord CORD Power LABEL Caution Japan LABEL Caution Sing LABEL Directions for Use Rev A SLABEE LABEL CSA PLATE Serial Number Aluminum PLATE Serial number Lexan FILM Overlay Serial Number LABEL 24 Hour Service Rev A LABEL Comm Port LABEL Fuse Rev A SCREW Binder Head M3X16 07 19 A1 729 07 19 1 729 Illustrated Parts Breakdown 8 11 Illustrated Parts Breakdown Pump Head 1 Door Assembly Figure 8 5 Item Sve Part Mfg Part Description Qty 8 5 F059120015 059120015 PUMP 1 HEAD ASSY 1 1 2059120016 2059120016 DOOR ASSEMBLEY PI 1 2 CHNDP100 G S047879 1 LATCH Door Assy Pl 1 3 JHNDP100 C S048630 LATCH PI Pee aa 1 4 LPLTP106 A 504440 PLATE Door Latch Label 1 5 LXRZ1003 A 8048882 E RING 1 6 MSPRC101 D S048500 SPRING Door Latch 1 7 OiCMP32T H 504886 sa WASHER 4 0 8 1 8 OiCMP32T L 5048897 4 WASHER 1T 2 9 PMAGT100 B S048498 1 111 MAGNET DoorLatch 1 10 TLABH109 A 07 26 06 029 na LABEL Push 1 11
185. r s s suffix administration set if required Check that ambient and solution temperatures are above 60 F Check for solution spills liquids or residues on the inside of the door and or on the base plate Raise ambient and or solution temperatures Clean all accessible areas with cotton swabs dampened with one of the cleaning agents listed in Table 2 1 Remove fibers or foreign particles Do not use hard instruments for cleaning An INSERT SLIDE CLAMP alert or alarm occurs when the Check that the slide clamp is in the slide clamp slot Push the slide clamp all the way into the slide clamp slot pump door is closed Note The alarm option is available only on pumps running software versions 1 09 or later Check for solution spills liquids or residues on the slide clamp or safety slide clamp assembly Check if the administration set is equipped with the slide clamp designed for use with this pump See the instructions accompanying the administration set 07 19 A1 729 Clean the slide clamp and the safety slide clamp assembly If not use an administration set which has the proper slide clamp for use with the pump Insert the slide clamp into the slide clamp slot before closing the pump door 3 3 Problem Checklist Table 3 1 Problem Checklist PROBLEM CHECKS CORRECTIVE ACTION The safety clamp will not latch Check
186. rated Parts Breakdown Pump 2 Base Plate Assembly w Pump Mechanism Figure 8 13 Item Sve Part Mfg Part Description Qty 8 13 2049120020 2049120020 PUMP 2 HEAD ASSY 1 Note See Figure 8 13 for details on items 1 through 30 1 CCRA1006 A 047875 CLAMP SAFETY SLIDE ASSEMBLY2 1 2 LBRC1006 A 5048426 RETAINER Motor Spring 1 3 LBSHZ101 D S048497 we STOPPER daban 1 4 LPLTM104 D 5048488 WHEEL Encoder c 1 5 LPLTP104 A 5048484 RINGER iru hak Re 4 6 LPLTP104 B S048485 w FINGER 3456 Lu le cs a 4 4 100 5048483 CAM us 8 8 MJNTM100 B 5048454 we COUPLING Motor 1 9 MSPRD102 A 048471 as SPRING MOLE BE ee SS 2 10 NBRGY100 B 048511 BEARING Pumping Finger 9 11 100 5048512 BEARING Finger Box 1 12 NSFTD103 A 5048433 se SHAFT Finger a 1 13 OiCMP32T F 048894 WASHER 2 14 OiCMP32T G 5048895 WAS HER orae I 4 15 PBOX1005 A S048431 COVER Finger 1 16 PCOVP101 B 5048427 iv COVER Encoder Wheel 1 17 PSPAB102 A S048496 SPACER Encoder Wheel 1 18 CPBWMIO5 B S047876 PCB ASSEMBLY 1 19 VHPGP3S2 A S048006 OPTOCOPLER pla a 1 20 RMOTP100 B S04
187. repare the administra tion set according to instructions accompanying the set 2 Spike the solution container and fully prime the set Remove all trapped air bubbles from all set components Hang the solution container such that the fluid level is a minimum of 18 above the top of the pump handle throughout the test Make sure that the tubing is clean and dry before placing it in the pump Make sure that the tubing is placed and seated properly in the guide channel pump mechanism sensors and safety clamp Ensure that there is no slack in the tubing and that it is not kinked or pinched before closing the pump door 3 Load the set into the pump Close the pump door If excessive resistance is felt check that the set is loaded properly through the tubing guides Never use tools or excessive force to close a pump door 4 Place the distal end of the administration set in a container or sink to dispose of pumped solution 07 19 A1 729 7 3 Checkout 7 3 2 2 Self Test Turn pump s on by pressing appropriate ON OFF CHARGE key s Check that the device per forms the following self test The following displays for both channels illuminate momentarily ALARM PUMPING and ALERT LEDs OPTIONS and NEXT indicators COMPUTER CONTROL and MONITOR icons Plug icon or Battery icon is also illuminated depending on the device s power source All segments of the Pump 1 and Pump 2 Message and Main Displays illuminate momen tarily The Hos
188. replace CPU board 07 19 A1 729 5 15 Troubleshooting 5 5 Troubleshooting Chart Table 5 2 identifies specific failures by symptoms rather than failure identification codes Table 5 2 Troubleshooting Chart SYMPTOM One or both pumps cannot be turned on CHECKS CORRECTIVE ACTION Check backup battery voltage in accordance with Section 5 3 1 Check front panel cables for short circuits Check CN601 and CN602 for proper connection and continuity One or both pumps cannot be turned off All front panel keys other than BACKLIGHT and TOT VOL STATUS are disabled One or more front panel keys are not accepted Check front panel cables for short circuits Check CN601 and CN602 for proper connection and continuity Does Loc appear in the Main Display Sometimes this condition is followed by an F49 or F94 code Charge or replace battery Repair if necessary Replace front panel film Replace CPU board Turn device off and back on and try the key again Check front panel cables for proper connection and continuity Press and release PANEL LOCK switch on the rear panel Loc in the Main Display should disappear Replace front panel film Replace Display board PANEL LOCK switch is not accepted Beep does not sound when a key other than BACKLIGHT or SILENCE is pressed when the pump is stopped Check the oper
189. replace the battery to clear the condition Check CNDISP for proper connection and continuity Check CNDISP for proper connection and continuity Audible alarm is always on 07 19 A1 729 Replace Display board Replace Display board Momentarily disconnect battery and reconnect Check F302 or F15 ICP301 Check CN302 CN amp 01 CN751 and CNI F for proper connection and continuity Charge or replace battery Replace F302 F15 and or connectors as required Replace CPU board 5 17 Troubleshooting Table 5 2 Troubleshooting Chart SYMPTOM Audible alarm does not sound CHECKS CORRECTIVE ACTION Turn device off and back on DOOR OPEN alarm occurs while door is closed or does Optional nurse call is always on not occur when door is opened Check magnet on door latch Check CN851 Pump 1 or CN852 Pump 2 for proper connection and continuity If problem recurs replace CPU board Replace speaker Replace pump door latch if magnet is missing Repair or replace connector if necessary Replace CPU board Check CN401 and CNI F for proper connection and continuity Optional nurse call is always off Verify that the Nurse Call feature has been enabled via the addition of a jumper R421 on the terminal PCB Check CN401 and CNI F for proper connection and continuity Replace CPU board Replace CPU b
190. ry compartment and turn them over while taking care not to drop them and then remove the cover 6 Disconnect the two female connectors from the battery terminals 7 Reassemble the battery into the device in reverse order Tightening torque for the five screws is 9 kgf cm 7 8 in Ib Caution Be sure to match up the polarities of the female connectors Red wires must be connected to red marked battery terminal See the battery label on the underside of the battery cover The bat tery must be placed with its connectors up See Figure 8 4 The wires must be placed in the battery compartment Figure 8 4 item 15 so that the red battery terminal is positioned next to the bushing item 21 for the battery harness item 25 07 19 A1 729 6 19 Disassembly and Calibration Be sure to place the battery compartment seal item 20 appropri ately in the groove of the compartment Be sure to place the battery harness behind the printed circuit board and power transformer bracket at left side before placing the battery compartment assembly into the front housing Be careful not to pinch wires between the front housing and battery compartment cover Be sure to place the battery cover seal item 19 appropriately in the groove located on the rear housing 8 Perform the Self Test Section 7 3 2 2 and Battery Check Section 7 3 8 6 3 19 Replacement of Power Supply Board 1 Turn off and unplug the device 2 Separate front and
191. ry program 1 1 999 mL hr in 1 mL hr increments and 1 0 99 9 mL hr in 0 1 mL hr increments Upper limit can be reduced by authorized service personnel Secondary program 1 999 mL hr in 1 mL hr increments and 1 0 99 9 mL hr in 0 1 mL hr increments VTBI Range Air in Line Detection Fuse Nurse Call 1 9 999 mL in 1 mL increments and 1 0 99 9 in 0 1 mL increments for both primary and secondary Upper limit can be reduced by authorized service personnel Factory set to NORM which causes the device to alarm on air bubbles approximately 75uL or larger The MIN setting causes the device to alarm on bubbles approximately 50 uL or larger 0 5 A Slo Blo 9 pin D connector Pin 1 N C normally closed Pin 4 N O normally open Pin 9 Common Contact rating 0 4A at 30 VAC 2A at 30 VDC resistive load internal connection required 07 19 A1 729 1 3 General Description 1 4 Controls and Indicators All controls and indicators are shown in Figures 1 1 1 2 and 1 3 Service personnel should be familiar with the pump s features and operation before servicing the device Items 1 through 9 in Figure 1 1 are associated with Pump 1 The controls associated with Pump 2 are identical and function in exactly the same manner Items 10 through 27 Figure 1 1 are common to the opera tion of both pumps When the word device is used in this manual reference is bein
192. s GJ w v v V vo Mn NAN N 0 wv v v iw O em NL Om an BO 0 08 0 0 0 0000 gt ax O 9 gt gt 5 gt gt gt gt gt gt gt N Figure 10 27 LCD Drivers for Pump 1 10 29 07 19 A1 729 Oj o r o9 e co e 4 Ni 19010 ju cool jaja pico as uo aad v e t Ojo jr e Lind ANVOANMT HON DAGOANMETMORDAGANMEMOKRDAOMNM TIN Q 3 QD QD QD Q3 4D A A 0m m AHH NL INL NL NN m m m Uu UJ UJ uJ UJ UJ UJ UJ MJ CO CO CD CO QD D D OD OO 2 Q CO C U D Q CO Q O ww ww vivi wi viv v v ly La Uu i uUi Ul uj GJ UJ UJ GJ UJ GJ UJ UJ aj GJ I VJ UJ 1 93 1 93 aw 0 gt ces rn fEEXEXoo0oooDooogooouo
193. s s suffix administration set if required Clean all accessible areas with cotton swabs dampened with one of the cleaners listed in Section 2 Remove fibers or foreign particles Do not use hard instruments for Cleaning Check that the door latch roller pin turns smoothly Clean the roller with an approved cleaner Check for possible damage to the door latch latch pin roller or door hinge The backlight is off when the device is running on internal battery power A RATE VTBI or START key is not accepted by the pump Hi or Lo is displayed during Volume Time programming Check if the front panel is locked Loc appears in the Main Display See Section 6 3 5 for instructions on replacing the door latch and Section 6 3 7 for replacing the latch pin Replace the door as described in Section 6 3 6 Press the BACKLIGHT key as long as required to view the pump settings Press the PANEL LOCK switch to remove the panel lock Calculate the rate and verify that it is within the allowable range set by the configuration option A FLOW RATE or CHECK VTBI alarm occurs when Check that the rate or VTBI are within the limits set by the START key is pressed configuration option Enter a rate within the range set by the configuration option or change the maximum rate setting in the configuration option if appropriate Change
194. s alarm open the pump door and insert the slide clamp into the slot Close the door 07 19 A1 729 General Description 1 7 Alerts Alert messages call attention to a condition which will require operator intervention in the near future or indicate that a procedure has been initiated which requires that the operator complete a sequence of keystrokes These alerts are generally cleared by the operator taking the appropriate action Table 1 3 lists the various alerts and possible causes a Alert Message LED Flow Status Key Alert Condition Pressed STOPPED Yellow No flow None Either pump has been left in the STOPPED mode for more than two minutes KVO Green KVO rate None Primary VTBI has been delivered and the PRI VTBI 0 Yellow pump has switched to 5 mL hr KVO rate or programmed rate whichever is lower NEW RATE Green No change SEC Primary or Secondary flow rate is being Yellow until RATE changed while pump is running Pump will procedure is not exit this alert condition until the completed appropriate START key is pressed PRIRATE 0 No flow PRI SEC The pump cannot be started without START entering a primary flow rate BATTERY LOW Green No change None Battery needs recharging The device will with intermittent Yellow stop operating in approximately fifteen audible alert minutes or longer unless it is plugged into an AC s
195. sert remain in place during use See Section 6 3 16 9 Channel Guide Ridges Function as a guide to keep the tubing properly aligned over the pumping fingers 07 19 A1 729 1 9 General Description Figure 1 3 Rear View 1 10 07 19 A1 729 General Description The following items are located on the rear of the device and are shown in Figure 1 3 1 IV Pole Clamp 2 Power Cord Strap 3 Audio Speakers 4 Battery Compartment 5 Fuse Compartment 6 Power Cord 7 PANEL LOCK Switch 8 COMMUNICATIONS PORT 9 VOLUME Knob 07 19 A1 729 Secures the device to the IV pole Stores power cord during battery operation and device stor age For generation of audible alarm and alert tones Allows authorized service personnel easy access to the bat tery EPROMS and battery fuse The power cord cover must be removed to access the fuses Removable only by authorized service personnel Disables all front panel keys except BACKLIGHT and TOT VOL STATUS while the pump is running without alerts The communications port contains wiring for a nurse call jack as well as RS 232 serial communications See the Technical Specifications listed previously in this section Adjusts loudness of audible alarm and alert tones The audible alarm cannot be turned completely off General Description 1 5 Configuration Option Feature This section describes the configuration option feature of the device which allows qualified p
196. six screws Figure 8 2 item 16 that hold the CPU board in the front hous ing 5 Hold the top and bottom center of the CPU board and remove the printed circuit boards carefully from the front housing Note If resistance is felt the top portion of the printed circuit boards may be affixed to the front housing by the adhesive of the seal around the LCDs Incline the bottom center of the CPU board until the seal comes off the front housing before the removal 6 Place the printed circuit boards with the LCD display face down on a dust free flat sur face Be careful not to touch or damage the LCD display Keep the LCD display surface away from dust Take care not to place the LCD display on components such as screws that could damage it 7 Reassemble in reverse order gt Note Be sure to remove any dirt or dust on the LCD or its windows on the front housing before replacing and tightening the CPU board to the front housing Placing the one side of the CPU board under the two connectors CN601 and CN602 first simplifies the replacement of the board Do not pinch the pump head harness and the grounding wire between the pump head fixing brackets Figure 8 2 items 6 and 7 Be sure to reconnect all the removed connectors Tighten the six screws Figure 8 2 item 16 securing the CPU board to 7 kgf cm 6 1 in Ib 8 Perform the Operational Checkout procedure in Section 7 6 6 07 19 A1 729 Disassembly and Calibration 6
197. slide clamp assembly Tighten the two screws Figure 8 9 or 8 14 item 30 to 6 kgf cm 5 2 in 1b Apply a trace of Loctite 211 or 222 to the set screws Figure 8 8 or 8 13 item 27 Place a 0 3 mm flat feeler gauge between the motor bottom surface and the motor hold ing plate Ensure that the edge of the flat feeler gauge is touching the motor shaft Press the motor against the plate and tighten the set screws to 5 kgf cm 4 3 in Ib Loctite Inc 07 19 A1 729 6 15 Disassembly and Calibration Note When the set screws have been properly tightened the screw heads zx will be recessed in the motor coupling and the screw ends will be in contact with the flat surfaces of the finger shaft 2 Install the springs removed in step 6 22 Install pump head assembly into case in accordance with Section 6 3 8 23 Perform the Operational Checkout procedures in Section 7 6 3 14 Replacement of Safety Slide Clamp Assembly 1 Remove pump door cover in accordance with Section 6 3 4 2 Separate the front and rear housings in accordance with Section 6 3 1 3 Remove pump motor in accordance with Section 6 3 13 4 Press the safety clamp pin Figure 8 9 or 8 14 item 6 to close the safety clamp Remove the screw Figure 8 7 or 8 12 item 2 on the right side of the safety clamp arm cover item 10 and remove the arm cover Close the pump door 5 Place the pump head face down and remove the two screws Figure 8 9 or 8 14 item 35 to remov
198. spection mode press and hold the STOP key and the TIME key while pressing the TOT VOL STATUS 1 12 07 19 A1 729 General Description 1 5 2 Modifying the Configuration Option Settings 1 Turn off the device 2 Press and hold either STOP key and the PANEL LOCK switch while pressing either ON OFF CHARGE key The following will occur a The MODIFY CONFIG message appears in the Pump 1 Message Display Note If the message LOCKED OUT is displayed the configuration option set tings can be changed only via computer control See the Program mer s Manual for additional information b The parameter descriptor appears in the first line of the Pump 2 Message Display when the NEXT or SEC START key is pressed c The current parameter setting appears in the second line of the Pump 2 Message Display d The programming displays are blank 3 Press the NEXT or SEC START key to advance to the desired parameter The parame ters appear in the order shown in Table 1 1 4 change the settings enter the desired value on the front panel The selected numeric value will be displayed in the Pump 2 Primary Rate display until the value is locked in by the PRI START key or the next parameter is displayed by pressing the NEXT or SEC START key Note The alarm log for each pump can be cleared via the configuration op tion See Table 1 1 5 To lock in the selected value press the PRI START key The selected value will then be display
199. ss the appropriate pump select key and START key The pump should now begin operation Repeat steps 1 through 6 for the other pump 07 19 A1 729 Checkout 7 3 5 Drive Defect Test Occlusion Check With a fluid filled tube loaded into pump head door closed and all clamps open program the pump for a rate of 1999 mL hr and a VTBI of at least 30 mL Start the pump and allow it to de liver for at least 15 seconds without a downstream occlusion alarm or an F 78 or F 79 alarm If a downstream occlusion or F 78 or F 79 alarm occurs perform the appropriate corrective ac tion in Table 5 1 7 3 6 Downstream Occlusion Testing If a pump fails to detect a downstream occlusion the device must be removed from service and repaired Perform the following steps at room temperature to ensure proper operation of the downstream occlusion sensor 5 1 Prime and load Baxter s suffix standard administration set See Section 7 3 2 1 steps 1 4 2 Start the pump at rate of 125 mL hr and run for 1 minute 3 Fold and completely pinch the tubing just below the pump The OCCLUSION message should be displayed in the Message display the red ALARM LED should flash the audi ble alarm should sound and the pump should stop 4 Repeat the procedure for the other pump Warning If either pump does not respond as described remove the device from service troubleshoot in it accordance with Section 5 and repair in ac cordance with Se
200. static mat or other anti static work surface Calibration tubing part no 3 2 92 479 Precision 0 1 uL gas tight syringe part no S9662 81 or equivalent Precision 250 uL gas tight syringe part no 9662 82 or equivalent Oscilloscope dual trace Tools Razor blade Metric Phillips head screwdriver 0 Metric Phillips head screwdriver 1 Metric Phillips head screwdriver 2 UPP extractor UKOG1020 A Wire harness connector extractor part no UKOG1021 A Slide Clamp Resetting Tool part no 020416132 Torque screwdriver 0 15 kgf cm or 0 20 in Ib Metric ball point Allen wrench 1 5 mm Soldering Iron temperature regulated 600 700 F 20 48 Watts 1 32 tip 6 2 2 Recording the Configuration Option Settings It is necessary to record the configuration option settings and the alarm log data before begin ning maintenance procedures so that the device can be reconfigured properly when maintenance is completed Note When the battery EPROMS or a circuit board is disconnected or re placed or a calibration is performed all the configuration options must be reset See Section 1 5 2 1 Turn on Pump 2 Enter the configuration review mode by pressing the TIME and TOT VOL STATUS keys simultaneously Hold the keys for 1 second 2 Press the NEXT or SEC START key to access each parameter sequentially Record the configuration settings 3 Exit the configuration inspection mode by pressing TI
201. t and re move them Be sure not to cut or nick any other wires during this process Remov ing one cable tie usually frees the cable but in some instances more will need to be removed They will be replaced with new wire ties upon completion of these steps 3 Disconnect the air sensor connector s CN811 and or CN812 from the CPU board Re move the screws that secure the air sensor to the pump head and carefully pull out the air sensor assembly Desolder the green ground wire from the back of the air sensor 4 Desolder and discard the green ground wire from the back of the new air sensor assem bly Part 5048992 for Pump 1 5048993 for Pump 2 if it is present 5 careful not to disconnect the ribbon cable of the slide clamp mechanism during this step Insert the new air sensor connector through the air sensor opening on the pump head and pull the wires all the way through Solder the ground wire to the new air sensor 6 Secure the new air sensor to the pump head tightening torque of 3 kgf cm or 2 6 in lbs and reconnect CN811 This connector is keyed and will only mate in the correct orienta tion Route the wires to their original locations and replace any cable ties removed The number of ties and their locations should approximate the original configuration Trim the ends of all newly added cable ties so that they are flush with the cable tie buckles 7 Perform the calibration in Section 6 4 1 and 6 4 2 8 Perform
202. t by time per volume 1 Program a PRI RATE of 200 mL hr and a PRI VTBI greater than 35 mL 2 Measure the time within 3 seconds that it takes to collect 35 mL 0 2 mL 3 Calculate the flow rate in mL hr by dividing 35 mL by the measured time converted to hours Note The Dynatec Model 404A Flow Analyzer can be used for this method 4 The flow rate should be between 186 0 and 214 0 mL hr 7 3 14 4 Measurement incorporating option 1 Program a PRI RATE of 200 mL hr and PRI VTBI of 35 mL 2 Start the pump and collect the solution in a container of known weight When the pump goes into KVO alert mode stop the pump within 20 seconds Important Stop the pump within 20 seconds after the KVO alert since fluid de livered after the KVO alert adds to the test error 3 Use a calibrated scale with a resolution of 0 1 grams or better to weigh the container and solution Then divide the solution weight by the specific gravity of the solution water s specific gravity is 1 g mL 4 The solution collected should be between 32 5 mL and 37 5 mL 7 3 14 5 One Hour Accuracy Test Note Perform this test if the pump fails tests 7 3 14 1 7 3 14 2 7 3 14 3 or 7 3 14 4 Important Do NOT reuse a tubing segment that has already been used to con duct an accuracy test 1 Connect the device to AC power and power it on 7 14 07 19 A1 729 Checkout 2 Program a PRI RATE of 125 mL hr with a PRI VTBI of 1000 mL 3 Place the dista
203. the Operational Checkout procedures in Section 7 6 3 12 Replacement of Force Sensing Resistor FSA Devices for Tube Misloading Sensors 1 Remove pump door cover in accordance with Section 6 3 4 2 Separate the front and rear housings completely Section 6 3 1 Interlink Electronics Interlink Electronics 6 12 07 19 A1 729 Disassembly and Calibration 3 Disconnect the tube misloading sensors Figure 8 6 or 8 11 items 10 and 11 from the connector at rear top of the pump head assembly by pulling their connector housings Do not remove them by pulling the film 4 Open the pump door 5 Remove two Phillips screws Figure 8 7 or 8 12 item 16 which secure the upstream oc clusion sensor Figure 8 7 or 8 12 item 9 to the pump head base plate Caution Do not scratch the ribbon connectors located above the sensors Scratches can damage the connectors 6 Pull and rotate the sensor 45 clockwise and take it out of the pump head base plate 7 Ifthe left FSR for the pump will be replaced remove the screw Figure 8 6 item 17 holding the latch pin mounting block If the right FSR will be replaced remove the screw Figure 8 11 item 17 holding the latch pin mounting block for Pump 2 Caution Do not damage the base plate the surface of the other tube mis loading detector with the tool Do not reuse the removed tube misload ing detector 8 Remove the tube misloading sensor from the pump head base plate with
204. the lithium battery 6 Install replacement battery in reverse order 7 Verify that the configuration option is set as desired and modify if necessary See Sec tion 1 5 2 8 Perform the Operational Checkout procedures in Section 7 6 3 27 Tube Guide Shim Installation Required Parts Air Sensor Tubing guide shim Part no 722003396 Loctite Prism 454 adhesive Part no 722003397 Cellophane tape Note Open the pump head door and check for a white tubing guide shim or a letter on the door opposite the air sensor If the shim or letter is present it is NOT necessary to perform this procedure Note Make sure the pump is not plugged into AC power Clean the tube guide area on the door with a small paint brush soaked in a solution of dishwater and then rinse with clean water Use a clean dry air source to dry the tube guide area or allow to air dry Loctite Inc 6 24 07 19 A1 729 Disassembly and Calibration 1 Lay the pump on its side opposite this pump head Place the tube guide shim on the tube guide and note the surfaces making contact with the tube guide for the adhesive applica tion on the next step To help handle the shim press a 3 inch piece of cellophane tape onto the shim lengthwise Use the tape to lift the shim from the door Save the tape and shim combination 2 Use the applicator on the tube to apply a thin uniform layer of Loctite Prism 454 adhe sive to the surfaces of the tube guide to which
205. the positioning and seating Position the clamp all the way into open of the slide clamp in the slide the slide clamp slot clamp slot Check if the administration set is If not use an administration set equipped with the slide clamp which has the compatible slide designed for use with this pump clamp Insert the slide clamp into See the instructions the slide clamp slot before closing accompanying the administration the pump door set Make sure the safety clamp arm Exercise the safety clamp by cover is in the full open position opening and closing it several times Check for solution spills liquids or Clean with cotton swabs residues dampened with one of the cleaning agents listed in Table 2 1 Remove fibers or foreign particles Do not use hard instruments for cleaning A CHECK SET LOADING Open the door and check the Load the set properly in the guide alarm occurs when the pump position of the tubing in the guide _ channel door is closed _ channel 3 07 19 A1 729 Section 4 Theory of Operation This section covers the operating principles of the device The theory of operation does not cover the specific circuitry in great detail but provides general information needed to perform fault isolation Active low signals on all schematic diagrams in Section 10 are denoted by an exclamation point preceding the signal name Figure 10 1 is a block diagram of the ma jor components in
206. the shim is to be bonded To achieve a good bond you must apply adhesive to all of the shaded areas See Figure 6 1 ES 5 A 2 f sss PUMP 1 Door PUMP 2 Door gt Figure 6 1 Adhesive Application amp Do 3 Immediately place the shim back onto the tube guide using the tape as a handling aid and apply finger pressure to the corner of the shim at a 45 angle as indicated in Figure 6 2 Apply pressure at the ends as well as at the middle of the shim The tape acts as a barrier preventing adhesive from contacting the fingers PUMP 1 Door PUMP 2 Door Figure 6 2 Pressure Application Points Loctite Inc 07 19 1 729 6 25 Disassembly and Calibration 4 Hold the shim motionless for 60 seconds while continuing to apply pressure 5 Remove the tape and visually inspect the shim for excess adhesive Remove excess adhe sive using a dry cotton swab 6 Ensure that the shim is properly bonded to the door by verifying that there are no gaps between the shim and the tubing guide Use a fingernail to attempt to lift each end and the middle section of the shim to verify that the bond is secure 7 Perform the Operational Checkout procedures in Section 7 6 3 28 LCD Cushion Installation Note These instructions are for devices that exhibit blanking displays Cushions will be installed on the inside of the case to keep the case in terior from t
207. tinuity with an ohmmeter 6 If necessary replace with a new fuse of the same value type and voltage 7 Replace and tighten the fuse caps with a screwdriver Over tightening the fuse caps may cause the fuse holders to break 8 Replace the power cord cover 9 Perform the Electrical Safety Test to verify proper grounding impedance See Section 7 3 13 2 2 Cleaning The device should be cleaned as soon as possible after each use to minimize the accumulation and hardening of spilled solutions The case and front panel may be cleaned with a soft cloth or cotton swabs dampened with a properly diluted cleaning agent listed in Table 2 1 07 19 A1 729 2 1 Hospital Service Procedures Be sure to follow the manufacturer s dilution instructions for concentrated cleaners where appli cable Do not spray cleaning agents directly onto the inside of the pump door the pump mecha nism and the front panel film If these areas require cleaning wipe carefully with a soft cloth sparingly dampened with a cleaning agent listed in Table 2 1 If solution spillage onto the pump ing mechanism or front panel occurs it should be cleaned immediately If necessary contact Product Service at 1 800 Table 2 1 Cleaning Solutions CLEANER MANUFACTURER LpH Septisol Vestal Labs Inc Cidex 7 Surgikos Inc Super Edisonite Edison Chemical Co Bafix
208. tion Do not pinch the ground wire between the housings 6 3 2 k Plug power cord into an AC outlet and check that the Plug Icon is lit If not check for proper connection of CN301 Press an ON OFF CHARGE key and check that the self test is performed correctly If the back up audible alarm sound is not heard check for proper connection of CN751 Unplug the power cord and check that the Battery Icon is lit If not check for proper connection of CN302 Be sure the front and rear housing surfaces are flush before tightening Replace 8 screws Figure 8 4 item 10 and tighten them to 9 kgf cm 7 8 in Ib with a torque screwdriver Replace 2 screws Figure 8 4 item 60 at handle Tighten them to 9 kgf cm 7 8 with a torque screwdriver Perform the Operational Checkout procedure in Section 7 if no other repairs are performed Separation of Printed Circuit Boards Separate the front and rear housings completely except for the ground wire Section 6 3 1 Disconnect the two connectors CN601 and CN602 of the front panel film Figure 8 1 item 4 from the CPU board Figure 8 2 item 3 07 19 A1 729 6 5 Disassembly and Calibration 3 Disconnect the following pump head connectors Figure 8 17 Sheet 1 from the CPU board with the wire harness connector extractor part no UKOG1021 A Pump 1 CN201 CN803 right side and CN851 CN811 left side Pump 2 CN202 CN852 CN812 and CN804 left side 4 Remove the
209. triggered and stops the pumps with vis ual and audible alarms The accompanying audible tone whenever either watchdog function is activated is continuous rather than intermittent 4 1 4 Controllers See Figures 10 21 PPI Block 1 and 10 22 PPI Block 2 The I O controller U601 performs the following functions activating backlight addressing the keyboard and scanning the ON OFF CHARGE key PANEL LOCK switch and LCD drivers and writing display data from the master CPU into the display drivers The other I O controller 0602 performs the following functions controlling the air and occlu sion sensors and activating all LEDs and icons except ALARM and OPTIONS LEDs and key beep It also transfers the slide clamp sensor signals to the master CPU 4 1 5 Multiplexer See Figure 10 23 The occlusion sensing block contains the multiplexer U851 which selects one of the four occlusion sensor outputs in accordance with the address signals from an I O control ler and sends it to the master CPU 4 1 6 Universal Pulse Processor See Figure 10 11 The universal pulse processor UPP is controlled by the master CPU and con verts the following analog signals into digital signals air sensor outputs tube misloading detec tor outputs battery voltages motor currents and the voltage of the CPUs The digital signals are periodically read by the master CPU The UPP generates 2 kHz and 4kHz signals for the audible alarm and key beep and a 1
210. ttery should be replaced per Section 6 3 18 5 3 2 Automatic Test Mode 2 Calibration Mode 2 The purpose of this automatic test mode is to check the calibration of the air sensors and to check the tube misloading sensor outputs Open the door and check for a white tubing guide shim or the letter A on the door opposite the air sensor If the shim or A is present use the air sensor calibration values of 330 565 if the shim or A is NOT present use the calibration values of 400 650 1 Plug the device into a 115 5 0 VAC 60 Hz power source Enter Automatic Test Mode 2 2 Load a Baxter s 5 suffix standard administration set and prime it with fluid Close the pump head door Ambient and solution temperatures must be between 72 and 82 F 22 and 28 3 Open and close the pump door two more times and wait 2 minutes 4 Check the NORM value at PRI RATE window and the MIN value at PRI VTBI win dow Both values should display between 330 and 565 or between 400 and 650 Check above for the proper values 5 Remove the primed tubing and load an unprimed calibration tubing segment and close the door Open and close the door two more times and wait 2 minutes View the NORM value displayed in the PRI RATE location at the upper left of the device s main display Next view the MIN value displayed in the PRI VTBI location at the lower left of the main display Both values must be less than 11 If they are out of sp
211. um secondary rate is 999 At values below 999 the maximum secondary rate matches the value of the maximum 11 Flow Check Display Determines whether the flow check display will appear during pump operation or only when the decimal point key and TOT VOL STATUS keys are pressed simultaneously Setting Options Factory Settings 1 7 7 1 1999 mL hr 1999 mL hr 1 9999 mL 1 OFF 2 ON 12 Baud Rate Determines the baud rate for normal communications between the device and a computer The baud rate is 9600 when the device is in modify configuration mode 13 Computer Control available at power up 14 Hospital Area Designator communications feature 15 Close Clamp Message 300 1200 2400 4800 9600 Determines the type of computer control option Determines the hospital area designator to be displayed upon power ON for 3 seconds These messages can be redefined using the computer Determines whether or not the CLOSE CLAMP message appears with the DOOR OPEN message G FON Disabled 2 Off with Alarm The pump will drop out of remote control when an alarm occurs 3 On with Alarm The pump will remain in remote control when an alarm occurs See the Programmer s Manual for additional information 9999 mL OFF 9600 Disabled HAD no message NICU PICU MED SURGICAL TRAUMA BURN UNIT CARDIAC ICU SURGICAL ICU
212. upstream occlusion sensor Then close the pump door Apply Loctite 211 or 222 to the threads and reassemble the stop in the door Slowly turn it with a screwdriver until the value in the PRI RATE window of the appropriate Main Display is between 3273 and 3277 Knock on the center of the door with the back of fingers and check that the reading does not change more than 2 counts Allow the threadlock to set Remove the thickness gauge and stand the device upright Turn the device off The following procedure confirms that the calibration is correct Load a Baxter s 5 suffix standard administration set prime it with fluid and close the pump head door Ambient and liquid temperatures should be between 72 and 82 F 22 and 28 C Apply an upstream occlusion the appropriate pump on and set Primary Rate to 125 mL hr and Primary VTBI to 50 mL Start the pump and ensure that an upstream occlusion alarm occurs Press and hold the SILENCE and TOT VOL STATUS keys until an Alarm Code appears in the lower right corner of the appropriate Main Display The Alarm Code should be 4 5 or 12 07 19 A1 729 6 35 Disassembly and Calibration 4 Turn off the device and reassemble the pump door cover See Section 6 3 4 6 4 5 Slide Clamp Sensor Calibration 1 6 36 Equipment required 2 channel oscilloscope with input impedance of 10 Megohms or higher DC Voltmeter can also be used Slide Clamp Part n
213. ver in accordance with Section 6 3 4 Remove the two set screws Figure 8 5 item 29 Slide the hinge pins item 14 toward each other and remove the door 07 19 A1 729 Disassembly and Calibration 6 3 7 6 3 8 Install the replacement door assembly in reverse order Note the alignment of the hinge pins and make sure that the tapered ends are pointed toward each other Calibrate the air sensor in accordance with Section 6 4 1 through 6 4 4 Perform the Operational Checkout procedures in Section 7 Replacement of Door Latch Pin Remove one screw Figure 8 6 or 8 11 item 17 that secures the latch pin mounting block to the pump head base plate Install replacement door latch pin and secure with 1 screw Calibrate in accordance with Sections 6 4 1 through 6 4 4 Perform the Operational Checkout procedures in Section 7 Replacement of Pump Head Assembly Separate the front and rear housings completely Section 6 3 1 Disconnect the following pump head connectors Figure 8 17 Sheet 1 from the CPU board Figure 8 2 item 3 with the wire harness connector extractor part no UKOG1021 A Pump 1 CN201 CN803 right side and CN851 CN811 left side Pump 2 CN202 CN852 CN812 and CN804 left side Remove the screw that secures the pump head ground wires Figure 8 2 item 14 to the pump head mounting plate item 6 or 7 Remove the pump door cover Section 6 3 4 Open the pump door and remove one black flat head scr
214. w No flow PGM DELIV CLEAR ALL Yellow No flow PRI SEC attempt was made to start a PDP profile START prior to reviewing all the programmed steps Press NEXT until the first step is again displayed or press OPTIONS to leave the PDP mode CLR The CLR key was pressed after entering the PDP mode to clear all steps Do one of the following press CLR to erase the profile press NEXT to review the rest of the profile press PRI RATE or PRI VTBI to modify this step press OPTIONS to leave the PDP mode 07 19 A1 729 Section 2 Hospital Service Procedures This section contains a table describing preventive maintenance performed on Flo Gard 6301 Dual Channel Volumetric Infusion Pump in the hospital The maintenance procedures outlined in this section may be performed in the hospital If an abnormal condition occurs which is not correctable by performing the following procedures remove the device from service and trou bleshoot it in accordance with Section 5 or return it to Product Service for repair 2 1 Replacement Of Main Power Fuse 1 Plug the device into an AC power outlet 2 Check if the Plug Icon is illuminated 3 Ifitis not replace the fuse Remove the power plug from AC power outlet 4 Remove the power cord cover on the back of the device and unscrew the fuse caps with a small screwdriver 5 Remove the fuses and check them for electrical con
215. y turn VR1 counterclockwise until the voltage between pin 2 red and pin 3 black is 11 5 0 5 Adjust the variable transformer output to 135 VAC and check that the voltage between pin 2 red and pin 3 black is 13 65 0 1 d Turn the device off and disconnect the external circuit 16 Reassemble the device 07 19 A1 729 6 31 Disassembly and Calibration 6 4 2 Air Sensor Calibration Note This section must be performed if the pump head CPU board air sensor door door assembly door latch or latch pin is replaced Verify if a modification to the pump head door is necessary to com plete this calibration procedure Open the door and check for a white tubing guide shim or a letter A on the door opposite the air sensor If the shim or letter A is present the modification was already per formed Proceed to step 1 below If the white tubing guide shim or letter A is NOT present go to Sec tion 6 3 27 to install the tubing guide shim 1 Modify an LV tubing set by cutting the tubing about 6 inches below the first Y site and splicing in a length of calibration tubing Part no 3 2 92 479 using tubing connectors Fully prime the set with distilled water Note This fluid filled tube along with a dry calibration tubing segment will be used to calibrate the pump These sections of tubing should only be used to calibrate five pumps with the tubing moved to an un used section for each pum
216. ziz o o x xix rajas e e AUDO S O oc o wen me ed N N e ww wn Maw wan Nin ne a X o oo gt oo won ow Maen RICTEST R M IREYI1M OCCLCHK Ye 1 LIRQ SYSCLK AIRLVE BATTLVL 2 MISLOAD2A CURR2 VCPULYL MEMLVL MISLOADIB MISLOADZE DIMMER S64KHZ 7 X BAUDO AM lt SYSCLK BATTLVL MISLOADI MISLOAD CURRI gt VCPULYL MEMLVL MISLOADIB MISLOAD28 BAUDO RXRDY TXRDY OCCLCHK GND TXRDY RTCTEST 10 13 Figure 10 11 UPP RTC and SRAM Block P O CPU Board C502 10p C501 8 R GND 07 19 A1 729 07518 4 5 pt gt S gt s 97514 97016 74 14 BEEPBZ lt BEEPBZ 8040 74 14 LALMMDET 2 S 3 0 97540 7520 gt 8 11 GN D V GND ATHPHT ALMPMI ALMEN ALMPMZ BACKBZM ALARMI R770 74HCO2F 74HC14F gt gt gt gt z x R768 Ve TRACE ONLY 1ALMMDET 10 761 1 DAN202U Yc JALMSDET 74HC1l4F aN 76 04 16 ANTALUM an

BAXTER Flo-gard 6301 Infusion Pump Service Manual

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