Service Manual
202 Pages
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Page 1
07-l g-A1 -688
Service Manual
Flo-Gard@6201 Volumetric Infusion Pump Product Code: 2M8063
Baxter Healthcare Corporation Deerfield, IL 60015, USA 0 Copyright 1992, 1995, Baxter Healthcare Corporation. All rights reserved.
Change Record Page Specification number: 7- 19-01-688 Original issue: 1l/92 Revision A: 06/95 Page
Revision
A A A A 111 - Vlll A l-l - l-22 A 2-l - 2-4 A 3-l - 3-4 A 4-l - 4-8 A 5-l - 5-20 A 6-l - 6-38 A 7-l - 7-16 A 8-1 - 8-42 A 9-l - 9-2 A A 10-l - lo-32 (Backs 10-3 - lo-32 blank) A A-l - A-2 A B-l A A (Back of B 1 blank) (inside of back cover blank) A Back cover A A zero in the revision column indicates original issue. Cover (Back of cover blank) Title Page Change Record Page . .. . ..
Table of Contents ... General Description 1.1 Introduction ... 1.2 Features ... 1.2.1 Nurse Call ... 1.3 Technical Specifications ... 1.4 Controls and Indicators ... 1.5 Configuration Option Feature ... 1.5.1 Reviewing the Configuration Option Settings ... 1.5.2 Modifying the Configuration Option Settings ... l.6Alarms ... 1.7Alerts ...
l-l l-l l-l l-2 l-3 l-4 1- 12 1- 12 1-12 1-17 1-19
Hospital Service Procedures ... 2.1 Replacement Of Main Power Fuse ... 2.2 Cleaning ... 2.3 Battery Charging ... 2.4 Preventive Maintenance ...
2-1 2-l 2-2 2-3 2-4
Problem Checklist
... 3-1
Theory of Operation ... 4.1CPUSystem ... ... 4.1.1CPUs 4.1.2 Programmable Timer Module (PTM) ... 4.1.3 Watchdog Function ... 4.1.4 I/O Controllers ... 4.1.5 Multiplexer ... 4.1.6 Universal Pulse Processor ... 4.1.7 Communication Controller ... ... 4.1.8 Air Sensor Circuit 4.1.9 Occlusion Sensors ... 4.1.10 Tube Misloading Detector ... 4.1.11 Slide Clamp Detector ... 4.1.12 Battery Low Alert/Alarm Detector ... 4.1.13 Interlock Switch ... 4.1.14 Panel Lock Circuit ... 4.1.15 Keypad ... 4.1.16 Displays ... ... 4.1.17MotorDriver 4.1.18 Motor Rotation Detectors ...
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111
4.2 DC Power Supply and Power Control Circuit
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Disassembly and Calibration ... 6.1 Introduction ... 6.2 Preparation for Maintenance ... 6.2.1 Tools and Test Equipment ... 6.2.2 Recording the Configuration Option Settings ... 6.3 Disassembly/Reassembly ... 6.3.1 Separation of Front and Rear Housings ... 6.3.2 Separation of Printed Circuit Boards ... 6.3.3 Replacement of Front Panel Film ... 6.3.4 Replacement of Pump Head Door Cover ... 6.3.5 Replacement of Pump Door Latch ... 6.3.6 Replacement of the Pump Door or Pump Door Assembly ... 6.3.7 Replacement of Door Latch Pin ... 6.38 Replacement of Pump Head Assembly ... 6.3.9 Replacement of Upstream Occlusion Sensor ... 6.3.10 Replacement of Downstream Occlusion Sensor Assembly ... 6.3.11 Air Sensor Assembly Replacement ... 6.3.12 Replacement of (FSR**) Devices for Tube Misloading Sensors . . 6.3.13 Replacement of Pump Motor ... 6.3.14 Replacement of Safety/Slide Clamp Assembly ... 6.3.15 Spring Retainer Removal ... 6.3.16 Spring Retainer Installation ... 6.3.17 Replacement of Back Plate ... ... 6.3.18 Replacement of Battery 6.3.19 Replacement of Power Supply Board ... 6.3.20 Replacement of CPU Board ...
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Troubleshooting... 5.1 Introduction... 5.2 Failure Identification Codes... 5.3 Automatic Test Modes... 5.3.1 Automatic Test Mode 1: Calibration Mode 1... 5.3.2 Automatic Test Mode 2: Calibration Mode 2... 5.3.3 Automatic Test Mode 3: Manufacturing Test Mode... 5.3.4 Automatic Test Mode 4: Aging Mode... 5.3.5 Automatic Test Mode 5: Display Check Mode... 5.3.6 Automatic Test Mode 6: Time Information Display Mode . . 5.3.7 Automatic Test Mode 7: Pumping Sensor Monitoring Mode . 5.38 Automatic Test Mode 8: Air Sensor Test Mode... 5.3.9 Automatic Test Mode 9: Elapsed Time Test Mode... 5.3.10 Automatic Test Mode 0: Downstream Occlusion Test Mode 5.4 Failure Identification Code Troubleshooting Table... 5.5 Troubleshooting Chart...
**Interlink
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Electronics
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6.3.21 Replacement of Display Board ... 6.3.22 Replacement of Sensor Board ... 6.3.23 Replacement of Audible Alarm/Alert Board ... 6.3.24 Replacement of Backup Audible Alarm/Alert Board ... 6.3.25 Replacement of Terminal Board ... 6.3.26 Replacement of Power Transformer ... ... 6.3.27 Replacement of PANEL LOCK Switch 6.3.28 Replacement of Lithium Backup Battery ... 6.3.29 Tube Guide Shim Installation ... 6.3.30 LCD Cushion Installation ... 6.3.3 1 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 ... 7.1 Introduction ... 7.2 Maintenance Flowchart ... 7.3 Operational Checkout ... 7.3.1 Administration Set Placement ... 7.3.2 Functional Testing ... 7.3.3 Door Open Alarm Testing ... 7.3.4 Air Alarm Testing ... 7.3.5 Drive Defect Test/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 AlarmVolume 7.3.12 Slide Clamp Test ... 7.3.13 Electrical Safety Tests ... 7.3.14 Accuracy Tests ... Illustrated Parts Breakdown
...
... Warranty and Service Information 9.1 Warranty Information ... ... 9.2 Service Information ... 9.3 General Information
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6-20 6-21 6-21 6-22 6-22 6-23 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-l . 7-l . 7-l . 7-3 . 7-3 . 7-3 . 7-5 . 7-6 . 7-7 . 7-7 . 7-8 . 7-9 7-10 7-10 7-10 7-11 7-12 7-13 8-l 9-1 9- 1 9- 1 9-2
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Diagrams
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10-l
Data Sheet, Flo-Gard@ 6201 Volumetric Infusion Pump (2M8063)...
A-l
Multiple Key Combinations
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... B-l
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List of Illustrations Figure l-l. Front View of Pump ... Figure l-2. Pump With Door Open ... Figure l-3. Rear View of Pump ... Figure 6- 1. Adhesive Application ... Figure 6-2. Pressure Application Points ... Figure 6-3. LCD Cushion Placement (Inside View) ... Figure 6-4. Calibration Equipment Setup ... Figure 7- 1. Maintenance Flowchart ... Figure 8-l. Front Housing Assembly ... Figure 8-2. Front Housing Assembly ... Figure 8-3. Rear Housing Assembly ... Figure 8-4. Rear Housing Assembly ... Figure 8-5. Pump Head Door Assembly ... Figure 8-6. Pump Base Plate Assembly ... Figure 8-7. Pump Base Plate Assembly - Rear ... Figure 8-8. Pump Base Plate Assembly ... Figure 8-9. Safety/Slide Clamp Assembly ... Figure 8-10. Display Bd (Sheet 1 of 2) Component Side ... Figure 8-10. Display Board (Sheet 2 of 2) Solder Side ... Figure 8-l 1. DC Power Supply Board ... Figure 8-12. CPU Board (Sheet 1 of 2) Component Side ... Figure 8-12. CPU Board (Sheet 2 of 2) Solder Side ... Figure 8-13. Sensor Board, Component Side (Sheet 1 of 2) ... Figure 8-13. Sensor Board, Solder Side (Sheet 2 of 2) ... Figure 8- 14. Terminal Board ... Figure 8- 15. Backup Buzzer Board ... Figure 8-16. Audible Alarm Board ... Figure 10-l. 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. Address Decoder for 60K ROM Area (P/O CPU Board) Figure 10-6. Master CPU Block (P/O CPU Board) ... Figure 10-7. Slave CPU Block (P/O CPU Board) ... Figure 10-8. UPP, RTC and SRAM Block (P/O CPU Board) ... Figure 10-9. Alarm Control Circuit (P/O CPU Board) ... Figure 10-10. Slave RAM and PTM (P/O CPU Board) ... Figure lo- 11. Additional CPU Circuitry ... Figure 10-12. Sensor Board Block Diagram ... ...
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Figure lo- 13. Power Supply Control Block (P/O Sensor Board) ... Figure 10-14. Occlusion Sensing Block (P/O Sensor Board) ... Figure 10-15. Motor Control Block (P/O Sensor Board) ... Figure 10-16. PPI Block #1 (LCD, Keys) (P/O Sensor Board) ... Figure 10-17. PPI Block#2 (P/O Sensor Board) ... Figure 10-18. Serial Communication Block (P/O Sensor Board) ... Figure lo- 19. Additional Sensor Board Circuitry ... Figure 10-20. Display Board ... Figure 10-21. LCD Drivers (P/O Display Board) ... Figure 10-22. Liquid Crystal Displays (P/O Display Board) ... Figure 10-23. LED Lamps (P/O Display Board) ... Figure 10-24. Audible Alarm Board ... Figure 10-25. Backup Buzzer Board ... Figure 10-26. Terminal Board ... Figure 10-27. Accessories ... Figure 10-28. Pumphead Sensors ... Figure 10-29. Front Panel Key Assignments ... Figure 10-30. Power Supply ...
lo- 15 lo-16 lo-17 lo- 18 lo-19 lo-20 10-2 1 lo-22 lo-23 lo-24 lo-25 lo-26 lo-27 lo-28 lo-29 lo-30 10-31 lo-32
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Section 1 General Description
1.I Introduction This manual provides service information for the Flo-Gard@ 6201 Single Channel Volumetric Infusion Pump (product code 2M8063) for qualified hospital biomedical engineers and service personnel. See the pump’s Operator’s Manual for detailed operating instructions.
1.2 Features The Flo-Gard@ 6201 Single Channel Volumetric Infusion Pump is an electromechanical pump used for the intravenous infusion of liquids at user-selected rates. The pump contains a linear peristaltic pump head which is 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 pump operates on standard 115 VAC 60 Hz electrical power, or on its self-contained rechargeable 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, 20537s. When infusing solutions through a central line catheter, sets with a Luer lock adapter should be used. Sets 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.Oto 99.9 mL/hr in 0.1 mL/hr increments. The secondary rate is selectable from 1 to 999 mL in 1 mL/hr increments and 1.Oto 99.9 mL/hr in 0.1 mL/hr increments. The volume to be infused (VTBI) 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 accumulated 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 (KVO) 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. The pump may be stopped at any time by pressing the STOP key unless the pump is in the lockout mode.
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l-l
General Description
The Programmed Delivery Profile (PDP) enables manual programming or ramped calculation (available only on pumps running software versions 1.09 or later) of up to 10 sequential infusion programs for situations where multiple flow rates are indicated. See the appropriate Operator’s Manual for additional information.
1.2.1 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 relay contact points (normally closed, normally open, and common) are accessible from the COMMUNICATIONS PORT on the rear of the pump (pins 1,4, and 9, respectively). The Nurse Call feature may be used when the pump 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.
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General Description
1.3 Technical Specifications Item
Characteristic
Catalog Code Number
2M8063
Description
Single channel linear peristaltic volumetric
Administration
Set
Baxter’s standard administration
infusion pump
set with “s” suffix
Keep Vein Open (KVO) rate
5 mL/hr or programmed
Battery
12 Volt, 2.0 Ah sealed lead acid
Battery Life
Approximately
Battery Recharge
8 hours for 80% recharge
AC Power Requirements
110/12OV, 60 Hz
Power Cord
2.9 m (9.5 ft.) long, with Hospital Grade plug
Leakage Current
Typically less than 50 microamps (using UL-544 specified test methods)
Power Consumption
30 watts
Weight
5.3 kg (11.6 Ibs)
Dimensions
20cmWxl3cmDx29cmH (7.9” W x 5.1” D x 11.4” H)
Flow Rate Range
Primary program: 1 - 1,999 mL/hr in 1 mL/hr increments and 1 .O - 99.9 mUhr in 0.1 mUhr increments. Upper limit can be reduced by authorized service personnel. Secondary program: 1 - 999 mUhr in 1 mUhr increments and 1 .O - 99.9 mUhr in 0.1 mUhr increments.
VTBI Range
1 - 9,999 mL in 1 mL increments and 1 .O - 99.9 in 0.1 mL increments for both primary and secondary. Upper limit can be reduced by authorized service personnel.
Ramp PDP Parameter Ranges
Total VTBI: 100 - 9,999 in 1 mL increments. Upper limit can be reduced by authorized service personnel. Delay Time: 0O:OO - 08:OO hours in minute increments. Run Time: 0l:OO - 16:OO hours in minute increments. 0l:OO - 24:00 hours in minute increments (software versions 1.14 and later). Ramp Up: 0O:OO to 45% of the Run Time minus Ramp Up, in minutes. Ramp Down: 0O:OOto the Run Time minus Ramp Up, in minutes.
(available only on pumps running software versions 1.09 or later)
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rate, whichever
is less
6 hours with pump running at rates from 1 to 1400 mL/hr
1-3
General Description
,I Item , / Air-in-Line Detection
I
Characteristic Factory set to NORM which causes the device to alarm on air bubbles approximately 75 t.rL or larger. The MIN setting causes the device to alarm on bubbles approximately 50 PL or larger. 0.5 A Slo-Blo
I Fuse
g-pin D connector, Pin 1: N/C, Pin 4: N/O, Pin 9: Common i Contact rating: 0.4A at 30 VAC, 2A at 30 VDC resistive load (internal actrvatron required).
1 Nurse Call I
1.4 Controls and Indicators All controls and indicators are shown in Figures l-l, 1-2, and l-3. Service personnel should be familiar with the pump’s features and operation before servicing the pump. The pump’s serial number is recorded on a label on the back of the pump. ITEM
FUNCTION
1. Message Display
Shows all messages.
2. BACKLIGHT
Provides backlighting of the displays when the pump is used in darkened areas.The key toggles the backlighting on and off. If the pump is operating on battery power, the backlight remains on for 60 seconds and turns off automatically to conserve battery power.
key
3. SILENCE Key
Temporarily silences an audible alarm or alert for two minutes. All visual alarm or alert information remains displayed.
4. NEXT Legend
When the NEXT legend is lit, the TOT VOL/STATUS key functions as a scrolling key to advance to the next step of a programmed delivery profile (PDP) or configuration option. See Section 1.5.
1-4
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General Description
6 /
27
7
26
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8 /
25
24
9 /
23
/
/
22
10 11
/I2
/
21 / 20 / 19 ’ Flo-Gard@ VOLUMETRIC
6201
INFUSION
PUMP
1
Figure l-l. Front View of Pump
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l-5
General DescriDtion
Key
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 Configuration, Modify Configuration and Programmed Delivery Profile modes. The word “NEXT” above the key is illuminated when the key is functioning as a NEXT key.
6. CLEAR TOT VOL Key
Resets the total volume delivered to zero when the pump is stopped.
7. TIME Key
Enters desired time interval for an infusion during VolumeTime or Rate-Time programming.
8. STOP Key
Stops the pump. The STOPPED message appears when the key is pressed. An alert will sound if pump is stopped for more than two minutes. Clears all programming alerts while pump is running.
9. Door Latch
Opens and closes pump door.
5. TOT VOL/STATUS
10. ON-OFF/CHARGE
Key
Turns the pump on and off. The internal battery charger remains on regardless of the ON-OFF/CHARGE key as long as the pump is plugged in.
11. Battery Icon
Yellow LED, always lit while the pump is operating on battery power.
12. Plug Icon
Green LED, always lit while the pump is plugged in and the battery is charging.
13. MONITOR Legend
Lights for at least 2 seconds each time the host computer communicates with the pump when the pump is in monitor mode.
14. COMPUTER CONTROL Legend
Flashes when the pump is initiating communications with a host computer to enter the computer control mode. It is constantly illuminated when the pump is in computer control mode.
15. SEC START Key
Starts the delivery of the secondary solution.
16. SEC VTBI Key
Allows programming of the secondary VTBI.
1-6
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General Description
17. OPTIONS Key/Legend
Allows the pump to operate in special modes, if enabled. The OPTIONS legend lights when the key is enabled.
18. SEC RATE Key
Allows programming of the secondary infusion rate.
19. CLR Key
Clears any locked in values and programming values currently being entered.
20. Numerical Keypad
The numerical values for rate, VTBI, and time are entered with these keys.
21. PRI VTBI Key
Allows programming of the primary VTBI.
22. PRI RATE Key
Allows programming of the primary infusion rate.
23. PRI START Key
Starts the primary infusion.
24. Main Display
Shows rate, volume to be infused (VTBI), and total volume infused for primary and secondary infusion programs.
25. ALARM
Red LED that blinks on and off during an alarm, accompanied by a visual message display and a repeated sequence of three beeps. An alarm indicates that the pump requires immediate attention.
LED
26. PUMPING LED
Green LED which is constantly lit while pump is running.
27. ALERT LED
Yellow LED which lights during alerts, accompanied by a message display and a repeated single beep. An alert indicates that the pump needs timely attention.
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1-7
General Description
See Figure l-2 for the location of the following items. 1. Upstream Occlusion Sensor
Detects a complete tubing restriction upstream of the pump.
2. Pump Mechanism
Linear peristaltic pump mechanism.
3. Tube Misloading Sensor
Detects misloaded tubing out of the channel guide slots.
4. Downstream Occlusion Sensor
Detects a complete tubing restriction 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 administration set with the slide clamp before the set can be removed 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 SLIDECLAMP message is 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 insert 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 insert remain in place during use. See Section 6.3.15.
9. Channel Guide Ridges
Function as a guide to keep the tubing properly aligned over the pumping fingers.
1-8
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General Description
9
.
a
Figure 1-2. Pump With Door Open
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1-9
General Description
The following items are located on the rear of the pump and are shown in Figure l-3. 1. IV Pole Clamp
Secures the pump to the IV pole.
2. Power Cord Strap
Stores power cord during battery operation and pump t(~i-age.
3. Audio Speakers
For generation of audible alarm and alert tones.
4. Battery Compartment
Allows authorized service personnel easy access to the battery, EPROMS, and battery fuse.
5. VOLUME Knob
Adjusts loudness of audible alarm and alert tones. The audible alarm cannot be turned completely off.
6. PANEL LOCK Switch
Disables all front panel keys, except BACKLIGHT and TOT VOL/STATUS, while the pump is running without alerts.
7. Power Cord
Removable only by authorized service personnel.
8. Fuse Compartment
The power cord cover must be removed to access the fuses.
9. COMMUNICATIONS
l-10
PORT
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.
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General Description
1
/= ..lo::*.-
>
3
/4
_--
a/
Figure 1-3. Rear View of Pump
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l-11
General Description
1.5 Configuration
Option Feature
This section describes the configuration option feature of the pump, which allows qualified personnel to inspect and/or modify certain pump operating parameters to suit customer requirements. 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:
1.5.1
Although the configuration option data is stored in battery backed-up RAM, it may be lost if the main battery connector (CN302) is disconnected from the CPU board without turning off the device. The configuration option data is also lost if the lithium backup battery connector (CN304) is disconnected while the main battery is disconnected. Therefore, we advise that the configuration options be recorded before beginning repair procedures and reset when repairs are complete.
Reviewing
the Configuration
Option Settings
To review the configuration option settings, the pump must be powered on and stopped. Press TIME and TOT VOWSTATUS simultaneously for one second. The message REVlEW CONFlG will be displayed in the Message Display. The option description will be displayed in the first line of the 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 pump to advance to the next setting, in the order shown in Table l-l, starting with Occlusion Alarm Level. To exit the inspection mode, press the STOP key or press TIME and TOT VOLBTATUS simultaneously.
1.5.2
Modifying
the Configuration
Option Settings
1. Turn off the pump. 2.
While pressing the STOP key and PANEL LOCK switch, press the ON-OFF/CHARGE key. The following will occur: a. The MODIFY CONFIG message appears in the Message Display.
Note:
1-12
If the message LOCKED OUT is displayed, the configuration option settings can be changed only via computer control. See the Programmer’s Manual for additional information.
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