OrchesTA Model 100 Syringe Pump Service Manual
Contents
1. 4 es SMe RICREA wa p 288 sus ay ST z ni TRILLO n ae etta at K REL 4 far one 001 5119 BENNI 1109 REV 2 ora Motor connector Speaker connector Page 34 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 EJ bal roy Lar 7 DIM IE PR TILEN ha e z S OE SET eg d d ET f Motor Speaker Position Encoder Position Pot T AREA ir LEDs Syringe flange retainer Page 35 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 7 6 Bottom housing reassembly l Reinstall the syringe flange retainer to the saddle with the two screws and washers note that the screws go under the retainer Reinstall the encoder sensor to the bottom housing position the sensor over under the encoder wheel and then secure with the two screws Reinstall the position pot assembly to the bottom housing with the 2 screws The position pot gear must be preset to the encoder gear at a value of QA 1A with the track at the empty position The value can be viewed in the system check mode main menu page 3 of 3 then system check Note position calibration must be performed Reinstall the speaker to the bottom housing with the one screw Reinstall the motor to the bottom housing with the two long screws and washers The motor and its gear must be meshed with the leadscrew gear correctly to prevent excessive drag on the motor This can be checked by using a power2. Improved serviceability with replaceable modular units 2 Description of Hardware System 2 1 Hardware Components The Hardware system is divided into two major sub assemblies S A Top S A Bottom S A A battery pack can be installed or removed externally without a tool The major system components and their interconnection are shown in the SYSTEM BLOCK DIAGRAM See Appendix 1 Page SI of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 The Hardware components are organized as below 2 1 1 Top Housing S A Top Housing Keypad Size Sensor S A AC Inlet S A Communication Port Cable Top Printed Circuit Board PCB amp LCD S A Keypad is mounted on the outside surface of the Top Housing and covered with overlay AC inlet S A and Communication port are mounted on the back side of the Top Housing Size sensor S A mounted on the inside of the Top Housing consists of a potentiometer engaged with a gear to a syringe clamp holding down the syringe barrel to detect the size of the syringe Top PCB S A mounted on the inside of the Top Housing receives the connectors of the keypad size sensor and communication port An LCD display module is mounted on the Top PCB S A A ribbon cable connects and provides communication between the Top PCB S A and Main PCB S A on the Bottom Housing S A 2 1 2 Bottom Housing S A Bottom Housing Syringe Saddle S A Syringe LED S A Speaker S A Main PCB S A Motor S A
3. Set screw Clamp plug Spring Syringe clamp Size Pot Top PCBA LCD Page 28 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 ZIF retainer down locked ZIF retainer up un locked 7 4 Top housing reassembly l Reinstall the ac inlet and communication cable assemblies with the same hardware Secure the green ground cable of the ac inlet to the top housing with the 8 32 screw Place the syringe clamp into the top housing with the concave side of the clamp facing up Reinstall the clamp gear into the clamp Place one end of the spring into the gear and the other end into the clamp plug If the spring needs tightened loosen the set screw and then turn the clamp plug CCW approximately Y to turn and then tighten the set screw Note size calibration must be performed Reinstall the size pot to the top housing by first turning the size gear fully CW Place the keypad ground cable under the size pot bracket and then install the 2 each 4 40 X 3 16 screws The position size gear must be preset to a value of 25 50 with a BD 1 cc syringe loaded The value can be viewed in the system check mode main menu page 3 then system check Note size calibration must be performed If replacing the keypad remove the existing one and then completely remove any adhesive residue left on the top housing with isopropyl alcohol Route the keypad cables through the slot in the top housing Peel the backing from the keypad and place the ke
4. lt 3 gt key to CLONE BASE This programming will take approximately 15 20 seconds and when complete the unit will indicate Page 15 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 UPDATE VERIFY CODE B CAF19200 E BASE CRC B001 WAITING EXIT lt Stop gt Power OFF the 4100 Power ON the 4100 and then unit will proceed through the power on self test and go to MAIN MENU PAGE 1 OF 3 as described above Programming is complete Disconnect the communication cable from the 4100 that was just updated Page 16 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Section 4 ABC Model 4100 Service Manual Spare Parts and Tool Equipment List Spare Part List Battery pack 001 5104 PO Line cord 120V US hospital grade 200 0061 Line cord 120V US 200 0060 gt S Line cord 240V 200 0062 S Overlay ONO Keypad SOON LCDS OOST Lens ooo ooo Main PCB Assembly 120V 001 5950 Main PCB Assembly 240V_ 0001 5951 Top PCB Assembly 001 5111 __ ____ Force Sensor Assembly 001 SHA Top Housing Assembly 1001 5100 Track Transducer Assembly 001 5112 Speaker Assembly 001 5211 PO Potentiometer Assembly 1001 5202 Top Cable Assembly 0001 5206 Case seal 001 0050 Transducer housing seal 001 0022 PO Syringe flange retainer 1001 6010 Rubber foot 00031 ____ Retainer cluster gear 1001 0040 PO Cup seal N04 Ground ring 000 0432 ff Seal cove
5. Motor Motor Mount Motor Pinion Cluster gear Leadscrew Sub system Leadscrew Leadscrew Gear Leadscrew Bushing Leadscrew Bearing Position Sensor Sub system Position Pot S A Position Encoder S A Position Encoder Wheel Pinion The Position Pinion engaged with Position Gear Rack assembled onto Track to monitor the proper track movement The Position Encoder Wheel provides signal for the Encoder and drives the Position Pot Track Transducer S A Track Position Gear Rack Clutch Sub system Clutch Half Nut Pair Clutch Cams Clutch Tube Clutch Pusher The cutch halves can be opened to engage or closed to disengage with Leadscrew via a Clutch Handle in the Plunger Retaining Sub system Page 52 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Transducer Sub system Transducer Housing Transducer Housing Cover Transducer Plate Force Transducer Force Transducer PCB S A Force Sensor Cable The Force Transducer is mounted on the Transducer Plate to detect the pushing force at the back of the syringe plunger The Transducer PCB amplifies the transducer signal and also has a encoder to detect the syringe plunger detector These two signals are sent to main PCB via Force Sensor Cable Plunger Retaining Sub system Retainer Housing Retainer Bars Retainer Cluster Gear Clutch Handle Clutch Torsion Spring Syringe Plunger Detector Clutch handle engages cluster gear to move the retainer bars to secure the syringe p
6. TEACHER the screen will list TEACHER at the top and SENDING DATA at the bottom The STUDENT unit should now list RECEIVED DATA CONN at the bottom At the TEACHER unit press the 3 key to copy the options from the TEACHER to the STUDENT unit Note at the TEACHER unit lt 5 gt to COPY PROTOCOLS lt 1 gt to COPY OPT amp PROT Press the Stop key 3 times on the STUDENT unit to exit and get back to MAIN MENU PAGE 3 OF 3 You can verify the options are the same as follows From MAIN MENU PAGE 3 OF 3 lt l gt VIEW OPTIONS then Enter The bottom of the screen will list a CRC code this code should match between the TEACHER and STUDENT units You can also see and page through the options by pressing the Menu key Use the Stop key to exit out of VIEW OPTIONS Page 13 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 3 4 Software Update This will allow updating the software from one master Model 4100 to another Model 4100 The master 4100 must be programmed by Atlanta BioMedical Connect the Communication Cable between the master 4100 and the 4100 to be updated Master 4100 Power ON the unit and then press the Menu key twice to get to MAIN MENU PAGE 3 OF 3 Press key lt 5 gt BIOMED SERVICE then the Enter key Key in code 7319 then Enter key Screen should indicate CLONE CODE lt 1 gt CLONE APPLICATION lt 3 gt CLONE BASE USE TO SELECT ITEM EXIT lt Stop gt 4100 to be updated Hold
7. battery charging circuits and motor driver logic circuit Motor driver uses voltage VA directly d VSN SV is generated by a regulator for the power to Force Transducer PCB ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 2 2 1 2 Microprocessor System 1 Microprocessor ST Microelectronics uPSD 33334DV 40U6 1s used It has the following features a Fast 8 bit 8032 core microprocessor with reduced machine cycle time per instruction with relatively low power consumption Variety of peripherals b Two UART ports for serial communication c Three 16 bit standard 8032 timers d 256K byte Main Flash Memory divided into Eight 32K byte sectors for program code and archived history records e 32K byte Boot Flash Memory divided into Four 8K byte sectors for booting code and storage for system parameters library and current history records f 8K byte Static RAM SRAM for general purposed use It can be made non volatile with battery back up g Very Flexible Address Decoding Circuit to allow dynamic configuration of memory during boot up and normal operation h Built in JTAG circuit to simplify Software Debugging without expensive Emulator 2 Additional I O Ports The microprocessor does not provide enough I O port lines to control various circuits A Programmable Peripheral Interface chip PPI Intersil 80C55A provides additional 24 I O port lines 3 System Clock A 11 0592MHz crystal is used
8. down the Menu key and then Power ON Screen should indicate BASE VERSION 01 01 or newer version REV DATE 09 01 2011 or newer date CRC EA57 S N 8000 or newer CRC S N of unit 1 UPDATE VERIFY CODE USE TO SELECT ITEM REMOVE POWER TO EXIT Press the 1 key Screen will indicate UDPATE VERIFY CODE EXIT lt STOP gt Master 4100 Press the 1 key to CLONE APPLICATION The master 4100 will indicate SENDING DATA The 4100 being programmed will indicate date being received Page 14 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 The programming will take approximately 2 3 minutes When programming is complete the 4100 that was being programmed will sound the audio alarm briefly Then the middle of the screen will indicate 2 CRC COM B001 B001 B001 7B65 7B65 7B65 The master 4100 will now indicate CLONE CODE lt 1 gt CLONE APPLICATION lt 3 gt CLONE BASE USE TO SELECT ITEM EXIT lt Stop gt Power OFF the 4100 that was just programmed Power ON this 4100 The screen will indicate ABC 4100 SYRINGE PUMP VERSION version just programmed MM DD YY YY date of this version S N 8000 SELF TEST Then the unit will proceed to MAIN MENU PAGE 1 OF 3 Programming is complete If the unit indicates WRONG BASE VERSION THEN PRESS lt Enter gt Press the Enter key on the 4100 The unit will indicate UPDATE VERIFY CODE B WAITING EXIT lt Stop gt At the master 4100 Press the
9. with microprocessor and to generate the baud rate for serial communication 2 2 1 3 Real Time Clock Dallas Real Time Clock IC DS1337 is used to provide system real time clock It uses 32 768KHz watch crystal to provide signal to Counter IC 4060 to generate 32Hz and 2048Hz signals 32Hz signal is constantly compared with system clock to assure its accuracy 2048Hz signal is for the audio system malfunction alarm 2 2 1 4 Motor Driver Circuit Allegro IC A3965SLB is designed for battery operation with low logic supply current It uses PWM Pulse Width Modulation method to control the power to the Stepper Motor With this feature the motor current consumption at low infusion rate can be greatly reduced to save battery power while providing more than ample power to drive the specified load Page 55 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 2 2 1 5 Alarm LED Circuit 1 Watchdog Circuit A mono stable logic IC 4538 serves as watchdog circuit It will trigger system malfunction LED alarm and shut down motor power if it does not receive pulses from microprocessor within a specified time period 2 Audio alarm Circuit Audio amplifier TI TPA301 and a Speaker provide the audio alarm The microprocessor generates a variable frequency signal to the amplifier to generate variable frequency alarm Logic IC 4052 and resistors provide 3 volume settings Low Normal High for the alarm 3 LED Circui
10. 00 Service Manual P N 6 011 0002 1 Carefully remove the keypad from the top side of the top housing Remove any adhesive from the top housing that may have been left behind using isopropyl alcohol 4 Removal of the size potentiometer and syringe clamp Tools required 5 64 hex driver Phillips 1 screwdriver Disconnect the size flex cable from connector J3 Remove the 2 screws that secure the size pot bracket to the housing Loosen the set screw securing the clamp plug at the left side of the housing Remove one end of the spring from the clamp plug Remove the other end of the spring from the clamp gear Remove the gear from the housing Remove the syringe clamp from the housing 5 Removal of the ac inlet and communication cable Tools required 5 16 inch open end wrench Phillips 2 and 1 screwdriver 19 mm open end wrench Remove the screws and hex nuts that secure the ac inlet to the housing Remove the ac inlet from the housing Note there is a seal cover on the AC inlet Remove the large hex nut from the inside of the communication port connector Note There is a plastic black ring and then an O ring on the communication port connector Remove the communication port cable from the housing Reference the following pictures for the top housing Page 27 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Overlay Keypad under overlay AC inlet ground cable AC inlet Communication cable
11. 9 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Soe 5 EEG roe a With a syringe loa tatus should be YES De tte ati in If this 1s not correct recheck the timing of the gear in step 16 Page 50 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Section 8 ABC Model 4100 Service Manual Theory of Operation 1 Introduction ABC Syringe Infusion Pump Model 4100 provides a continuous or bolus infusion in neonatal and pediatric intensive care anesthesia adult critical care or any other area where the pump use can be monitored or supervised by a trained healthcare professional Syringe pumps are typically used when safe and precise administration of fluids contained inside a syringe is required Infusates include drugs antibiotics lipids blood blood products enteral solutions or other therapeutic solutions The pump must be friendly to the user and easy to operate Various sensors are required to minimize user error or to detect questionable device operation to enhance patient safety The design of this new syringe infusion pump attempts to include the following features Front syringe loading and one hand operation to actuate clutch and to secure the syringe plunger Wider size sensing range 1cc to 140cc and higher motor driving torque and rate Battery pack can be removed externally Metal Housing for durability and rigidity Water resistant seals
12. ME CLOCK YEAR YY 12 MONTH MM 06 DAY DD 10 0 AM 1 PM 00 HOUR HH 07 MINUTE MN 05 ENTER YY 12 PROGRAM OR USE AV THEN PRESS lt ENTER gt Change the appropriate settings as necessary 3 2 Programming the Options From the MAIN MENU PAGE 1 OF 3 go to MAIN MENU PAGE 3 OF 3 then lt 3 gt PUMP DEFAULTS and Enter Use code 4321 and Enter There are 2 programming options pages and one page of Alarm Alert options The options are OPTIONS Page of 2 lt l gt SYRINGE MFGER lt 2 gt USE B D ICC LL lt 3 gt DELIVER LIMIT lt 4 gt BOLUS ENABLED Page 10 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 lt 5 gt STAND BY MODE lt 6 gt MAX RT ML HR lt 7 gt PLUNGER FORCE lt 8 gt LOCK STAND BY lt 9 gt LAST SETTING Use the Menu key to go to the next options screen OPTIONS Page 2 of 2 lt l gt TOTAL UNIT lt 2 gt RATE INPUT lt 3 gt USE ALL MODES lt 4 gt DISPLAY CLOCK lt 5 gt REVERSE MOTOR lt 7 gt ENTERAL CHECK lt 8 gt LOCK START UP lt 9 gt LOCK CRTE PROG lt 0 gt LOCK TEMP ADJ Use the Menu key to go to the ALARM ALERT OPTIONS screen lt l gt ALARM VOLUME lt 2 gt ALARM FREQ lt 3 gt ALARM DELAY lt 4 gt STOP ALARM lt 5 gt EMPTY ALARM lt 6 gt LOW BATT ALARM lt 7 gt NEAR EMP ALARM lt 8 gt NEAR EMP DELAY lt 9 gt BOLUS COMPLETE Use the number keys to select an option then again a number key to select an item and then the scroll
13. Service Manual ABC Syringe Infusion Pump Model 4100 Atlanta BioMedical Corporation 305 Shawnee North Drive Suite 250 Suwanee GA 30024 770 904 3766 Always Best Care Copyright by Atlanta BioMedical Corporation All rights reserved Contents of this publication may not be reproduced in any form without the written permission of Atlanta BioMedical Corporation Printed in the USA Page 1 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 ABC Model 4100 Service Manual Table of Contents Section 1 Introduction Warnings Cautions 3 Section 2 Punctonal Teste essensen eean 5 Section 3 Programming Options seen eee e eens 10 Section 4 Spare Parts and Tool Equipment List 17 Section 5 Cobra 19 Section 6 Alarm Error Codes eiris 22 Section 7 Se PVC REDAT eaii 23 Section 8 Eneor oEOperdlon apii dirai SI Page 2 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Section 1 ABC Model 4100 Service Manual Introduction Warnings Cautions This manual contains the technical service information for the ABC Model 4100 Syringe Infusion Pump The purpose of this manual is to provide the necessary technical information for servicing troubleshooting and repair of the Model 4100 This manual is intended for use by trained biomedical technicians who are authorized by their medical facility to perform se
14. T FORCE and PLUNGER DETECTED 6 Completely squeeze the clutch lever and move the track all the way in the POS reading inches should be less than 030 IN Move the track all the way out and the reading should be between 5 570 5 630 IN 7 With a BD I cc syringe loaded the SIZE reading should be between 15 80 17 80 and Mono 1 should be 15 25 17 25 With a BD 60 cc syringe loaded the SIZE reading should be between 49 75 51 75 Mono 60 should be 49 80 51 80 Gently release the syringe clamp to its resting position 8 The BATTERY voltage will indicate the voltage charge of the battery 9 The FORCE is a reading of the force sensor with no syringe loaded no force the reading should be close to 0 LB Apply some finger pressure to the transducer plate and the force reading should increase 10 The PLUNGER DETECTED with no syringe loaded should be NO Load a syringe and the PLUNGER DETECTED should be YES Remove the syringe and it should change back to NO 11 TEST LED ALARM Press the Select key and the LEDs should flash and the audio alarm should sound Note that the System Malfunction LED and audio alarm should be activated for a very short interval at the end of the test Check note the battery voltage during this test if the voltage is less than 4 8V the battery may need to be charged Page 5 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 12 Press the Stop key to exit the SYSTEM CHECK and go
15. UTIONS The Model 4100 may be cleaned externally with the following Isopropyl Alcohol Clorox Cleaner with Bleach Sporicidin Cidex OPA Soap water Insure that the battery pack is installed in the Model 4100 prior to cleaning Tighten battery thumbscrew by hand DO NOT overtighten Clean by pouring or spraying the cleaner onto a soft cloth not directly onto the Model 4100 then wipe the unit clean Do not use strong detergents organic solvents or solutions containing ammonium chloride to clean any portion of the Model 4100 Do not immerse the Model 4100 Avoid spills and inadvertent fluid entry into the Model 4100 housings Do not autoclave or gas sterilize the Model 4100 Page 4 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Section 2 ABC Model 4100 Service Manual Functional Testing 1 Install the battery 2 Press the Power ON key and the unit will proceed through a power on sequence displaying the software version date and the S N the LEDs should flash and then the display should indicate MAIN MENU PAGE 1 of 3 3 The battery LED should be flashing yellow 4 Connect the line cord and check that the unit battery LED 1s flashing green or steady green if battery fully charged Disconnect the line cord and check battery LED is flashing yellow 5 Press the Menu key twice to get to MAIN MENU PAGE 3 of 3 select enter lt 9 gt SYSTEM CHECK The display should indicate reading for POS SIZE BAT
16. YSTEM BLOCK DIAGRAM Page 62 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1
17. and tested for any of the occlusion forces listed in the table LOW NORM MID or HIGH Reference section 8 2 4 in the Operations Manual for temporary adjusting the occlusion plunger force 4 Plunger driver test Load a BD 60 syringe set a delivery limit of 50 mL and a rate of 1500 ml hr Prime the syringe to approximately the 55 mL mark on the syringe Measure with a caliper the distance between the right edge of the clear syringe clamp and the transducer plate record this reading Start the delivery and allow the unit to deliver until the DELIVERY LIMIT alarm occurs Measure the same distance between the syringe clamp and the transducer plate Subtract this reading from the first reading this difference should be 3 473 to 3 615 inches Page 7 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 e g 4 495 minus 0 945 equals 3 550 Flow rate accuracy with displacement measurement use this chart for any of the other syringes and flow rates B D Size 1 3 S VINC 0 44049 1 47036 2 86731 4 15229 7 23958 9 29884 14 10862 MONO Size 1 38 8S 60 140 TERU Size 1 3 S 0 20 30 60 __ VINC 0 44086 1 59779 3 37154 4 97965 8 09982 10 6451 16 89392 BDMF size S ___ VINC 0 46512 1 59575 2 73973 4 28266 ABC size do VINC 28 72713 _ _ O Unit for VINC is ml inch VL ml Volume to be de
18. back to MAIN MENU PAGE 3 of 3 then press the Menu key to get to MAIN MENU PAGE 1 of 3 13 Select Enter ML HR mode then Select Enter either BD or MONO as the syringe MANUFACTURER 14 Load a BD or Mono 60 syringe confirm that the unit recognizes the size Enter 0 for DELIVER LIMIT and 0 for BOLUS enter the max rate should be 1500 for BD 60 or 1497 for Mono 60 as default values Then press and hold the Prime key to prime the priming should only be approximately 5 seconds and the audio alarm should then turn on and the display should indicate RELEASE prime KEY Then press the Deliver key to run the unit at the max rate for a full delivery Check that the unit runs to SYRINGE EMPTY with audio alarm The syringe should be empty If any other alarms or errors occurred refer to the alarm error chart This functional testing tested all the basic functions of the unit The next section lists more detailed testing 1 Power on the unit 2 Syringe size recognition test Program the unit for BD syringe then load a BD 10 mL syringe and check for syringe recognition Press the Go Back key remove the 10 mL syringe Then incorrectly load a BD 5 mL syringe by loading on top of the syringe finger tab Check that the unit does not recognize the syringe and indicated invalid size Load the 5 mL syringe correctly and check syringe recognition Remove the 5 mL syringe Correctly load other syringes and check size recognition Press the Go Back key 3 ti
19. ck or replace the force sensor assembly Error code 65 or 66 Check that the clutch is closed Perform POSITION calibration Check that the position encoder and position potentiometer are securely assembled to the bottom housing Error code 62 or 63 Contact Atlanta BioMedical Corporation Any other error codes Contact Atlanta BioMedical Corporation that are not listed here Page 22 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Section 7 ABC Model 4100 Service Manual Service Repair 7 1 Final Unit Disassembly The following steps must be performed at an ESD safe workstation Reference pictures on next page for instructions below 1 Disconnect the line cord ac power from the unit and remove the battery pack from the unit 2 Move the track in to the empty syringe position 3 Remove the six screws securing the bottom housing to the top housing Note that each screw will have a plastic cup seal retain this on the screw There 1s also a ground ring over each screw retain these also on the screws You do NOT need to remove the 3 saddle screws at this time 4 Carefully start to remove the top housing from the bottom housing 5 Disconnect the flat ribbon cable from the main PCBA disconnect the 3 pin ac cable connector from the main PCBA 6 Remove the one screw securing the green ground wire 7 Completely remove the top housing from the bottom housing Carefully remove the case seal do not
20. e BD 5 ml syringe and repeat above followed by the BD 20 ml BD 60 cc and lastly the Mono 140 cc syringe Press the Stop key to exit SIZE calibration Press the Stop key a second time to exit the SENSOR CALIBRATION mode Size test Go to MAIN MENU PAGE 1 of 3 Select any appropriate syringe manufacturer Load each syringe size and check that the size 1s recognized If not repeat the size calibration procedure above Page 20 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Position calibration From MAIN MENU PAGE 3 of3 Press the lt 5 gt key BIOMED SERVICE then the Enter key Enter the biomed access code 9876 and press the Enter key Then key lt 1 gt SENSOR CALIBRATION Press the lt 2 gt key for POSITION calibration Unit will be displaying POS 0 and hex numbers dependent on track position Manually move the track all the way in to the empty position and keep the clutch lever squeezed press the Enter key Move the track out place the ruler onto the saddle with the 1 3 inch line at the front edge of the saddle Move the track until it just contacts the edge of the ruler keep the clutch lever squeezed press the Enter key Then move the track farther out and place the ruler 2 3 inch line at the front edge of the saddle Move the track in to just contact the edge of the ruler With the clutch lever squeezed press the Enter key Then move the track all the way out and while keeping the clutch lever squee
21. eth of the retainer bar If the teeth do not line up rotate the gear counter clock wise to line up the gears 17 Check that the retainer bar is still up against the transducer front plate oPatRrarir Page 46 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 18 Install replace the long retainer bar Place the retainer bar completely to the left in the black retainer top The bar should be up against the stop on the front of the retainer 20 Loosen the bottom hex screw in the trandsducer housing Place the centering tool through the hole in the housing and then into the top hole of the transducer Then tighten the bottom screw Remove the centering tool Page 47 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 21 Rotate the plunger cam so the arm is pointing to the back the slot on the cam should then be pointing to the front 22 Place the transducer seal into the hole of the transducer housing Then install the transducer plate retainer housings onto the transducer housing Engage the pin on the retainer housing with the slot in the plunger detector cam Secure the plate to the housing with the remaining hex head screw Reconnect the transducer cable to the connector lock latch the connector and secure the ground portion of the cable to the housing with the screw 23 With the retainers back against the plate check that the cam arm is centered in the plunger
22. he 2 screws Squeeze actuate the clutch lever and slowly and carefully pull the track off of the leadscrew and the bottom housing Remove the screw that is securing the track green ground wire to the bottom housing Page 37 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 3 Leadscrew removal Page 38 of 62 Tools required 2 each 7 16 open end wrenches Use one wrench and retain the hex nut at the gear end of the leadscrew Loosen the other hex nut just inside the bottom housing at the end of the leadscrew Unscrew remove the leadscrew from the gear nut Check that the wave spring washer is retained If removing the leadscrew gear simply pull off Note the 3 part bearing next to the gear Reference the following pictures for the track and leadscrew Saddle 3 screws Transducer housing ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 ZIF connector Flex cable ae gt Screw securing flex ground cable Note saddle removed for clarity Flex cable Saddle Ground wire Track ground wire Page 39 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Saddle ground wire Track ground wire Wave washer Loctite 242 threadlocker Leadscrew hex nut and gear hr Page 40 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 3 part bearing Force sensor assembly Twa N 7 8 Leadscrew and track reassemb
23. he flex cable from the connector Disconnect the LED flex cable from J8 Disconnect the force flex cable from J2 Disconnect the encoder flex cable from J5 Disconnect the position pot flex cable from J4 Remove the 5 screws that secure the main PCBA to the bottom housing Note the middle screw is longer that the other 4 Start to remove the PCBA from the housing On the bottom side of the PCBA disconnect the speaker from J12 and the motor from J6 Completely remove the PCBA from the housing Page 31 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 4 Removal of motor assembly Tools required Phillips 1 screwdriver Remove the 2 screws that secure the motor to the bottom housing Remove the motor from the bottom housing 5 Removal of speaker assembly Tools required Phillips 1 screwdriver Remove the one screw that secures the speaker bracket to the housing Remove the speaker and bracket from the bottom housing Remove the speaker from the bracket by peeling off the double sided tape 6 Removal of the position potentiometer pot Tools required Phillips 1 screwdriver Remove the 2 screws that secure the pot bracket to the bottom housing Remove the pot and bracket from the bottom housing Remove the hex nut that secures the pot to the bracket Remove the pot from the bracket retain the lockwasher d Removal of the encoder sensor Tools required Phillips 1 screwdriver Remove the 2 screws
24. ide the pump 2 4 1 Syringe Barrel Size Sensor Top Housing A potentiometer mounted with size sensing pinion engaging with the gear to the syringe clamp to translate the syringe barrel diameter to an analog signal to determine the size of the syringe 2 4 2 Syringe Plunger Force Sensor and Detector Transducer Housing S A 1 Force Sensor Force Sensor is a double beam aluminum part with a strain gauge sensor It is used to sense the force by Transducer plate pushing the syringe plunger 2 Plunger Detector This detector senses the presence of the plunger detector arm to determine if the syringe plunger is properly retained by the plunger retainer bars 2 4 3 Motor Shaft Rotation Sensor Main PCB S A An opto interrupter mounted on the underside of Main PCB S A senses the vans of the disc mounted on the motor shaft to determine if motor is turning at proper speed and correct direction 2 4 4 Track Position Sensors Bottom Housing 1 Position Opto Encoder A pinion encoder wheel with bars and gaps engages the gear rack on the track to translate the movement of the track The bars and gaps on the encoder is sensed by an opto interrupter to provide a digital signal for the incremental movement of the track 2 Position Potentiometer A potentiometer mounted on the position pot gear engaging with the pinion encoder provides an analog signal of the absolute positional information of the track 2 5 Handling Different AC Voltage
25. install the Saddle to the Bottom housing using the 3 saddle screws ensuring that the plastic Cup Seals are over them Note Position calibration must be performed 7 9 Retainer cluster gear and shoulder bushing removal and installation Tools required Philips 0 screwdriver l 5 32 hex driver 3 32 hex driver Power off the unit disconnect the line cord from the unit Place the unit with the plunger retainer extended toward you 2 Remove the 2 screws securing the cover to the transducer housing 3 j 4 Remove the Phillips screw securing the transducer ground cable Then release the latch on the ZIF connector disconnect remove the cable from the connector Page 42 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 4 Remove the top hex head screw this will allow the front plate and retainer housings to be removed from the transducer housing 5 Turn this assembly over and remove the tamper labels if present then remove the 4 screws securing the retainer bottom a 6 Remove the long retainer bar remove the short retainer bar remove the gear If plastic gear this will not be reused va Page 43 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 7 Place the front plate and retainer top right side up with the front plate away from you ee 8 Remove unhook the spring from the pin in the retainer top Then slide the front plate
26. keys to select and then confirm with the Enter Key Press the Stop key to exit back to the options page Note The last two lines of the LCD display operational instructions and status information From page of 2 on the options page press lt 1 gt to select syringe manufacturer the choices are lt l gt B D lt 2 gt MONOJECT lt 3 gt TERUMO lt 4 gt B D GLASS Page 11 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 lt 5 gt ABC Press the Menu key to select the ENTERAL SYRINGE s the choices are lt l gt EIBD B D amp ETIP lt 2 gt ETMN MONOXKETIP lt 3 gt BAXA NeoThrive lt 4 gt NEOM NeoMed lt S gt AMP Ameritus lt 6 gt VYGO Vygon lt 7 gt ACAC Acacia Then lt 4 gt key for NEOM then the arrow keys or the Select to choose Yes or No and then confirm the entry with the Enter key Press the Stop key to exit back to the options page In this manner if your facility only uses NeoMed syringes you can choose Yes for NEOM and No for the other syringes and then the unit will only be set for NeoMed syringes On page 1 of 2 on the options page press lt 2 gt to use BD Icc luer lock syringe the choices are YES or NO this can be chosen using the scroll keys or the Select key Use the Enter key to confirm your choice If your facility uses BD 1 cc luer lock syringes then this should be set to YES This will avoid any size recognition errors with the BD 3 cc syringe which has an outside diameter simi
27. l keys for power control of the pump The keypad 1s connected to the TOP PCB Buffer and Multiplex IC s 74HC257 74HC05 are used for scanning the Keypad Control signal KEYS from Main PCB is used to read the keypad data to EBUS 2 2 2 5 Latch IC Latch IC 74HC373 is used as expansion of I O port to drive LED indicators and various control signals to LCD backlight RS 232 circuit LE signal enables the data on EBUS to the latch 2 2 2 6 RS 232 driver Converter IC MAX3311E converts the TTL RX TX from the Main PCB to RS232 level for communication port 2 2 2 7 A customized graphic LCD module The LCD module is mounted on the Top PCB The module has 128x128 pixels and with on board controller provides the visual display for user interaction It can also display 16 row 21 character text lines Microprocessor communicates with LCD controller via 8 bit parallel data bus EBUSO 7 and other control signals Page 57 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 2 2 3 Force Transducer PCB S A The Force Transducer PCB provides amplified signal of the Force Transducer and Plunger Detecting signal to the Main PCB 1 Force Sensor Amplifier INA126 is configured as an instrumentation amplifier to amplify the differential signal from strain gauge mounted on the Transducer Plate pushing the syringe plunger A Dip switch is used to adjust the offset voltage of the amplifier 2 Plunger Detecting Opto interrupter se
28. lar to the BD 1 cc luer lock syringe Example From the alarm alert options page press the lt 1 gt key to select alarm volume then the scroll keys to change between normal low and high then the Enter key to confirm the entry A brief sound will occur after confirmation The factory default options can be set with the following instructions Go to MAIN MENU PAGE 3 OF 3 then lt 5 gt BIO MED SERVICE press the Enter key Enter the biomed access code 9876 and press the Enter key Then lt 5 gt FACTORY DEFAULTS Note that the unit will return to MAIN MENU PAGE 3 OF 3 where choice lt 1 gt 1s VIEW OPTIONS 3 3 Duplicate the options configuration and saved programs You will use one unit that already has the options as the teacher unit and the other units that need the options will be the student units Connect the communication cable P N 001 5217 to the comm port on the back of each unit Set up a student unit as follows From MAIN MENU PAGE 3 OF 3 THEN lt 5 gt BIOMED SERVICE then Enter Used code 9876 then Enter Page 12 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Then lt 3 gt TEACHER STUDENT Then lt 3 gt STUDENT the screen will list STUDENT at the top and WAITING at the bottom Set up the teacher unit unit with the options as follows From MAIN MENU PAGE 3 OF 3 THEN lt 5 gt BIOMED SERVICE then Enter Used code 9876 then Enter Then lt 3 gt TEACHER STUDENT Then lt 1 gt
29. livered Rate ml HR x Time HR Displacement inch VL ml VINC ml inch Procedure to determine expected displacement 1 Find VINC with given Syringe Manufacturer Size 2 Determine Volume to be delivered using Volume Limit by multiplying Rate with Time 3 Find the expected Displacement by dividing VL with VINC Testing 1 Load syringe and set up rate and volume limit 2 Prime the syringe Page 8 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 3 Measure the initial track position 4 Start Stopwatch and Delivery 5 Check Stopwatch reading when delivery is stopped to verify the Delivery Time 6 Measure the track position and calculate the displacement the by the difference between the beginning and ending track position readings Confirm that the displacement is within specification Di Leakage current test Connect the unit to the leakage current tester Power on the unit Measure the leakage current to any of the exposed metal screws of the unit the reading should be less than 100uA in both the normal and reversed settings Page 9 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Section 3 ABC Model 4100 Service Manual Programming 3 1 Setting the Real Time Clock From the MAIN MENU PAGE 1 OF 3 go to MAIN MENU PAGE 3 OF 3 then lt 7 gt REAL TIME CLOCK and Enter Use code 6543 and Enter Screen will list the current clock settings REAL TI
30. lunger onto the Transducer Plate One of the retainer bars is also used to actuate the Clutch halves via the Clutch actuation linkage parts Plunger detector parts provide the status of the engagement of the retainer bars with the syringe plunger The Syringe LED S A Speaker S A Speaker S A Position Encoder S A Position Pot S A are assembled onto the Bottom Housing Then Motor S A and Leadscrew Sub system and Force cable are assembled The Track Transducer S A and Saddle S A are then assembled with the Bottom Housing The Main PCB S A is the last one to be mounted onto the Bottom Housing 2 1 3 Battery Pack Battery Housing Battery pack Battery PCB S A Battery Thumb Screw 2 2 PCB Assemblies 2 2 1 Main PC Board S A This is the brain of the pump It coordinates the AC and battery power for the system The microprocessor drives the motor receives signals from the sensors communicates with LCD module and keypad on the Top S A and controls the audio alarm and LED indicator A Motor shaft rotation sensor and a Battery contact are mounted on the Main PCB Power transformer and fuses are also on the Main PCB Page 53 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 2 2 1 1 Power Supply 1 AC power is applied to the transformer XF1 via a connector and fuses FI amp F2 The output AC voltage from the transformer 1s full Wave rectified to unregulated DC voltage VY 2 A step down switching regulator conve
31. ly 1 Install the leadscrew nut onto the leadscrew and then place the wave spring washer on the leadscrew 2 Install thread the leadscrew with wave washer and nut through the black bushing in the bottom housing and onto the gear nut Check that the wave washer is still centered on the leadscrew and then tighten both hex nuts Place a drop of Loctite 242 threadlocker on the leadscrew nut 3 Position the track onto the bottom housing and leadscrew feed the flex cable into the channel of the track 4 Squeeze the clutch lever to open the clutches and install the track to approximately mid point of travel 5 Remove the 2 screws retaining the transducer plate and then remove the plate 6 Reconnect the flex cable to the ZIF connector and secure the ground portion of the cable to the housing with the screw Page 41 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Check that the transducer housing seal is in place and reinstall the plate to the housing and secure with 2 screws Place the track to approximately full travel to expose the screw point for the track ground wire Reinstall the track ground wire Note The plastic spacer washer goes under the ring terminal Position the saddle under the bottom housing and reconnect the green ground cable Note The plastic spacer washer goes under the ring terminal CAUTION Ensure the green ground cables are reconnected to maintain proper ground safety 10 Re
32. mes to get to MAIN MENU PAGE 1 of 3 If there are any problems with syringe recognition then perform SIZE calibration 3 Plunger force test With force gage Press the Menu key twice to get to MAIN MENU PAGE 3 of 3 select enter lt 9 gt SYSTEM CHECK The display should indicate SYSTEM CHECK with FORCE listed Move the track all the way out and load the spacer onto the plunger retainer Then load the force gage onto the unit Turn on the force gage and zero the reading With no force on the plunger the unit should read 0 0 12 Lbs Slowly turn the knob on the force fixture to apply force to the plunger until 5 Lbs is indicated on the force gage then check the reading on the unit the reading should be 5 0 25 Lbs Then check the Page 6 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 reading at 10 Lbs unit should read 10 0 40 Lbs and then 15 Lbs unit should read 15 0 40 Lbs If there are any problems with the force readings then perform FORCE calibration With syringe Reference appendix HI Occlusion Force chart in the Operations Manual Prepare a syringe half filled with water and load onto the unit Set up program the unit for the syringe being used Deliver start the infusion at maximum rate and then occlude the syringe The unit will run to an occlusion condition Note the reading in lbs in the lower right corner of the LCD this is the occlusion point Note the unit may be set up
33. nd then re tighten the screws Install the battery pack into the unit The unit is now ready for final testing see section 2 Functional Testing Page 25 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 7 3 Top housing disassembly The following steps must be performed at an ESD safe workstation 1 Perform final unit disassembly as noted above 2 Removal of the LCD Top PCBA Tools required Phillips 1 and 0 screwdriver 3 16 nut driver Note The flex cables are connected to Zero Insertion Force ZIF connectors To disconnect pull back on the ZIF retainer and then remove the flex cable from the connector Disconnect the keypad flex cable from connector J2 Disconnect the size flex cable from connector J3 Disconnect the communication cable from connector J6 Disconnect the flat ribbon cable from connector J1 Remove the 4 screws and black spacers from the top PCBA Carefully remove the top PCBA LCD from the top housing Note that there are white plastic retaining washers at the end of the screws Remove the 4 screws spacers and hex nuts that secure the LCD to the top PCBA Carefully separate remove the LCD from the top PCBA 3 Removal of the keypad Carefully remove by peeling off the overlay from the top side of the top housing Carefully remove the keypad flex cables from the 2 pieces of the double sided tape in the top housing Page 26 of 62 ABC Syringe Infusion Pump Model 41
34. nses the presence of the plunger detector arm to determine if the syringe plunger is properly retained by the plunger retainer bars 3 ZIP Connector J2 sends the amplified force signal and the plunger detecting signal to Main PCB via the Force cable 2 2 4 Battery PCB S A The Battery PCB provides the gold plated contact fingers for the battery charging contact from the Main PCB 3 wires BAT GND TEMP from the Battery cell S A terminals and the thermistor inside the Battery cell S A are soldered onto this PCB to be routed to the contact fingers There is a resettable fuse for over current short circuit protection 2 3 Electrical Interconnection 2 3 1 Connection form Top Housing to Top PCB S A 1 Keypad Cable 2 Size sensor cable 3 Communication Port Cable 2 3 2 Connection from Bottom Housing to Main PCB S A 1 Position Encoder cable 2 Position Pot Cable 3 Speaker Cable 4 Motor Cable 5 Syringe LED Cable 6 Force Cable 2 3 3 Connection between Top Housing S A and Bottom Housing S A 1 AC input Cable 2 Top PCB S A Cable 2 3 4 Safety Grounding 1 Ground wire from AC input connector to Top Housing 2 Ground wire from AC input connector to Hex Standoff on Bottom Housing 3 Ground wire from Saddle to Bottom Housing 4 Ground wire from Track S A to Bottom Housing Page 58 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 2 4 Sensors This section summarized various sensors implemented ins
35. nt Thus if more current is used for the motor less current will be used to charge the battery A variable resistor is used to calibrate the total current to a specified value thus limiting the maximum battery charging current Page 56 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 2 2 2 Top Board S A Power and Control signals to the Top PCB are sent from Main PCB via 26 pin flex cable The control signals includes Bus EBUS 0 7 to LCD module Keypad scanning and Latch The major circuits on the Top Board S A are the following 2 2 2 1 Power ON OFF circuit The Power ON amp OFF keys on the Keypad actuate the latching circuit to provide a signal KEYON to Main PCB to signal the Pump Power status 2 2 2 2 TOP PCB Power Supply Circuit The power supply circuit converts power source VA from Main PCB to 5V regulated voltage LCD bias voltages 1 5MX SV is provided by a regulator to supply regulated voltage to the LCD module and the most of the circuits on Top PCB 2 VEE 12 5 for LCD bias voltage is generated from 5MX by voltage converter IC s 2 2 2 3 Backlight Driver Circuit The power to the LCD backlight 1s generated by a switching power supply consisting of controller IC NCP1406 and an inductor Microprocessor controls the light intensity of the backlight OFF LOW and HIGH via Latch 74HC373 2 2 2 4 Keypad circuit The keypad consists of a 4 rows and 7 columns switch matrix and two specia
36. osition keep the spacer in place Turn the force gage on by pressing it s ON ZERO key Place the force gage onto the track and check that the force gage 1s reading 0 lbs Then turn the knob on the gage clockwise to apply force to the transducer plate turn until the gage reads 30 lbs Then press the Enter key Turn the knob counterclockwise and then remove the force gage and spacer from the unit Press the Stop key to exit force calibration Press the Stop key a second time to exit the sensor calibration mode Force test Go to MAIN MENU PAGE 3 of 3 then lt 9 gt SYSTEM CHECK Force readings will be displayed Check the force sensor by setting 5 lbs on the gage and then check that the displayed reading is 5 0 25 Lbs Repeat for 10 and 15 Ibs The displayed readings should be within 0 40 Ibs If not repeat the force calibration above Press the Stop key to get to MAIN MENU PAGE 3 of 3 Page 19 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Size calibration From MAIN MENU PAGE 3 of 3 Press the lt 5 gt key BIOMED SERVICE then the Enter key Enter the biomed access code 9876 and press the Enter key Then key lt 1 gt SENSOR CALIBRATION Press the lt 1 gt key for SIZE calibration Unit will be displaying B D 1 and hex numbers e g 0000 Properly load the BD 1 ml syringe onto the unit Exercise the syringe clamp a few times and then with the clamp down on the syringe Press the Enter key Load th
37. out of the retainer top P 9 Place the front plate upside down and remove the hex head screw securing the bushing spring handle If plastic bushing this bushing and screw will NOT be reused 10 Remove the white spacer from the end of the spring this space will NOT be reused al Page 44 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 12 Install place the end of the spring into the small hole in the front plate Place the new metal bushing with the longer screw into the handle Bias the handle to the right as the screw is tightened 13 Place this assembly back into the retainer top slide the pin into the hole in the retainer top and then hook the spring onto the pin x 14 Install replace the short retainer bar Place the retainer bar completely to the right in the black retainer top The bar should be up against the stop on the front of the retainer tHe MIS RHR IEI Page 45 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 15 IMPORTANT Move the black retainer top with the retainer bar toward the back it will move approximately 1 8 inch which will place the retainer bar up against the transducer front plate 16 IMPORTANT While holding the retainer in this position install the metal cluster gear small gear first into the retainer if the gear does not drop right in recheck step 12 The larger gear teeth will engage with the gear te
38. r AC inlet 001 0113 PO Seal plug comm port 1110750 Box shipping 001 9202 Inserts shipping 001 9200 amp 001 9201 Contact Atlanta BioMedical Corporation at 770 904 3766 for pricing Page 17 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Tool Equipment List Too Description Nts Phillips 0 1 and 2 screwdrivers Force fixture holder and hardware supplied by ABC minus the gage Contact Atlanta BioMedical Corporation at 770 904 3766 for pricing on force fixture 5 64 hex driver eee Page 18 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Section 5 ABC Model 4100 Service Manual Calibration This section is used to calibrate the syringe pump force size and position Force calibration From the main menu screen page 1 of 3 press the menu key twice to get to MAIN MENU PAGE 3 OF 3 Press the lt 5 gt key BIOMED SERVICE then the Enter key Enter the biomed access code 9876 and press the Enter key Then key lt 1 gt SENSOR CALIBRATION Next press key lt 3 gt to enter force calibration Screen should be at force calibration displaying 0 LB and hex numbers e g 0098 Place the spacer onto the transducer plate Manually squeeze the gear onto the plate a few times and check that the hex numbers increase Then with NO force applied press the Enter key Screen should now list 30 LB and hex numbers e g 007A Place the track to the full outside p
39. rts VY voltage to a regulated voltage VX 6 2V 3 Battery power BAT about 5 0V when fully charged and VX jointly supply the power VZ for the device If AC power is ON VX is higher than BAT and thus VX power is used When AC power is removed VX 0 BAT will supply power to VZ 4 A step down switching regulator converts VZ to a constant DC voltage VA 5 5V VA remains at 5 5V when battery power BAT is used VA increases to 5 8V when AC power is ON VX 6 2V is used If AC line voltage drops from 115V to 90V step down regulator can no longer maintain VX at 6 2V As long as VX does not drop below BAT power from VX will be used If battery is not present and AC power drops to 90V then step up regulator steps up voltage from VX to maintain 5 5V at VA 5 Distributed Power Page 54 of 62 DC voltage VA is distributed to various circuits for further conversion to other voltages 5V and 3 3V a 3 3M 3 3V is provided by a regulator to supply a stable DC power to Microprocessor and to reference diode to provide a system reference voltage VREFX 2 5V to calibrate ADC readings b 5M SV is provided by a regulator to supply a stable DC power to microprocessor PPI chip Real Time circuit and analog circuits ADC chip Size sensor and Position Sensor c SMI SV is provided by a regulator to supply a stable DC power to other peripheral devices alarm circuit watchdog circuit digital sensors drivers
40. rvice and repair of medical devices Do not modify the Model 4100 perform any repairs not contained in this manual or install substitute parts Unauthorized modifications or repairs will void the warranty All information contained in this service manual is current as of the effective dated listed and is subject to change without notice To obtain technical assistance or repair service contact Atlanta BioMedical Corporation 305 Shawnee North Drive Suite 250 Suwanee GA 30024 770 904 3766 WARNING WARNING WARNING CAUTION CAUTION Do not operate the Model 4100 if it has been dropped or any physical damage is noticed Attempts to repair or service the Model 4100 by technicians without the proper qualifications or training may create a hazard which could result in serious injury to the user or patient Use only the approved parts and procedures as listed for the repair and servicing of the Model 4100 Failure to follow this service manual may create a hazard which could result in serious injury to the user or patient Always disconnect the AC power to the Model 4100 and remove the battery when performing service or repair Use only the line cord as supplied by Atlanta BioMedical Corporation When the Model 4100 is opened for service you must work at an electrostatic controlled workstation Page 3 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 ABC 4100 Service Manual CLEANING CA
41. s in Foreign Countries The current configuration of this device is for 115VAC line voltage It can be configured for 220VAC by changing the jumper wires for the transformer XF1 and the size of the fuses FI F2 If the line voltage falls below 100VAC e g Japan then similar transformer with different secondary voltage should be used The frequency of the line voltage does not affect the operation of this device Page 59 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 3 Other related information 3 1 Mechanical Driving System The rotating shaft of stepper motor translates into linear movement of the Tack via gear system and leadscrew The syringe plunger is pushed by the Transducer Plate mounted on the Track when the clutch halves inside the Track are engaged with the leadscrew Motor shaft rotation 96 steps per revolution to drive a motor pinion 64 pitch 20 teeth and via a cluster gear 64 pitch 84 teeth 48 pitch 18 teeth to the leadscrew gear 48 pitch 72 teeth Thus a leadscrew gear rotation will need 1612 8 motor steps 96x 84 20 x 72 18 The leadscrew gear drives a leadscrew 20 threads inch double start 1 e equivalence of 0 050 per leadscrew revolution to move the Track S A when the clutch halves are engaged with the Leadscrew The Motor Gearing system and Leadscrew provide a combined resolution of 0 000062 per motor step 1 16128 The Saddle housing has two stop ribs to allo
42. sensor on the PCBA Centered in sensor Reference only Page 48 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 24 Place the transducer housing seal onto the inside of the transducer housing cover Place the cover and seal over the back side of the transducer housing and secure with 2 each screws 25 Check the operation of the retainers as follows Slightly squeeze pinch the black lever toward the white extension piece of the Transducer Back Plate the black retainer base housing and retainer bars should first move outward away from the front plate Then as you continue to squeeze pinch the lever up against the white extension piece the retainer bars should then move in opposite directions away from each other and all the way out At this point the clutch should be open and you can then move the retainer track in or out If the retainer bars do not move all the way out or if the lever does not reach the white extension piece then the timing of the gear 1s not correct and must be redone 26 Test the timing and operation of the plunger detector as follows Power on the unit and using the menu key go to main menu page 3 of 3 Select Enter lt 9 gt SYSTEM CHECK Then observe the PLUNGER DETECTED line on the screen With no syringe loaded the status should be NO gt a r CIO i LIGA ll stili f N a a Me 7 i a p Ca TT 1 aint an i ge Infusion Pump Model 4100 il Page 4
43. stretch or pull on the seal Page 23 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 6 screws securing top to bottom Top Bottom Seal Flat ribbon cable AC cable Green ground wire Page 24 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 7 2 Final unit reassembly l Position the top housing over the bottom housing and secure the green ground cable to the screw stud CAUTION Ensure the green ground cable is reconnected to maintain proper ground safety Connect the flat ribbon from the top housing to JI on the main PCBA Connect the 3 pin ac cable to J9 on the main PCBA ensure cable locks in place Place the top housing onto the bottom housing carefully position the wires and take care not to pinch the flex cables along the front of the housing Secure the housings with same 6 screws the short one inch screw is placed in the right front corner The remaining 5 each 2 1 2 inch screws are placed three along the back and 2 along the front Be sure that each screw has a plastic Cup Seal and Ground Ring in place Start the screws but do not tighten Allow a small gap between the housings Place the Top Housing Seal in this gap positioning the seal corners into the housing corners Then start to tighten the 6 screws tighten each screw a little at a time until tight Check that the Top Housing Seal is in place If the seal comes out loosen the screws re position the seal a
44. supply to the unit and measuring the unit current input while running max rate with a BD 60cc syringe Reinstall the main PCBA to the bottom housing Connect the speaker to J12 and the motor to J6 Then carefully position the PCBA onto the bottom housing Then secure the PCBA with 4 small screws and the one long screw Then connect LED flex cable to J force flex cable to J2 encoder flex cable to J5 and the position pot flex cable to J4 Make sure to lock the ZIF retainers onto the connectors cable 7 7 Track and leadscrew removal a The following steps must be performed at an ESD safe workstation Perform final unit disassembly as noted above Track removal Tools required Phillips 1 and 2 screwdriver 5 32 hex allen driver Remove the 3 screws that secure the saddle to the bottom housing Note These 3 screws may have their plastic cup seals loose on the screws and not secured to the saddle housing Retain these plastic cup seals Page 36 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Position the track at approximately midpoint of travel on the bottom housing Start to remove the saddle remove the one screw that secures the green ground cable to the saddle Remove the saddle from the bottom housing Note at reassembly that the saddle needs to remain aligned with the bottom housing Remove the 2 screws on the back of the transducer housing and remove the plate Caution Do not operate the clu
45. t a Syringe Light the Bi Color LED indicator on the Bottom Housing is driven by a driver to illuminate the syringe so that the delivery status is visible when the surrounding lighting is dim b System Malfunction the Red LED on Top Housing is turned on by a driver with signal from the Watchdog circuit c Pump Syringe Status Tri color LED on Top Housing provides the Red Green Yellow signals for various Pump Syringe conditions This LED is driven by a latch IC on TOP PCB 74HC373 d Battery Status Tri color LED on Top Housing provides the Red Green Yellow signals for various battery conditions This LED is driven by a latch IC on TOP PCB 74HC373 2 2 1 6 Battery Charging Circuit 1 There is a 4 pin battery contact mounted on the underside of Main PCB to connect the battery pack 1 BAT 2 TEMP 3 RES 4 GND 2 The charging circuit on the Main PCB consists of a dedicated controller IC TI BQ2000T and supporting IC FET IRFU5505 Inductor and other resistors capacitors The charging circuit senses the temperature of the pack to determine the charging status of the battery It is also used to indicate the presence of the battery pack Microprocessor also monitors the temperature and voltage of the pack to assure proper battery charging A current sensing resistor allows charging controller IC to modulate FET to regulate the charging current This resistor senses the total of battery charging current and system curre
46. tch lever while the transducer back plate is removed The seal should come off with the plate Remove the phillips screw securing the flex ground cable to the housing Pull back on the ZIF retainer of the flex cable and then remove the flex cable from the connector Place the flex cable down into the channel of the track To remove the force sensor assembly Remove the top 10 32 screw with the 5 32 hex allen driver With this screw removed the transducer front plate and retainer housings will also be removed from the assembly Then remove the bottom 10 32 screw The forces sensor assembly can then be removed To reinstall the force sensor assembly Install the force sensor assembly into the transducer housing Center the force sensor assembly and secure with the bottom 10 32 screw do not completely tighten this screw at this time Ensure that the transducer seal is in place on the front of the housing Rotate the plunger cam so the arm is pointing to the back the slot on the cam should then be pointing to the front Install the transducer plate retainer housings onto the transducer housing Engage the pin on the retainer housing with the slot in the plunger detector cam Secure the plate to the housing with the top 10 32 screw Do not fully tighten at this time Check that the cam arm is centered in the sensor Fully tighten both screws Note Force calibration must be performed Replace the plate and seal onto the housing and secure with t
47. terval conversion functions are executed twice and the identical results are verified b Safeguard of the Motor pulse data with duplicated data and or CRC code after the data are generated 2 Generating Accurate Motor Pulse from Motor Control Data a Since Motor Pulse Interval determines the motor speed the delivery accuracy depends mainly on the correct conversion data and the accurate generation of the motor pulse interval by the Hardware Software system b The system uses a hardware timer and a timer interrupt function to generate the motor pulse The timer is directly tied to system clock Thus the clock accuracy is directly related to the delivery accuracy 3 Monitoring the Progress During Delivery Various mechanisms are used to detect possible errors during pump operation a System clock accuracy is monitored by comparing with a 32Hz signal from an independent real time clock b The generated motor pulse is measured with another system timer to monitor its accuracy c The integrity of motor pulse control variables are continuously monitored to detect any abnormal modification d Various hardware sensors are used to monitor the actual output from the motor 1 e motor shaft rotation and plunger movement However delivery accuracy does not depend on the sensors e Additional sensors Force Size Plunger detector are monitored during delivery to detect any abnormal conditions e g occlusion syringe dislodged
48. that secure the encoder to the bottom housing Remove the encoder from the bottom housing 8 Removal of the syringe flange retainer Tools required Phillips 1 screwdriver From the underside of the retainer remove the 2 screws securing the retainer to the saddle housing Page 32 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Remove the retainer Note Retain the plastic spacers washers and make note of the placement between retainer and housing Reference the following pictures for the bottom housing 2 Cable removed from ZIF connector ZIF connector down locked ZIF connector up 5 screws securing main PCBA PTL ft Pmi iH 000000 00006060600 000 gt 3 le A of T i U25 Se i f 5 TR gt iy t B e 3 Fi o v 0 t de SS LE x o FI Js saba Cd vi n F7 GR arf i x RF 5 UZA z n RJ a hi TPS N Ove Ta Eiye Ceco T ere pe eo a 4 B TEL Wine oy NG a so an p 2 Ai d m Ls x T 4 0 W778 Ri e x 7 Quet 3332222 ts lt a i BE x E SEELE TRO DE een Dini minin Snn T f uig A x OTS U 2 h sa M t Ge gt le w gt Encoder J5 Position pot J4 Force J2 LEDs J8 Fuse cover Page 33 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 lem ieee ie i t Frente bie bri f ow ent AZ Aa oo00000n o o O o o o e
49. to alert the user 4 Malfunction Detection As a safety measure any error above will trigger system malfunction to cut off motor power to stop pump delivery and place the pump in an alarm state Page 61 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 APPENDIX 1 Top Housing S A Top Housing Top PCB S A KevPad Power ON OFF Circcuit ii Top PCB Power Supply 5MX 5V Syringe Clamp JZ3 VEE 12 5V Size Sensor Backlight Driver LCD Module SIP Connector KeyPad Circuit eg Latch Communication Port J6 RS 232 Driver J1 Bottom Housing S A Bottom Housing Syringe LED S A Speaker S A Position Pot S A Position Encoder S A Syringe Saddle Leadsrew Sub System Motor S A Main PCB S A Power Supply Transformer amp Fuses VY VX 6 2V Track Transducer S A Track Clutch Sub system Clutch Half Nuts Clutch Tube Clutch Cams Clutch Pusher 5M 5V 5M1 5V VSN Microprocessor System System Clock Real Time Clock Motor Driver Alarm LED Circuit Battery Charging Circuit Battery Contact BAT TEMP RES GND Plunger Retainer Sub system Retainer Hosuing Plunger Retainer Bars Retainer Cluster Gear Clutch Handle Clutch Torsion Spring Syringe Plunger Detector Transducer Sub system Transducer Housing Plate Cove Force Transducer Force Transducer PCB S A Amplifier Plunger Detector Opto Force Sensor Cable Battery Pack Battery Cells Thermistor Battery PCB S A S
50. w a maximum traveling distance of the Track S A of 5 6 3 2 Factors affecting delivery accuracy of the pump Stepping motor is used to drive the syringe Each motor step advance is performed by the microprocessor at the motor timer interrupt The motor timer is derived from the system clock A separate clock is used to monitor the accuracy of the system clock Delivery Accuracy is determined by the following components 1 Accuracy of the system clock of the microprocessor 2 Accuracy of Leadscrew 3 Size sensor is used to determine the syringe size and the motor speed Once the size is properly recognized accuracy does not depend on sensors any more 4 All sensors are used only to confirm the system performance No sensor feedback is used to maintain the motor speed or the delivery accuracy Page 60 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 3 3 Description of Software relating to delivery accuracy The main function of the device is to operate the stepper motor accurately and safely to drive the syringe plunger to deliver therapeutic fluids to the patient This can be achieved by the following measures 1 Generating Accurate Data for Motor Control The data entered by the user together with the characteristics of the loaded syringe are used to calculate the motor pulse rate and to determine the maximum pushing force allowed at the syringe plunger a Double calculation The motor pulse in
51. ypad in the cutout area on the top housing Route the keypad flex cable as shown and secure to the housing with double sided tape Remove the backing from the overlay and place the overlay onto the housing and keypad in the cutout area Page 29 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 5 Reinstall the top PCBA and LCD into the top housing Check that the black spacers are set correctly on the top PCBA and then place the 4 each 4 40 X 7 16 screws through the spacers and PCBA LCD place a white plastic retaining washer over the end of the screws Then place the PCBA LCD into the housing and tighten the screws 6 Reconnect the cables as follows Keypad cable to J2 and lock the ZIF retainer Communication cable to J6 Note top 2 pins unused Size pot cable to J3 and lock the ZIF retainer Page 30 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 7 5 Bottom housing disassembly The following steps must be performed at an ESD safe workstation l Perform final unit disassembly as noted above 2 The ac line fuses are located under the fuse cover Remove the fuse cover Remove the fuses and check 1f the fuse is open Replace the fuses 1f needed Reinstall the fuse cover 3 Removal of main PCBA Tools required Phillips 1 screwdriver Note The flex cables are connected to Zero Insertion Force ZIF connectors To disconnect pull back on the ZIF retainer and then remove t
52. zed press the Enter key Remove the ruler from the unit Press the Stop key to exit POSITION calibration Press the Stop key a second time to exit the SENSOR CALIBRATION mode Track at empty position 1 3 inch line Page 21 of 62 ABC Syringe Infusion Pump Model 4100 Service Manual P N 6 011 0002 1 Section 6 ABC Model 4100 Service Manual Alarm and Error Codes Troubleshooting Refer to the Operations Manual section 9 battery operation Replace battery Check that the battery pack is installed correctly Charge the battery pack A completely discharged battery should charge fully in about 3 4 hours Replace battery pack Invalid size Check using correct MFR syringe Check that the syringe is loaded correctly Check if any labels or tape on the syringe are affecting the size Perform SIZE calibration Check or replace the size potentiometer Syringe dislodged Check if syringe was actually dislodged or moved Check that the syringe is loaded correctly Perform SIZE calibration Check or replace the size pot Plunger disengaged Check that the syringe plunger is engaged properly with retainers Check operation of optical sensor in plunger housing See section 2 Functional Testing Check track Check that the plunger track was not manually moved Perform POSITION calibration Check or replace position potentiometer Occlusion plunger Check the configured occlusion limit Check operation of force sensor Perform FORCE calibration Che
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