IVAC 597 and 598 Technical Service Manual Issue 9.pdf
Page 1
IVAC® Volumetric Pump
Models 597 and 598
Technical Service Manual
s
Page 2
IVAC® Volumetric Pump (Models 597 & 598)
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1000SM00016 Issue 9
Page 3
Contents
Chapter 1 Introduction
4
Chapter 2 Routine Maintenance & Calibration
9
Chapter 3 Troubleshooting
28
Chapter 4 Circuit Descriptions
34
Chapter 5 Spare Parts Replacement Procedures
38
Appendix A Specifications
54
Appendix B Spare Parts Listing
60
Appendix C Fitting & Replacement Guidelines
66
Appendix D Service Contacts
68
Appendix E Disposal
70
Appendix F Document History
72
Page 4
Chapter 1
Introduction
In this chapter
Introduction
5
General Precautions
6
Views of the IVAC® Volumetric Pump (Models 597 & 598)
7
Controls and Indicators
8
Flow Sensor
8
Page 5
Introduction
Introduction
The IVAC® Volumetric Pump - Models 597 & 598 automatically regulates the infusion rate of IV solutions using a linear
peristaltic, volume displacement mechanism to regulate fluid flow at the prescribed rate. The pump can be operated with
a Flow Sensor and is lightweight, compact and robust enough for most patient situations.
The IVAC® 598 Volumetric Pump operates in primary infusion mode only.
The IVAC® 597 Volumetric Pump has a primary and secondary infusion feature.
Product Familiarity
Ensure that you are fully familiar with the pump by carefully studying the Directions for Use (DFU) prior to operation and
prior to attempting any repairs or servicing. As part of continuous improvement, product enhancements and changes are
introduced from time to time.
Purpose of this Manual
This Technical Service Manual describes how to set up, test and maintain the following volumetric pumps:
IVAC® 597 Volumetric Pump
IVAC® 598 Volumetric Pump
This manual is intended for use by personnel experienced in medical equipment testing and maintenance procedures.
This manual has been prepared for use by qualified service personnel only.
CareFusion recommends that all servicing should only be carried out by CareFusion certified service personnel.
A
It is important to ensure that you only refer to the most recent version of the Directions for Use and
Technical Service Manual for your CareFusion products. These documents are referenced on www.
carefusion.com. Copies can be obtained by contacting your local CareFusion representative.
Conventions Used in this Manual
BOLD
Used for Display names, self-test codes, controls and indicators referenced in this manual, for
example, VTBI indicator, test code 08, ON/OFF switch.
'Single quotes'
Used to indicate cross-references made to another section of this manual. For example, see
Chapter 2, 'Configuration and Calibration'.
underline
Used to indicate a link to another section within this manual.
Italics
Used to refer to other documents or manuals. For example, refer to the relevant Directions for Use
(DFU) for further information. Also used for emphasis, for example, ...if the gap still measures less
than...
Wherever this symbol is shown a Hints & Tips note is found. These notes provide useful advice or
information that may help to perform the task more effectively.
Wherever this symbol is shown a Toolbox note is found. These notes highlight an aspect of test
or maintenance that is important to know about. A typical example is drawing attention to a
software upgrade that you should check has been installed.
IVAC® Volumetric Pump (Models 597 & 598)
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1000SM00016 Issue 9
Page 6
Introduction
General Precautions
Prior to using this pump, carefully read the Operating Precautions described in the Directions for Use
(DFU).
This pump contains static-sensitive components. Observe strict precautions for the protection of static
sensitive components when attempting to repair and service the pump.
An explosion hazard exists if the pump is used in the presence of flammable anaesthetics. Exercise care
to locate the pump away from any such hazardous sources.
Dangerous Voltage. An electrical shock hazard exists if the casing of the pump is opened or removed.
Refer all servicing to qualified service personnel.
M
This pump is protected against the effects of high energy radio frequency emissions and is designed
to be fail safe if extremely high levels of interference are encountered. Should false alarm conditions
be encountered, either remove the source of the interference or regulate the infusion by another
appropriate means.
If the pump is dropped, subjected to excessive moisture, humidity or high temperature, or otherwise
suspected to have been damaged, remove it from service for inspection by qualified service personnel.
d
When connected to an external power source, a three-wire (Live, Neutral, Earth) supply must be used. If
the integrity of the external protective conductor in the installation or its arrangement is in doubt, the
pump should be operated from the battery.
IVAC® Volumetric Pump (Models 597 & 598)
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1000SM00016 Issue 9
Page 7
Introduction
Views of the IVAC® Volumetric Pump (Models 597 & 598)
Front View
Main Display
Display
Indicators
VTBI
VOL
ml
KVO
RATE
ml/hr
CLEAR
VOL
READ
VOL
Keyboard
(Model 598)
Keyboard
(Model 597)
Door
VOL
TO BE
INF
RUN/
HOLD
CAM Follower
Assembly
ON /
OFF
VTBI
PRI
KVO
SEC
CLEAR
VOL
ml
ml/hr
READ
VOL
CAM Follower
Assembly Latch
AC power
Indicator
RUN/
HOLD
ON /
OFF
Vo l u m e t r i c P u m p
PRI /
SEC
Primary/
Secondary
Infusion Switch
Air-In-Line
Sensor
Model 598
VOL
TO BE
INF
Rear View
Pole Clamp
PE Connector
(not on XAX* model pumps)
Test Connector Cover
AC Power
Connector
Flow Sensor
Connector
Fuse Holders
* XAX refers to pumps with Serial numbers that include XAX, for example, 597XAX01AA.
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1000SM00016 Issue 9
Page 8
Introduction
Controls and Indicators
The English keyboard controls and indicators are described below. For information on keyboards in other languages, refer
to the relevant DFU. See also Appendix B, 'Spare Parts Listing' for keyboard part numbers.
PRI /
SEC
CLEAR VOLUME
Resets volume infused value to zero.
READ VOLUME
Displays volume infused value.
VOLUME TO BE
INFUSED (VTBI)
Sets value of Volume To Be Infused.
RUN/HOLD
Starts and stops pump infusions. Silences/cancels alarms.
PRIMARY/
SECONDARY
(Model 597 only). Switches the pump between PRIMARY and SECONDARY infusion
modes.
CHEVRONS
Double chevrons/single chevrons for faster/slower increase or decrease of infusion rate
and volume values.
Adjusts user selectable options (in self-test mode).
ON/OFF
Switches the pump on and off.
When any of the following are illuminated:
AC POWER INDICATOR - The pump is connected to an AC power supply and the battery is being charged.
VTBI
The value displayed is the Volume To Be Infused.
KVO
The pump is infusing at the Keep Vein Open (KVO) rate of 5ml/h (or current rate, whichever is less).
VOL
The value displayed is the volume infused.
RATE
The value displayed is the current infusion rate.
PRI
(Model 597 only). The pump is operating in PRIMARY mode.
SEC
(Model 597 only). The pump is operating in SECONDARY mode.
ml
(Millilitres) The value displayed is the VTBI or volume infused value.
ml/hr
(Millilitres / hour) The value displayed is the infusion rate.
Infusion indicator. Three horizontal bars in the left-hand display position flash sequentially when the
pump is infusing.
Infusion indicator with Flow Sensor in use. Upper two horizontal bars convert to a square when a drop is
detected by the flow sensor in the drip chamber.
Flashing
Display
When the pump is operating on battery power, the Display flashes on/off.
Flow Sensor
A flow sensor (part number 192) is used to detect an empty fluid container. It is connected to the drip chamber and when
a drop is detected in the drip chamber the infusion indicator in the top left position of the Display converts to a square
character, see above.
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1000SM00016 Issue 9
Page 9
Chapter 2
Routine Maintenance &
Calibration
In this chapter
Routine Maintenance
10
Self-Test Mode
10
Test Codes
11
Test Connector
17
Upgrading Software
17
Cam Follower Gap Check
18
Functionality Checks
19
Occlusion Verification Test
20
Rate Accuracy Verification Test (Code 13)
20
Physical Inspection and Clean
21
Calibration Procedures
23
Performance Verification Procedure
27
Page 10
Routine Maintenance & Calibration
Routine Maintenance
For routine maintenance, the following tests and Performance Verification Procedures (PVP) should be performed in
addition to the tasks described in the section 'Physical Inspection and Clean'.
Refer to the relevant DFU for the recommended routine maintenance period.
Self-Test Mode
Self-test mode is used to access a number of test routines which are designed to test and verify many of the pump
functions, defaults and calibrations without requiring internal inspection. Configuration settings are also enabled or
disabled via self-test mode.
Each test can be run in a single pass or in a continuous loop mode. See 'Test Execution' below for further details. Some
tests require a test jumper (part number 134646), see 'Test Connector' for further details.
Test Pass/Fail
The PRI & SEC (Model 597) or RATE & VOL (Model 598) indicator lights on the front panel of the pump are used to signal
whether the pump passes or fails a test as follows:
If the yellow PRI (Model 597) or VOL (Model 598) indicator light comes on, the pump has passed the test in progress.
If the red SEC (Model 597) or RATE (Model 598) indicator light comes on, the pump has failed the test in progress.
Most test procedures display data, such as numeric codes to indicate a test failure reason. See 'Test Procedure' table for
further details.
Entering Self-Test Mode
Press the CLEAR VOL and ON/OFF switches simultaneously until the display turns on. The pump then performs poweron self-tests. Initially, the current software revision level is displayed, followed by the battery voltage.
When the battery voltage is displayed, press the RUN/HOLD switch to display t=00 which means the pump is ready to
start test 00.
Note: To bypass the display of the software revision level and the battery voltage and advance directly to t=00, hold
the CLEAR VOL switch until the power-on display test completes.
Use the chevron switches (I, J, L and K) to select the test code required.
To exit self-test mode, turn the pump off.
Test Execution
Single Pass Mode
After selecting the test number (see 'Entering Self-Test Mode' above), press the RUN/HOLD switch to start the test for one
pass. The display changes to show the test number for example, t=13. If there is data to display, it can be viewed after the
test by pressing the READ VOL switch.
Continuous Loop Mode
Certain tests can be run in a continuous loop mode (see tables below). After selecting the test number, press the RUN/
HOLD switch twice within one second to enter the test loop. The display will change as in the single pass mode then the
test will be repeated continuously until the RUN/HOLD switch is pressed again.
To display the test data while the test continues, press the READ VOL switch.
To exit the loop, press the RUN/HOLD switch.
Exiting Self-Test Mode
Self-mode can be exited at any time turning off the pump.
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1000SM00016 Issue 9
Page 11
Routine Maintenance & Calibration
Test Codes
Summary
Code
Test Name
Code
Test Name
00
Self-Test (01 to 08)
19
EEPROM Test
01
Speaker and Speaker Drive Circuit Test
20
Rate Calibration Number Read
02
Motor and Drive Circuitry Test
21
Total Pump Life "On" Time Read/Clear
03
Pressure Sensor Test
22
Total Battery "On" Time Read/Clear
04
Air-in-line Test
23
Error/Alarm Stack Read/Clear
05
Safety Switch and Driving Circuitry Test
24
06
Front Panel LED Test
25
Language Code Read/Set
07
External RAM Test
26
CRIS Configuration
08
Tach/Volume Flag Test
27
Air Bubble Length Read
09
Drop Discriminator Circuitry, Simulated Drop Test
28
FLO Alarm Threshold Read
10
Drop Detector LED Drive Current Test
29
11
Door Sensor Test
30
Auxiliary Front Panel Display Enable/Disable
12
Dried Spillage Alarm Parameters Read
31
Secondary Mode Setting On/Off
Rate Accuracy Test
32
13
See 'Rate Accuracy Verification Test' section for details of test.
14
Switch Test
15
Burn-In Test
16
Battery Voltage Test
17
Seven-Segment Display Test
18
Factory Use Only
IVAC® Volumetric Pump (Models 597 & 598)
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Pressure Calibration Read/Set
See 'Pressure Calibration' section for details of test.
Door Calibration Read/Set
See 'Door Calibration' section for details of test.
Production/Quick Configuration Test
Factory Use Only. Test not available.
33
Pump Identification Number Read/Set
34
Hospital or Alternate Site Configuration Set
35
Secondary Mode Enable/Disable (Model 597 only)
36
Flow Sensor Optional/Mandatory
1000SM00016 Issue 9
Page 12
Routine Maintenance & Calibration
Test Codes (continued)
Test Procedures
Code
Test
Action/Data Displayed
Loop
00
Self-Test (01 to 08)
The pump cycles through tests 01 through 08 sequentially, displaying the test
number in progress, in the format t0.01 through t0.08.
If a test fails, the red SEC (or RATE) indicator lights, the current test stops and the
test number is displayed. Press the RUN/HOLD switch once to continue to the next
test (or twice to exit the test).
Loop
only
01
Speaker and Speaker
Drive Circuit Test
Test fail codes:
1=speaker senses as not turning on
2=speaker senses as not turning off
Yes
02
Motor and Drive
Circuitry Test
Test fail codes:
1=motor would not turn on (or shorted coil)
2=motor would not turn off
Yes
Pressure Sensor Test
Data displayed: D/A trim level is displayed at end of test.
Test fail codes:
1 = amplifier output stuck high
2 = amplifier output stuck low
3 = amplifier cannot attain 4.6 volts
4 = amplifier cannot go below 0.2 volts
5 = bridge will not trim (D/A bits bad)
6 = trim/amplifier gain > 4.4 7 = trim/amplifier gain < 3.6
Yes
Air-in-line Test
To run the test:
Load an air or fluid-filled IV infusion set.
Press the READ VOL switch to display the output code.
Test fail codes:
0 = fluid detected in IV infusion set
1 = air detected in IV infusion set
2 = output stuck high
3 = test line could not force air indication
Yes
05
Safety Switch and
Driving Circuitry Test
Test fail codes:
1 = safety logic line would not go low
2 = safety logic line would not turn off
3 = safety switch would not turn on
4 = safety switch would not turn off
5 = both safety switch and motor drive stuck on
Yes
06
Front Panel LED Test
All front panel LEDs are lit until the RUN/HOLD switch is pressed.
Inspect LEDs. Note that the AC charge LED only lights on AC power.
Yes
07
External RAM Test
Test fail: display shows the first address failed, hexadecimal. Note that the highest
address is tested first.
Yes
08
Data displayed: tt.vv where tt equals the last two digits of the number of tach flags,
and vv equals the number of volume flags. Normal display is 20.28, and the tt may
vary by +/- one count.
This test is designed to assist in aligning the encoder disk optics and is intended to
Tach/Volume Flag Test
be used in the loop mode.
When running test, if there is excessive noise, loosen retaining screws as required
and adjust the cam follower assembly as far as possible towards the bottom of the
pump. Tighten retaining screws then turn the pump off.
Yes
09
Note: The flow sensor must be connected to the pump.
Data displayed: output voltage in A/D counts. Ideal value is 205 counts = 4.00 volts
Test fail codes:
1 = no drop detected
2 = value too high, max = 4.257 V, 218 counts
3 = value too low, min = 3.750 V 192 counts
4 = simulated drop detected as multiple drops
5 = simulated drop detected as long or small drop
Yes
03
04
Drop Discriminator
Circuitry, Simulated
Drop Test
IVAC® Volumetric Pump (Models 597 & 598)
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1000SM00016 Issue 9
Page 13
Routine Maintenance & Calibration
Test Codes (continued)
Test Procedures (continued)
Code
Test
Action/Data Displayed
Drop Detector LED
Drive Current Test
Note: The flow sensor must be connected to the pump.
Data displayed: LED current, in mA
Test fails if the current exceeds 126 mA or falls below 2 mA.
Yes
11
Door Sensor Test
OPEN = door sensed as open
CLOS = door sensed as closed
Press READ VOL switch to display the A/D value.
See 'Door Calibration' for instructions on how to read and set door calibration value.
Yes
12
Dried Spillage Alarm
See 'Read Parameter/Values' table on the next page.
Parameters Read
13
Rate Accuracy Test
10
Loop
-
See 'Rate Accuracy Verification Test' section for details of test.
-
Press each switch and check the corresponding code is displayed:
14
Switch Test
I
0
E
5
J
1
6
K
2
L
3
C
B
F
D
4
7
No
8 (hidden switch on Model 598)
Note: the ON/OFF switch does not have a code.
To exit this test, press both the RUN/HOLD switch and PRI/SEC (hidden switch on
Model 598) switch simultaneously, or turn the pump off.
15
Burn-In Test
All front panel LEDs light continuously (except for run indicator which behaves as if in
normal mode). Pump runs at 125 ml/h, all FLO, OCCL, and Air alarms are ignored.
Data displayed: All detected errors. Door alarm is also active.
Note: It is not possible to run this test if any errors have been detected since entering
self-test mode.
16
Battery Voltage Test
Data displayed: battery voltage, in volts. Test passes with value above 5.7 volts .
Yes
17
Seven-Segment
Display Test
Test fail codes (LED segment assembly number):
0 = far left, 1 = 2nd from left, 3 = 2nd from right, 4 = far right
No
18
Factory Use Only
Factory Use Only
19
EEPROM Test
Data displayed: number of first registration to fail.
No
No
Read Parameters/Values
Code
12
Test
Action/Data Displayed
Dried Spillage
Alarm Parameters
Read
Read parameters by pressing the RUN/HOLD switch four times:
1st press displays the dried spillage scan start volume flag number.
2nd press displays the scan stop volume flag number.
3rd press displays the alarm threshold value.
4th press exits the test.
13 through 19
20
Rate Calibration
Number Read
Loop
No
See 'Test Procedures' table on the previous page.
-
Read the factory-set calibration number. If the Cam Follower Assembly is replaced and
the number is not "0033" change as follows:
Use the chevron switches until the display reads "0033"
Press the RUN/HOLD switch and verify "Cal Done" is displayed
IVAC® Volumetric Pump (Models 597 & 598)
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No
1000SM00016 Issue 9
Page 14
Routine Maintenance & Calibration
Test Codes (continued)
Read Parameters/Values (continued)
Code
Test
Action/Data Displayed
Total Pump Life
"On" Time Read/
Clear
Read the total pump "on" time, displayed in 10-hour increments. For example, 0037 =
370 hours.
To clear the total pump "on" time:
Install a test jumper. See 'Test Connector' for instructions.
Press the CLEAR VOL and PRI/SEC (hidden switch on Model 598) switches until the
display shows 0000.
No
Total Battery "On"
Time Read/Clear
Read the total total time the pump has been running on battery power, displayed in
10-hour increments. For example. 0048 = 480 hours.
To clear the total battery "on" time:
Install a test jumper. See 'Test Connector' for instructions.
Press the CLEAR VOL and PRI/SEC (hidden switch on Model 598) switches until the
display shows 0000.
No
23
Error/Alarm Stack
Read and Clear
Read the last 16 error or alarm codes.
The most recent alarm or error is always displayed first. Pressing the K switch
displays the previous error/alarm and cycles through the error or alarm codes. ---denotes the end of the alarm stack.
Notes:
1) All error and alarm messages will be displayed in English regardless of the
Language Code setting (Test 25).
2) The stack of alarms/error codes will be lost if the battery is removed and the
information will be unreliable until filled with new alarm messages or cleared.
To clear the alarm stack:
Install a test jumper. See 'Test Connector' for instructions.
Press the CLEAR VOL and PRI/SEC (hidden switch on Model 598) switches until the
display reads ----.
No
24
Pressure Calibration
See 'Pressure Calibration' section for details of test.
Read/Set
-
25
Language Code
Read/Set
See 'Configuration Settings' table on the next page.
-
26
CRIS Configuration
See 'Configuration Settings' table on the next page.
-
27
Air Bubble Length
Read
Read the air-in-line alarm threshold value, displayed in microlitres. This value is the
nominal air bubble alarm threshold in microlitres used for air-in-line detection and is
originally set at the factory.
No
28
FLO Alarm
Threshold Read
Read the FLO alarm threshold value in psi. This value is the upstream occlusion alarm
threshold pressure in psi and is originally set at the factory.
No
21
22
IVAC® Volumetric Pump (Models 597 & 598)
Loop
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1000SM00016 Issue 9
Page 15
Routine Maintenance & Calibration
Test Codes (continued)
Configuration Settings
Code
Setting
Action
25
Language Code
Read/Set
Read and/or set how error and alarm messages are displayed.
E = English text, for example door, Err6.
C = Codes or International, for example, P1, E1. For non-English language users.
To change the setting, press the PRI/SEC (hidden switch on Model 598) switch
and any chevron switch simultaneously for two seconds.
No
26
CRIS Configuration
Setting not in use. CRIS=CRIS enabled, OFF=CRIS disabled.
Ensure the setting is OFF.
No
27
Air Bubble Length Read
See 'Read Parameter/Values' table on the previous page.
-
28
FLO Alarm Threshold
Read
See 'Read Parameter/Values' table on the previous page.
-
29
Door Calibration Read/
Set
See 'Door Calibration' section for details of test.
-
Auxiliary Front Panel
Display
Enable/Disable
Enable or disable Auxiliary Front Panel Display feature, used to display
calibration data.
on.05 = feature enabled, where 05 equals the number of times remaining that
the pump can be powered on/off with Auxiliary Front Panel Display enabled
(five maximum).
OFF = feature disabled.
To enable the feature:
Press the PRI/SEC (hidden switch on Model 598) switch and any chevron switch
simultaneously for two seconds. The display will read on.05.
Turn the pump off then on. The pump is now in normal operating mode with
this feature enabled.
To disable the feature:
Enter test 30 and press the CLEAR VOL switch. The display will show OFF.
Alternatively, turn the pump off/on five times.
Warning: Ensure that this feature is OFF before returning the pump into service.
No
31
Secondary Mode Setting
On/Off
Enable or disable the Secondary Mode setting (code 35).
SC.On = Secondary mode setting enabled (Model 597 only)
SC.OF = Secondary mode setting disabled (Model 598)
Defaults to SC.On when the EPROM is first installed. If an EPROM is installed on a
Model 598, the setting must be changed to SC.OF (secondary off ).
To change the setting:
Install a test jumper. See 'Test Connector' for instructions.
Load a set segment into the cam follower assembly.
Press the PRI/SEC (hidden switch on Model 598) switch and any chevron switch
simultaneously for two seconds.
No
33
Pump Identification
Number Read/Set
Read and/or set the pump identification number (ID).
To set a new ID, use the chevron switches to select a desired value, then hold
the PRI/SEC switch and press the RUN/HOLD switch to exit the test. Press RUN/
HOLD again to display and verify the new pump ID.
No
30
IVAC® Volumetric Pump (Models 597 & 598)
Loop
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1000SM00016 Issue 9
Page 16
Routine Maintenance & Calibration
Test Codes (continued)
Configuration Settings (continued)
Code
Setting
Hospital or Alternate Site
Configuration Set
34
Note: This setting is
unavailable on pumps
with software version
10.03 or below.
Secondary Mode
Enable/Disable
(Model 597 only)
35
36
Note: This setting is
unavailable on pumps
with software version
10.03 or below.
Flow Sensor
Optional/Mandatory
IVAC® Volumetric Pump (Models 597 & 598)
Action
Loop
HOSP = Hospital Configuration
ASC = Alternate Site Configuration See Note below.
To change the setting:
Press the PRI/SEC switch and any chevron switch for 2 seconds to toggle the
selection. The new configuration choice is displayed.
Turn off the pump to exit the test and set the new configuration in memory.
Note: when set to ASC, note the following:
1) These test codes are not available, and cannot be changed:
25-Language Code set to E=English
26-CRIS setting is OFF=Disabled
30-Auxiliary Front Panel Display feature is OFF=Disabled
31-Secondary Mode Setting is SC.OF = Disabled
2) While the pump is running, the AIL alarm value is 500 microlitres. See test 27.
3) Any previous HOSP configuration values are stored while set to ASC. HOSP
values are restored when the HOSP setting is selected again.
No
Read and/or enable or disable Secondary Mode on the Model 597 pump.
SC.ON = Secondary mode enabled
SC.OF = Secondary mode disabled
When software is first installed, this setting may not be enabled when pump is
powered on. Ensure the setting is enabled.
To change the setting:
Load a set segment into the cam follower assembly.
Enter self-test mode and select test code 35.
Press the RUN/HOLD switch to enter the test. Press the PRI/SEC switch and any
chevron switch simultaneously to toggle the selection and select the mode.
Press the RUN/HOLD switch, then turn the pump off.
Note: This setting must be enabled via test code 31.
No
Set Flow Sensor usage to optional or mandatory.
FS.OP = Use of a flow sensor is optional when running an infusion
FS.On = A flow sensor is mandatory (must be fitted) in order to run an infusion
To change the setting:
Install a test jumper. See 'Test Connector' for instructions.
Press the PRI/SEC switch (the hidden switch on the Model 598) and any
chevron switch simultaneously for two seconds.
Release the switches when the required setting is displayed.
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No
1000SM00016 Issue 9
Page 17
Routine Maintenance & Calibration
Test Connector
In order to perform certain tests and to change any pump settings, a test jumper or a low value resistor of 1K5Ω or less,
connecting test connector pin 9 to pin 23 must be installed.
Procedure:
1. With the pump off, remove the test connector cover from the back of the rear case.
2. Using a test jumper (part number 134646), a wire, or a low-value resistor (1k5Ω or less), connect pin 9 to pin 23 on the
external test connector. See Figure 2-1 below. Take care not to short any pins adjacent to pin 9 or 23 as this may result
in a blown fuse.
Pin 1
Pin 2
Pin 9
Pin 23
Figure 2-1 External Test Connector (J3)
3. Place the pump in self-test mode then select and carry out the test(s) as required.
4. When the test is complete, remove the test jumper from the test connector.
5. Refit the test connector cover.
Upgrading Software
Upgrade of Model 597/598 volumetric pump software to V1.10 or greater is recommended when
serviced
Perform upgrades by acquiring the software upgrade kits specified in spare parts listings.
Equipment required: Software upgrade kit (includes EPROM fitting and removal instructions)
Software Upgrade Kits Available
Pump Model
597/598
Part Number
143053
IVAC® Volumetric Pump (Models 597 & 598)
Software Version
1.10
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1000SM00016 Issue 9
Page 18
Routine Maintenance & Calibration
Cam Follower Gap Check
Equipment required:
0.160" pin gauge (part number 305601), 0.160" block gauge or calibrated calipers
Indelible marker
Procedure:
1. Open the orange cam follower assembly latch.
2. Position the topmost follower closer to the pressure pad than the other followers. To do this:
Enter self-test mode and select test 08 (alternatively, select test 02). See 'Entering Self-Test Mode' for instructions. Press
the RUN/HOLD switch twice within one second to enter the test in loop mode, then press RUN/HOLD switch again to
exit the loop. Repeat this step until the topmost follower is positioned closest to the pressure pad.
3. Using the pin gauge, check the gap between the pressure pad and the end of the followers (while it is still positioned
closest to the pad). See Figure 2-2 below.
4. If the gap measures less than 0.160", check that the Cam Housing Assembly and the Cam Follower Assembly are
correctly seated.
0.160" minimum
5. If the gap still measures less than 0.160":
replace the Cam Follower Assembly
OR, replace the Cam Housing Assembly
OR, replace the Front Case
Top Follower
Pressure Pad
Orange
Cam Follower
Assembly Latch
Figure 2-2 Follower/Pressure Pad Gap
IMPORTANT: Failure to maintain the appropriate gap width may result in a set being incorrectly
loaded into the pump. If this situation arises, there is a risk that an undetected over-infusion may
occur. Refer to MHRA Hazard Notice 2002 (09) for more information.
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1000SM00016 Issue 9
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Routine Maintenance & Calibration
Functionality Checks
Alarms
Alarm
Action
Door (P1)
Open the door at least ¼ inch. Verify that the pump stops running, an alarm sounds, and the
display shows door (P1). Close the door. Press the RUN/HOLD switch momentarily to verify that
the alarm stops and the display alternates between the set rate and hold (P3)
FLO (P2)
Set rate to 200 ml/h. Press the RUN/HOLD switch. Verify that the pump starts. Close the set
regulating clamp and verify that a FLO (P2) alarm occurs within approximately 15 seconds. Open
the set regulating clamp. Note: If you are not using a flow sensor and the pump fails to alarm,
perform the 'Pressure Calibration' procedure.
Hold (P3)
Press the RUN/HOLD switch. Verify that the pump starts. Press the RUN/HOLD switch to put pump
on hold. Verify audible bleep and hold (P3) alarm displayed after two minutes.
Air (P5)
Load an air-filled IV infusion set (no fluid) into the pump. Press the ON/OFF switch to turn the
pump on. Set the rate and the VTBI. Press the RUN/HOLD switch to start the pump. Verify that the
pump alarms and displays Air (P5).
Reload ---- Air (P5)
With pump displaying Air (P5)—see above—press RUN/HOLD to put pump on hold, then press
the RUN/HOLD switch again and verify that the pump alarms and displays Reload ---- Air (P5)
alternating with Air (P5).
Reload (P6)
Start pump without an IV infusion set loaded. Verify that the pump alarms and displays Reload
(P6).
OCCL (P7)
Set rate to 200 ml/h. Press the RUN/HOLD switch. Verify that the pump starts. Occlude the set
at approximately 2.5 cm from the exit of the pump. Verify an OCCL (P7) alarm occurs within
approximately 15 seconds. If the pump fails to alarm, perform the 'Pressure Calibration'
procedure. Important: Run the 'Occlusion Verification Test' to verify that the pump occludes
between 5.5 and 11 psi (nominal 6 to 8 psi). See below for instructions.
KVO
Set rate to 200 ml/h. Press RUN/HOLD or VTBI. Set VTBI to 0001 ml by pressing the chevron
switches. Press RUN/HOLD switch to start pump. Verify that a KVO alarm occurs within
approximately 18 seconds.
Verify Volume Infused and Rate Retention
Battery Power Check
1. Press the READ VOL switch and note the infused volume.
1. Remove power cord from the AC power socket.
2. Press the ON/OFF switch to turn pump off. Wait 15
seconds, then press the ON/OFF switch again to turn
the pump on.
2. Press the RUN/HOLD switch and verify an audible
bleep.
3. Verify the infused volume and the rate displayed are the
same as before.
3. Verify that the pump operates and the display
flashes on and off. Verify that the moving horizontal
bars in the left-hand display position are sequencing
as before.
4. Plug the power cord back in to AC power socket.
Flow Sensor Check
See 'Physical Inspection and Clean' for instructions.
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1000SM00016 Issue 9
Page 20
Routine Maintenance & Calibration
Occlusion Verification Test
Equipment Set Up:
Set up equipment as per 'Pressure Calibration Equipment Set Up', with the pressure gauge connected and three-way
stopcock closed.
Procedure:
1. Set rate to 200 ml/h.
2. Press the RUN/HOLD switch. Verify that the pump starts.
3. Verify that an OCCL (P7) alarm between 5.5 and 11 psi (nominal 6 to 8 psi).
If the pump fails to alarm, perform the 'Pressure Calibration' procedure.
Rate Accuracy Verification Test (Code 13)
Equipment Set Up:
Set up the pump as shown in Figure 2-3 below.
Close the set roller clamp.
Plug the pump into AC mains.
Water Source
Burette
Ensure flow sensor is
removed.
30 ± 2 inches (76 ± 5 cm)
Burette Clamp
Equipment Stand
Three-way
Stopcock
Tubing
Table
or Bench
IV Tubing
Figure 2-3 Rate Accuracy Verification
Test Equipment Set Up
Middle of Follower
Assembly/Door Latch
Used Fluid
Receptacle
Procedure:
1. Using a Class A burette, adjust the fluid level so that the meniscus is level with the zero mark.
2. Enter self-test mode and select test 13. See 'Entering Self-Test Mode' for instructions.
3. Press the RUN/HOLD switch; the default rate of 300 ml/h will be displayed.
4. Press the RUN/HOLD switch; the default test time of 300 seconds (5 minutes) will be displayed.
5. Press the RUN/HOLD switch to start the test. The display will show the test time remaining in seconds. A click will
sound as each second is decremented.
6. When the display reaches zero seconds, the display shows STOP to indicate the end of the test. The PRI indicator will
also be lit.
7. Press the RUN/HOLD switch to display the volume infused and verify that the infused volume in the burette is 25 ±1.25
ml.
Due to variations between IV infusion sets, the reading may not fall within the stated parameters. If this occurs, retest
using another IV infusion set. If the variance still exceeds ±5% after retesting with another IV infusion set, replace the
Cam Follower Assembly.
Note: During the test run, operational alarms can be cleared by pressing the RUN/HOLD switch. The test must be rerun.
Error alarms are cleared by turning the pump off and back on. The test must be rerun.
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1000SM00016 Issue 9
Page 21
Routine Maintenance & Calibration
Physical Inspection and Clean
To ensure the pump remains in good operating condition, it is important to keep it clean and carry out the routine
procedures described below. All servicing should only be performed by a qualified service engineer.
Routinely clean the exterior surface of the pump, the door (including inside surfaces), the integral air-in-line detector,
and the cam follower assembly, especially if spillage has occurred.
Before cleaning always switch OFF and disconnect from the AC power supply. Never allow fluid to
enter the casing and avoid excess fluid build up on the pump.
Do not use aggressive cleaning agents as these may damage the exterior surface of the pump.
Do not steam autoclave, ethylene oxide sterilise or immerse this pump in any fluid.
Unplug the power cord from the AC wall outlet before cleaning. Do not allow fluids to enter the pump case.
Use a cloth dampened with warm water, or a mild, non-abrasive detergent (such as commercially available dish
cleaning liquid) mixed with water. After cleaning, pumps should be rinsed with a soft cloth soaked in water, followed
by a thorough drying. Then apply disinfecting solution with a soft cloth. Rinse using a soft cloth soaked in water after
the appropriate disinfecting time, and dry thoroughly. A cotton-tipped applicator is useful for cleaning in narrow
spaces.
The following cleaning/disinfecting solutions have been evaluated and found to be acceptable:
- Cidex
- Glutarex
- Hydrogen Peroxide (3% in water)
- Manu-Klenz
- T.B.Q
- Insurance
- Vesphene
Note: Alcohol, ammonia, acetone, benzene, phosphoric acid, xylene, and similar solvents can erode (wear away pit)
or otherwise damage the cam followers and other surfaces of the pump. The cam followers must be kept clean using
a solution of warm water and a mild non-abrasive detergent, and inspected for possible erosion. The cam follower
assembly should be removed and cleaned according to the procedure outlined below, see 'Clean and Inspect the Cam
Follower Assembly'.
Check that labels are flat, legible and fully adhered. Replace as necessary.
Inspect case components for damage and replace if necessary.
Inspect the door for damage and check that it closes and latches correctly.
Check door magnet is in place. Replace if necessary.
Inspect the AC power supply plug and cable for damage.
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Routine Maintenance & Calibration
Physical Inspection and Clean (continued)
Verify the cam follower assembly latch opens and closes properly.
It is important to clean the cam follower assembly after fluid spills and during routine inspections.
Spilled fluid left to dry may lead to FLO (P2), OCCL (P7) or Err n (En) alarms, or may cause a free-flow
condition. Do not use the pump under this condition. Remove the cam follower assembly and clean
as described below.
Inspect cam follower housing parts for fluid spill residue or foreign matter. If residue is noted in the cam follower
assembly, refer to the cleaning instructions for the appropriate method for removing and cleaning.
The Cam Follower Assembly
Inspect the Followers for Erosion
Shine a flashlight into the followers. The followers should be clean and shiny. A dull appearance may indicate
erosion. If the followers appear dirty or dull, remove and clean per the following procedure.
Remove the Cam Follower Assembly from the Pump
See 'Cam Follower Assembly' in Chapter 5, 'Spare Parts Replacement Procedures' for instructions.
Clean and Inspect the Cam Follower Assembly
1. Soak the cam follower assembly for 10 minutes in a warm, mild detergent solution. Commercially available dish
cleaning liquid is acceptable. Clean the surface of the followers using a cotton-tipped applicator.
2. Rinse the cam follower assembly well under running water.
3. Allow the cam follower assembly to dry thoroughly.
4. When dry, verify that the latch and all the followers of the cam follower assembly move freely, especially the
pressure-sensing follower.
5. If the followers do not move freely, repeat the soak, rinse, and dry process.
6. Check the cam followers for erosion. The followers should be clean and shiny. A dull appearance may indicate
erosion. If they are still dull after cleaning, replace the Cam Follower Assembly as described in Chapter 5, 'Spare
Parts Replacement Procedures'.
7. Examine the gasket on the front case. Clean or replace as needed.
Lubricate ends of
pressure pads
Follower
LUBRICATION NOT
REQUIRED
Pressure sensing follower
LUBRICATION NOT
REQUIRED
Lubricate ends of
pressure pads
Lubricate latch
Figure 2-4 Lubricating the Cam Follower Assembly
Lubricate the Cam Follower Assembly
1. Lubricate the cam follower assembly with a light consistency of silicone based lubricating grease, or equivalent.
2. Apply lubricant to both sides of both ends of the pressure pads, and both sides of the cam follower assembly latch,
as shown in Figure 2-4 below.
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1000SM00016 Issue 9
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Routine Maintenance & Calibration
Physical Inspection and Clean (continued)
Re-fit the Cam Follower Assembly
Re-fit the cam follower assembly into the pump following the instructions in the section 'Cam Follower Assembly' in
Chapter 5, 'Spare Parts Replacement Procedures'.
The Cam Follower Assembly (continued)
Placement Check: Run Test 08
1. Enter self-test mode and select test 08. Press the RUN/HOLD switch twice to run the test in loop mode.
2. If there is excessive noise, loosen retaining screws as required and adjust the cam follower assembly as far as
possible towards the bottom of the pump.
3. Tighten retaining screws then press the ON/OFF switch to turn the pump off.
Flow Sensor Check
Wash the flow sensor with warm water to dissolve and remove any dried IV solution that may cloud the lenses or
prevent the sliding parts from operating smoothly.
Check that labels are flat, legible and fully adhered. Replace as necessary.
Check that lenses are clean and clear, and show no signs of cracks.
Inspect the body of the flow sensor for signs of physical damage.
Check that the sliding action of the flow sensor operates smoothly.
Calibration Procedures
Door Calibration (Code 29)
Perform this procedure whenever the Door Assembly, Magnet, Cam Housing Assembly, Optical
Sensor Board, Logic Board, or EEPROM have been replaced.
Equipment required: 0.125" (3.175mm) pin gauge
Procedure:
1. Install a test jumper. See 'Test Connector' for instructions.
2. Enter self-test mode and select test 29.
Place gauge here
3. Open the door and rest a 0.125" (3.175mm) pin gauge on
top of the door latch. See Figure 2-5. Close the door and
hold it closed at the location across from the latch.
Latch
Hold door
against gauge
4. Press the PRI/SEC (hidden switch on the Model 598) and
RUN/HOLD switches simultaneously. The pump will beep
twice and display CAL DONE.
Note: To read the calibration number, press the READ VOL
switch.
5. Open the door and remove the gauge.
Figure 2-5 Door Calibration
6. Remove the test connector jumper and refit the test
connector cover.
To verify the door sensor is correctly calibrated, run test 11, Door Sensor Test.
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Routine Maintenance & Calibration
Calibration Procedures (continued)
Pressure Calibration
The following procedure describes how to calibrate the pressure sensor. Two pressure calibration values are read/set in
test 24, these are:
Pressure Slope is expressed in psi/volts, range is 9.0 to 51.0. Values can be changed in 0.1 increments, however, the
pump only retains values in 0.2 increments. The pressure slope value affects both upstream and downstream pressure
readings.
Pressure Offset is used to correct for a non-zero pressure reading when the actual downstream pressure is zero. This
calibration value is expressed in psi + 10.0 with a range of entered values from 5.0 to 15.0 which correspond to actual
offset values from -5.0 to +5.0. The pressure offset value affects the downstream pressure reading only.
Summary
Stage 1: Set up equipment
Stage 2: Read and compare downstream pressure values
Set up auxiliary front panel displays (test 30)
Measure (read and record) downstream pressure with zero pressure, for example P0 = -0.8
Measure (read and record) downstream pressure with 8 psi, for example P8 = 4.8
Examine P0 and P8 readings. Continue to Stage 3 if readings are not within +/- 1.2 psi.
Stage 3: Measure initial pressure calibration values - pressure slope/pressure offset (code 24)
Stage 4: Calculate new pressure calibration values
Stage 5: Program pump with two new pressure calibration values (test 24)
Stage 1: Set up equipment
Set up the equipment as shown in Figure 2-6 below.
The vertical distance (from the fluid level of the container to the centre of the cam follower assembly) of 30 ± 2 inches
must be maintained because the height of the solution container will affect the pressure readings
Ensure that the IV infusion set is completely primed with fluid (no air) before attaching to reservoir
Ensure that the IV infusion set loaded in the pump and any tubing used in the set up is not kinked
Ensure that fittings are secure and reservoir is airtight
DECV sets are not to be
used to perform pressure
calibration.
30 ± 2 inches (76 ± 5 cm)
Three-way
Stopcock
Pressure Gauge
Reservoir
Table Top or bench
Figure 2-6 Pressure Calibration Equipment Set Up
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Routine Maintenance & Calibration
Calibration Procedures (continued)
Pressure Calibration (continued)
Stage 2: Read and compare downstream pressure values
1. Enter self-test mode and select self-test 30 (set up auxiliary front panel displays). See 'Entering Self-Test Mode' for
instructions.
2. Press any chevron switch and the PRI/SEC (hidden switch on Model 598) switch simultaneously until on05 is displayed.
3. Turn pump off and on. Open the three-way stopcock.
4. Set the rate to 200 ml/h. Clear the volume infused, and set the volume to be infused to 500 ml.
5. Start the pump running.
6. Press the READ VOL and I switches simultaneously to enable Pressure Read mode.
Notes:
The display should read Pres 06 (indicating that the flow alarm threshold value is set to 006 in test 28).
Pressure Read mode will stay enabled until RUN/HOLD is pressed.
7. Press the I and L switches simultaneously to disable occlusion alarms OCCL and FLO. The pump will display FLO
OFF, OCCL OFF, and will beep three times. Note: FLO and OCCL alarms are automatically enabled at the next power-up.
8. After 30 seconds, press the K switch to display the downstream pressure. Record this downstream pressure reading
as P0. Note that it may be a negative number. For example, P0 = -0.8.
9. Connect the pump to the pressure gauge by closing the three-way stopcock. When the pressure gauge reads 8 ± .25
psi record this downstream pressure reading as P8.
10. Examine the pressure readings recorded in Step 8 and Step 9. If they are P0 = 0 ± 1.2 psi and P8 = 8 + 1.2 psi, then the
pressure calibration is complete. If not, turn the pump off and then perform Steps 11 through 18.
Stage 3: Measure initial pressure calibration values - pressure slope/pressure offset
11. Enter self-test mode and select test 24. See 'Entering Self-Test Mode' for instructions.
12. Read and record the initial pressure slope value displayed on entering test 24. Press RUN/HOLD to display the initial
pressure offset value. Record this value. These values will be used in the next stage (Stage 4) to calculate the new
pressure calibration values.
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