Service Manual
214 Pages
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Page 1
07-I g-Al -729 .-.
Service Manual
Flo-GardQ 6301 Dual ChannelVolumetric Infusion Pump Product Code: 2M8064
Baxter Healthcare Corporation Deerfield, IL 60015, USA 0 Copyright 1993, 1995, Baxter Healthcare Corporation. All rights reserved
Change Record Page
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Specification number: 7- 19-Ol-729 Original issue: 04/93 Rev A: 05/95 Page
Revision
Cover (Back of cover blank) Title Page Change Record Page . .. . ..
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Table of Contents ... General Description ... 1.1 Introduction ... 1.2 Device Overview 1.2.1 Principal Features ... 1.2.2 Nurse Call ... 1.3 Technical Specifications ... 1.4 Controls and Indicators ... 1.5 Configuration Option Feature ... 1.5.1 Reviewing the Configuration Option Settings ... 1.5.2 Modifying the Configuration Option Settings ... ... 1.6Alarms. ... 1.7Alerts
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Hospital Service Procedures ... 2.1 Replacement Of Main Power Fuse ... 2.2 Cleaning ... 2.3 Battery Charging ... 2.4 Preventive Maintenance ...
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Problem Checklist
Theory of Operation ... 4.1 CPU System ... ... 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 Detectors ... 4.1.11 Slide Clamp Detectors ... 4.1.12 Battery Low Alert/Alarm Detector ... 4.1.13 Interlock Switches ... 4.1.14 Panel Lock Circuit ... 4.1.15 Keypad ... 4.1.16 Displays ... ... 4.1.17MotorDriver
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4.1.18 Motor Rotation Detectors ... ... 4.2 DC Power Supply and Power Control Circuit
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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 . 5.3.8 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... 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 Door Cover ... 6.3.5 Replacement of Pump Door Latch ... 6.3.6 Replacement of Pump Door or Pump Door Assembly . . 6.3.7 Replacement of Door Latch Pin ... 6.3.8 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 Installation of Air Sensor Assembly ... 6.3.12 Replacement of Force Sensing Resistor* (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 ...
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6.3.19 Replacement of Power Supply Board ... 6.3.20 Replacement of CPU/Display Board ... 6.3.2 1 Replacement of Audible Alarm/Alert Board ... 6.3.22 Replacement of Backup Audible Alarm/Alert Board ... 6.3.23 Replacement of Terminal Board ... 6.3.24 Replacement of Power Transformer ... 6.3.25 Replacement of the PANEL LOCK Switch ... 6.3.26 Replacement of Lithium Backup Battery ... 6.3.27 Tube Guide Shim Installation ... 6.3.28 LCD Cushion Installation ... 6.3.29 Software Installation ... 6.4 Calibration ... 6.4.1 DC Line Voltages ... 6.4.2 Air Sensor Calibration ... 6.4.3 Downstream Occlusion Sensor Calibration ... 6.4.4 Upstream Occlusion Sensor Calibration ... 6.4.5 Slide Clamp Sensor Calibration ... 6.4.6 Slide Shaft Sensor Calibration ... 6.4.7 A/D Convertor Reference Voltage Calibration ... Checkout ... 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
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... Warranty and Service Information 9.1 Warranty Information ... ... 9.2 Service Information ... 9.3 General Information
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Diagrams
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Data Sheet, Flo-Gard@ 6301 Volumetric Infusion Pump (2M8064) Multiple Key Combinations
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List of Illustrations Figure 1-1. 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 ... Figure 6-4. Calibration Equipment Setup ... Figure 7- 1. Maintenance Flowchart ... Figure 8-1. Front Housing Assembly - External ... Figure 8-2. Front Housing Assembly - Internal ... Figure 8-3. Rear Housing Assembly - Internal ... Figure 8-4. Rear Housing Assembly - External ... Figure 8-5. Pump Head Door Assembly ... Figure 8-6. Pump 1 Base Plate Assembly with FSRs ... Figure 8-7. Pump 1 Base Plate Assembly-Rear ... Figure 8-8. Pump 1 Base Plate Assembly with Pump Mechanism ... Figure 8-9. Safety/Slide Clamp Assembly 1 ... Figure 8-10. Pump Head 2 Door Assembly ... Figure 8-l 1. Pump 2 Base Plate Assembly with FSRs ... Figure 8-12. Pump 2 Base Plate Assembly - Rear ... Figure 8-13. Pump 2 Base Plate Assembly with Pump Mechanism ... Figure 8- 14. Safety/Slide Clamp Assembly 2 ... Figure 8-15. Power Supply Board Component and Solder Sides ... Figure 8-16. Display PCB - Component Side ... Figure 8-16. Display PCB - Solder Side ... Figure 8-17. CPU PCB - Component Side ... Figure 8-17. CPU PCB - Solder Side ... Figure 8- 18. Terminal PCB ... Figure 8-19. Backup Buzzer Board ... Figure 8-20. Audible Alarm PCB ... 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. Power Supply Section ... Figure 10-6. DC Power Supply ... Figure 10-7. Power Supply Control ... Figure 10-8. Power Supply Control - Hybrid Circuit ... Figure 10-9. Master CPU Block Diagram ...
. l-5 . l-8 l-10 6-25 6-25 6-27 6-30 . 7-2 . 8-3 . 8-5 . 8-7 8-9 ‘8-13 8-15 8-17 8-19 8-23 8-25 8-27 8-29 8-31 8-35 8-37 8-39 8-40 8-42 8-43 8-44 8-45 8-46 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11
Figure 10-10. Master CPU Schematic ... Figure 10-l 1. UPP, RTC and SRAM Block (P/O CPU Board) ... ... Figure lo- 12. Alarm Control Circuit Figure lo- 13. Address Decoder ... Figure lo- 14. Serial Communication Block ... Figure 10-15. Slave CPU Block Diagram ... Figure lo- 16. Slave CPU Schematic ... Figure lo- 17. Slave RAM and Programmable Timer Module (PTM) ... Figure 10-18. Motor Driver Circuit - Pump 1 ... Figure 10-19. Motor Driver Circuit - Pump 2 ... Figure 10-20. CPU PCB (Sensor Block) ... Figure 10-21. PPI Block #1 ... Figure 10-22. PPI Block #2 ... Figure 10-23. Occlusion Sensing Block ... Figure 10-24. Air Sensing Block ... Figure 10-25. Misload and Slide Clamp Sensors ... Figure 10-26. Display PCB ... Figure 10-27. LCD Drivers for Pump 1 ... Figure 10-28. LCD Drivers for Pump 2 ... Figure 10-29. LCDs for Pump 1 ... Figure 10-30. LCDs for Pump 2 ... Figure 10-31. LED Lamps ... Figure 10-32. Audible Alarm PCB ... Figure 10-33. Backup Buzzer PCB ... Figure 10-34. Terminal PCB ... Figure 10-35. Accessories ... Figure 10-36. Sensors on Pumphead 1 ... Figure 10-37. Sensors on Pumphead 2 ... Figure 10-38. Front Panel Key Assignments ...
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Section 1 GeneralDescription 1 .I
Introduction
This manual provides service information for the Flo-Gard@ 6301 Dual Channel Volumetric Infusion Pump (product code 2M8064) for qualified hospital biomedical engineers and Product Service personnel. See the device’s Operator’s Manual for detailed operating instructions.
1.2 Device Overview 1.21
Principal Features
The Flo-Gard@ 6301 Dual Channel Volumetric Infusion Pump is an electromechanical device used for the intravenous infusion of liquids at user-selected rates. The device contains two linear peristaltic pump heads, allowing it to simultaneously infuse two different solutions. Each pump head is independently programmable and permits infusion of primary and secondary medication programs. The secondary program automatically switches over to the primary program when secondary infusion is complete (automatic piggybacking). The device operates on standard 115 VAC 60 Hz electrical power, or on its self-contained 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, 2C5537s. When infusing solutions through a central line catheter, sets with 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.O to 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.Oto 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. Either pump may be stopped at any time by depressing the STOP key unless the device is in the lockout mode.
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General Description
1.2.2 Nurse Call The Nurse Call feature is enabled by installing a jumper wire to the Terminal Printed Circuit Board at the location labeled R421 on the board. When the jumper is connected, the Nurse Call relay will be energized only during an alarm condition and when the ALARM LED is lit. The relay contact points (normally closed, normally open, and common) are accessible from the COMMUNICATIONS PORT on the rear of the device (pins 1,4, and 9, respectively). The Nurse Call feature may be used when the device is connected to a computer, however, provisions must be made at the communications port to connect both options simultaneously. Specifications for the 9-pin D connector are listed under Technical Specifications.
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1.3 Technical Specifications Item
Characteristic
Catalog Code Number Description Administration
Set
2M8064 Dual channel linear peristaltic volumetric Baxter’s standard administration
infusion pump
set with “s” suffix
Keep Vein Open (KVO) rate
5 mL/hr or programmed
rate, whichever
is less
Battery
12 Volt, 3.2 Ah sealed lead acid
Battery Life
- Approximately 6 hours with one pump running at a rate from 1 to 1400 mUhr using a fully charged battery - Approximately 4 hours with both pumps running at a rate from 1 to b 1400 mL/hr using a fully charged battery
Battery Recharge
8 hours for 80% recharge
AC Power Requirements
11 O/f20V, 60 Hz
Power Cord
2.75 m (9.0 ft.) long, with Hospital Grade plug
Leakage Current
Typically less than 50 microamps (using UL-544 specified test methods)
Power Consumption
50 watts
Weight
8.2 kg (18 Ibs)
Dimensions
33cmWx13cmDx29cmH (13” 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.
VT81 Range
I - 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.
Air-in-Line Detection
Factory set to NORM which causes the device to alarm on air bubbles approximately 75pL or larger. The MIN setting causes the device to alarm on bubbles approximately 50 PL or larger.
Fuse
0.5 A Slo-610
Nurse Call
g-pin D connector, Pin 1: N/C (normally closed), Pin 4: N/O (normally open), Pin 9: Common Contact rating: 0.4A at 30 VAC, 2A at 30 VDC resistive load (internal connection required)
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General Descridon
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 device. Items 1 through 9 in Figure I- 1 are associated with Pump 1. The controls associated with Pump 2 are identical and function in exactly the same manner. Items 10 through 27, Figure l-l are common to the operation of both pumps. When the word “device” is used in this manual, reference is being made to the entire Flo-GardB 6301 Dual Channel Volumetric Infusion Pump. Generally, the word “pump” is used to refer to either Pump 1 or Pump 2. Each device’s serial number is recorded on a label on the back of the device. ITEM FUNCTION 1. Pump 1 ON-OFF/CHARGE
Key Turns Pump 1 on and off. The internal battery charger remains on regardless of the ON-OFF/CHARGE key-as long as the device is plugged in.
2. Pump 1 Door Latch
Opens and closes pump door.
3. Pump 1 STOP Key
Stops Pump 1. The message STOPPED appears when the key is pressed. An alert will sound if Pump 1 is stopped for more than two minutes. Clears all programming alerts while pump is running.
4. PUMP 1 Key and Indicator
Allows the device to accept keystrokes and other controls common to both pumps for Pump 1 programming. Yellow LED lights to indicate that Pump 1 is selected.
5. Pump 1 Main Display
Shows rate, volume to be infused (VTBI) and total volume infused for Pump 1 primary and secondary infusion programs.
6. Pump 1 Message Display
Shows all Pump 1 messages.
7. Pump 1 ALARM LED
Red LED that blinks on and off during a Pump 1 alarm, accompanied by a visual message display and a repeated sequence of three beeps. An alarm indicates that Pump 1 requires immediate attention.
8. Pump 1 PUMPING LED
Green LED which is constantly lit while Pump 1 is pumping.
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General Description
8 hhi3
9
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45
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Figure l-l. Front View
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l-5
General Description
9. Pump 1 ALERT LED
Yellow LED which lights during Pump 1 alerts, accompanied by a message display and a repeated single beep. An alert indicates that Pump 1 needs routine attention.
10. BACKLIGHT
Provides backlighting of the displays when the device is used in darkened areas. The key toggles the backlighting on and off. If the device is operating on battery power, the backlight remains on for 60 seconds and turns off automatically to conserve battery power.
key
11. SILENCE Key
Temporarily silences an audible alarm or alert for two minutes. All visual alarm or alert information remains displayed.
12. TOT VOWSTATUS 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.
13. CLEAR TOT VOL Key
Resets the total volume delivered to zero when the pump is stopped.
14. TIME Key
Enters desired time interval for an infusion during VolumeTime or Rate-Time programming.
15. PRI RATE Key
Allows programming of the primary infusion rate.
16. PRI VTBI Key
Allows programming of the primary VTBI.
17. PRI START Key
Starts the primary infusion.
18. PLUG Icon
Green LED, always lit while the device is plugged in and the battery is charging.
19. MONITOR Legend
Yellow LED which lights for at least 2 seconds each time the host computer communicates with the device when the device is in monitor mode.
20. BATTERY Icon
Yellow LED, always lit while the device is operating on battery power.
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2 1. COMPUTER CONTROL Legend
Yellow LED which flashes when the device is initiating communications with a host computer to enter the computer control mode. It is constantly illuminated when the device is in computer control mode.
22. CLR Key
Clears any locked in values and programming values currently being entered.
23. SEC START Key
Starts the delivery of the secondary solution.
24. SEC VTBI Key
Allows programming of the secondary VTBI.
25. SEC RATE Key
Allows programming of the secondary infusion rate.
26. Numerical Keyboard
The numerical values for rate, VTBI and time are entered with these keys.
27. OPTIONS Key/Legend
Enables the device to operate in special modes.
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General Descridion
See Figure l-2 for the location of the following items. Note that this figure shows Pump 2 only. Pump 1 has identical features which function in the same manner. 1. Upstream Occlusion Sensor
Detects a complete tubing restriction upstream of the pump.
2. Pump Mechanism
Linear peristaltic pump mechanism.
3. Tube Misloading Sensor
Detects misloaded tubing out of the channel guide slot.
2
3
4
8 7
Figure 1-2. Pump With Door Open
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General Description
4. Downstream Occlusion Sensor
Detects complete tubing restrictions downstream of the pump.
5. Air Sensor
Detects air bubbles in the IV set.
6. Safety Clamp
prevents accidental fluid flow when the IV set is properly loaded and the pump door is opened.
7. Slide Clamp Feature
Provides an additional means of preventing accidental gravity fluid flow by occluding the tubing in the 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 SLIDE CLAMP message displayed. An alert tone will sound to notify the user that the slide clamp should be inserted. If the alarm mode is enabled (software versions 1.09 or later), the pump will NOT start and an alarm tone will sound if the slide clamp is not loaded.
8. Spring Retainer Insert
The pump is shipped from the factory with this plastic 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 6.3.16.
9. Channel Guide Ridges
Function as a guide to keep the tubing properly aligned over the pumping fingers.
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General Description
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Figure 1-3. Rear View
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The following items are located on the rear of the device and are shown in Figure l-3. Secures the device to the IV pole. 1. IV Pole Clamp 2. Power Cord Strap
Stores power cord during battery operation and device storage.
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. Fuse Compartment
The power cord cover must be removed to access the fuses.
6. Power Cord
Removable only by authorized service personnel.
7. PANEL LOCK Switch
Disables all front panel keys, except BACKLIGHT and TOT VOWSTATUS, while the pump is running without alerts.
8. COMMUNICATIONS
9. VOLUME Knob
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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. Adjusts loudness of audible alarm and alert tones. The audible alarm cannot be turned completely off.
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General Description
1.5 Configuration
Option Feature
This section describes the configuration option feature of the device, which allows qualified personnel to inspect and/or modify certain device operating parameters to suit customer requirements. These parameters and their setting options are shown in Table l- 1. The factory settings made at the time of manufacture are also shown in the table. Although the configuration option data is stored in battery backed-up Note: 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.
1.5.1 Reviewing the Configuration Option Settings To view the configuration option settings, both pumps must be on and stopped. Press TIME and TOT VOWSTATUS simultaneously for one second. The message REVlEW COW/G will be displayed in the Pump 1 Message Display. The option description will be displayed in the first line of the Pump 2 Message Display when the NEXT or SEC START key is pressed, beginning with OCCLUSION. The current setting will be displayed on the second line. To view the next setting, press the NEXT or SEC START key. Each press of the NEXT or SEC START key will cause the device to advance to the next setting, in the order shown in Table l1, starting with Occlusion Alarm Level. To exit the inspection mode, press and hold the STOP key and the TIME key, while pressing the TOT VOWSTATUS.
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