IVAC 597 and 598 Technical Service Manual Issue 9

Technical Service Manual

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IVAC® Volumetric Pump Models 597 and 598 Technical Service Manual

IVAC® Volumetric Pump (Models 597 & 598)

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Contents Chapter 1 Introduction

Chapter 2 Routine Maintenance & Calibration

Chapter 3 Troubleshooting

Chapter 4 Circuit Descriptions

Chapter 5 Spare Parts Replacement Procedures

Appendix A Specifications

Appendix B Spare Parts Listing

Appendix C Fitting & Replacement Guidelines

Appendix D Service Contacts

Appendix E Disposal

Appendix F Document History

Chapter 1 Introduction In this chapter Introduction

General Precautions

Views of the IVAC® Volumetric Pump (Models 597 & 598)

Controls and Indicators

Flow Sensor

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. is important to ensure that you only refer to the most recent version of the Directions for Use and A ItTechnical 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.

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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.

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.

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.

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Introduction

Views of the IVAC® Volumetric Pump (Models 597 & 598) Front View Main Display Display Indicators VTBI

VOL

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

ml/hr

CLEAR VOL

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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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.

(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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Chapter 2 Routine Maintenance & Calibration In this chapter Routine Maintenance

Self-Test Mode

Test Codes

Test Connector

Upgrading Software

Cam Follower Gap Check

Functionality Checks

Occlusion Verification Test

Rate Accuracy Verification Test (Code 13)

Physical Inspection and Clean

Calibration Procedures

Performance Verification Procedure

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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Test Codes Summary Code

Test Name

Code

Test Name

Self-Test (01 to 08)

EEPROM Test

Speaker and Speaker Drive Circuit Test

Rate Calibration Number Read

Motor and Drive Circuitry Test

Total Pump Life "On" Time Read/Clear

Pressure Sensor Test

Total Battery "On" Time Read/Clear

Air-in-line Test

Error/Alarm Stack Read/Clear

Safety Switch and Driving Circuitry Test

Front Panel LED Test

Language Code Read/Set

External RAM Test

CRIS Configuration

Tach/Volume Flag Test

Air Bubble Length Read

Drop Discriminator Circuitry, Simulated Drop Test

FLO Alarm Threshold Read

Drop Detector LED Drive Current Test

Door Sensor Test

Auxiliary Front Panel Display Enable/Disable

Dried Spillage Alarm Parameters Read

Secondary Mode Setting On/Off

Rate Accuracy Test

See 'Rate Accuracy Verification Test' section for details of test.

Switch Test

Burn-In Test

Battery Voltage Test

Seven-Segment Display Test

Factory Use Only

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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.

Pump Identification Number Read/Set

Hospital or Alternate Site Configuration Set

Secondary Mode Enable/Disable (Model 597 only)

Flow Sensor Optional/Mandatory

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Test Codes (continued) Test Procedures Code

Test

Action/Data Displayed

Loop

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

Speaker and Speaker Drive Circuit Test

Test fail codes: 1=speaker senses as not turning on 2=speaker senses as not turning off

Yes

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

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

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

External RAM Test

Test fail: display shows the first address failed, hexadecimal. Note that the highest address is tested first.

Yes

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

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

Drop Discriminator Circuitry, Simulated Drop Test

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Test Codes (continued) Test Procedures (continued) Code

Test

Action/Data Displayed

Loop

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

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

Dried Spillage Alarm See 'Read Parameter/Values' table on the next page. Parameters Read

Rate Accuracy Test

See 'Rate Accuracy Verification Test' section for details of test.

Press each switch and check the corresponding code is displayed:

Switch Test

E 5

C 6 B 7 F 8 (hidden switch on Model 598)

D 4

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.

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.

Battery Voltage Test

Data displayed: battery voltage, in volts. Test passes with value above 5.7 volts .

Yes

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

Factory Use Only

EEPROM Test

Data displayed: number of first registration to fail.

Read Parameters/Values Code

Test

Action/Data Displayed

Loop

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.

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

13 through 19

Rate Calibration Number Read

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Test Codes (continued) Read Parameters/Values (continued) Code

Test

Action/Data Displayed

Loop

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.

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.

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 ----.

Pressure Calibration See 'Pressure Calibration' section for details of test. Read/Set

Language Code Read/Set

See 'Configuration Settings' table on the next page.

CRIS Configuration

See 'Configuration Settings' table on the next page.

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.

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.

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Test Codes (continued) Configuration Settings Code

Setting

Action

Loop

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.

CRIS Configuration

Setting not in use. CRIS=CRIS enabled, OFF=CRIS disabled. Ensure the setting is OFF.

Air Bubble Length Read

See 'Read Parameter/Values' table on the previous page.

FLO Alarm Threshold Read

See 'Read Parameter/Values' table on the previous page.

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.

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.

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.

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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

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.

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.

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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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

Software Version

143053

1.10

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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": Pressure Pad  replace the Cam Follower Assembly Top Follower 

OR, replace the Cam Housing Assembly



OR, replace the Front Case

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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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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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. IVAC® Volumetric Pump (Models 597 & 598)

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1000SM00016 Issue 9

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

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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1000SM00016 Issue 9

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 IVAC® Volumetric Pump (Models 597 & 598)

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1000SM00016 Issue 9

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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1000SM00016 Issue 9

Routine Maintenance & Calibration

Calibration Procedures (continued) 13. Press RUN/HOLD to exit the test.

Pressure Calibration (continued) Stage 4: Calculate new pressure calibration values 14. Calculate the two new pressure calibration values as follows, rounding results to the nearest 0.1:

Calculation Formula

New pressure slope (psi/volts)

Initial pressure slope x 8 P8 - P0

New pressure offset (psi/volts)

Initial pressure offset

P0 x 8 P8 - P0

Example Formula

New pressure slope

25 x 8

4.8 - (-0.8) New pressure offset

11 -

200

= 35.7

5.6

-0.8 x 8 4.8 - (-0.8)

= 11 -

-6.4

= 11 - (-1.14)

= 11 + 1.14

= 12.1

5.6

Where: Initial pressure slope (Step 12) = 25.0 Initial pressure offset (Step 12) = 11.0 Measured P0 (Step 8) = -0.8 Measured P8 (Step 9) = 4.8

Stage 5: Program pump with two new pressure calibration values (code 24) 15. Install a test jumper. See 'Test Connector' for instructions. 16. Enter self-test mode and select test 24. See 'Entering Self-Test Mode' for instructions. 17. Enter the new pressure slope value calculated in Step 14. Press PRI/SEC (hidden switch on Model 598) and the RUN/ HOLD switches simultaneously. Verify a beep and a display of Cal done. Now enter the new pressure offset value calculated in Step 14. Press PRI/SEC (hidden switch on Model 598) and the RUN/HOLD switches simultaneously. Verify a beep and a display of Cal done. 18. Repeat Steps 3 through Step 10. If more than five power-on cycles are required during the procedure, repeat Steps 1 and 2 to reenable auxiliary front panel displays.

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Routine Maintenance & Calibration

Performance Verification Procedure

Model / Serial Number:

Service Order / Inventory Number:

Hospital Name / Reference:

Inspection

Updates

INSPECTION

Software Version:

Physical inspection and clean CH2 Recommended when serviced

UPDATE REF:

Update software to v1.10 (143053)

TSM CH2

Full length door label (141565 - English)

TSM CH5

Fitted 

Not fitted / Not Applicable 

Check cam follower gap with pin gauge CH2 Check all functions in self-test

Self Test CH2

Infusing

Check pressure calibration values (re-calibrate as required - self-tests 30 and 24) P0 = 0 psi ± 1.2 P8 = 8 psi ± 1.2 During standard infusion check the following: Start up sequence VTBI and rate retention KVO operation Flow Sensor Alarms functionality check CH2 Door (P1), FLO (P2), hold (P3), AIL (P5), RELOAD AIR (P5...P6), RELOAD (P6), OCCL (P7), KVO, Time Out. Ensure pump works on battery and AC mains Rate accuracy test (Automatic test in self-test 13) Pump set to 300 ml/h for 300 seconds, volume infused = 23.75 to 26.25 ml

_____________ ml

Verification Tests CH2 Occlusion tests Pump Infusing 200ml/h, OCCL is between 5.5 to 11 psi (nominal 6 to 8 psi) Setup

Electrical Safety Tests

_____________ psi

Set rate to zero (or lowest value possible), Clear Volume Infused and VTBI Clear Error / Alarm / Battery logs (as required) Class I Type CF Test in accordance with the standard EN 60601-1 and test equipment operation manual.

Test results are stored: Electronically ¨ Print-out ¨ Other ¨

PASS / FAIL

____________________ Verification Performed By

_______________________ Sign

_______________________ Print

______________ Date

CHX indicates the chapter number in the Technical Service Manual (TSM) - 1000SM00016. E.G. CH2 = Refer to TSM Chapter 2.

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Chapter 3 Troubleshooting In this chapter Introduction

Error Messages

General Fault Diagnosis

Troubleshooting

Introduction Use this troubleshooting guide to help identify the cause of errors and faults which may occur as a result of damage to the pump or failure of an internal component. The following table lists the error messages (and corresponding codes) and describes what action to take to resolve the problem. A general fault diagnosis checklist is also provided. For information on alarm procedures and messages, refer to the relevant DFU. Note: The configuration setting in test 25 determines whether messages are displayed as text or as codes. If the nature of the problem is unclear, enter self-test mode and step through test 00 to check that the main functions of the pump are operating correctly. See Chapter 2, 'Routine Maintenance & Calibration' for details. Test 23 ERROR/ALARM STACK READ/CLEAR displays the sixteen most recent malfunction codes. To run test 23, enter self-test mode and select the test. See Chapter 2 for instructions.

Error Messages Message

Code

Failure

Action/Replace

Air

Air in tubing detected by air-in-line sensor.

Purge air from infusion set. Check air-in-line sensor is clean.

IV infusion set adapter dislodged from air-inline sensor Reload ---- Air

alternating with Air

Air in tubing detected by air-in-line sensor. IV infusion set adapter dislodged from air-inline sensor.

Reload

Set adapter improperly loaded into air-inline sensor.

bat.

Low battery alert. Battery has one hour or less of usable charge remaining.

beeps 3 times every 2 minutes (alternating with delivery rate; pump continues to run)

batt.

Reload IV infusion set into air-in-line sensor, pressing firmly until adapter is flush. Plug into AC mains. Note: Recharge time with pump off is approximately 24 hours from discharge to 100%.

Batteries should be given a full 24 hour charge when replaced, when pump is to be stored for an extended period of more than 3 weeks and upon receipt of a new pump.

Battery has insufficient charge to operate pump.

H2/P4

Weak battery or battery charge circuit out of adjustment/malfunctioning

Check mains outlet power, verify battery charge voltage is 7.02 ± .0.05 VDC (see procedure below).

Power Regulator Board circuitry problem

Replace Power Regulator PCB.

Door open.

Check IV infusion set is properly installed. Close door and restart pump. If error persists:

Magnet/door assembly out of calibration, magnet broken, misaligned or missing.

Verify door calibration and recalibrate as necessary. Check door magnet. If loose, check polarization and reinstall or replace.

Optical Sensor PCB malfunction/failure.

Check Optical Sensor PCB. Move sensor toward magnet if required. Replace Optical Sensor PCB.

persistent alarm after charging

door

Purge air from infusion set.

audible alarm

bat. or batt.

Check IV infusion set is properly installed in air-in-line sensor.

See tests 11 and 29 and run as necessary. Wiring harness open or shorted.

Check cable wiring/connections and repair/replace.

Logic PCB failure.

Replace Logic PCB. Check tubing, clamp and container.

FLO

Upstream occlusion. Dried spillage in mechanism

Remove and clean mechanism.

FLO.1

Too few or no drops detected

Check for empty container, closed or partially closed clamp, clogged filter, occluded/kinked tubing.

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Troubleshooting

Error Messages (continued) Message

Code

Failure

Action/Replace

FLO.2

Abnormal drops detected. Fogging or droplets on sidewalls of drip chamber.

Shake drip chamber to clear sidewalls. If alarm persists, replace IV infusion set.

Drip chamber overfilled or splashing of fluid caused by excessive movement of drip chamber (as in transport of patient).

Reduce level of fluid in drip chamber.

Clamp not fully open.

Check clamp is fully open.

Flow sensor not plugged in or disconnected while operating; optical path obstructed.

Check flow sensor is plugged into back of pump, optical path is not obstructed; verify position of flow sensor on drip chamber.

Test 36 (Flow Sensor configuration setting) is set to FS.On so pump expects to detect a flow sensor.

Change configuration setting from FS.On (mandatory) to FS.off (optional) via test 36.

FLO.3

Flow detected in excess of set rate.

Check tubing is completely installed in mechanism and that the mechanism pinches off the tubing.

hold

Pump has been placed on hold.

Press the RUN/HOLD switch once to restart the pump.

2 minutes has elapsed since pump put on hold or since last switch was pressed in start-up mode.

Press the RUN/HOLD switch once to silence the alarm, and again to restart pump. To restart the 2-minute timer, press any front panel switch or open the door. If alarm repeats in 2 minutes, run test 14. Note: If alarm occurs in start-up mode with pump on battery power, pump will turn off if left in alarm for 3 minutes.

alternating with rate; no audible alarm hold flashing display; audible alarm

OCCL

A switch has stuck or shorted for 2 minutes while the pump was running.

Downstream occlusion.

Check for kinked tubing, clogged filter.

Dried spillage in the mechanism.

Remove and clean mechanism. If error persists, perform Pressure Calibration procedure. Also run the 'Occlusion Verification Test'.

Err.1

Display Board PCB problem (Display segment error).

Replace Display Board PCB.

Open or shorted Display LED.

Run test 6, test 17 or test 3.

Display cable problem.

Replace Display cable harness.

Logic PCB circuitry problem.

Replace Logic PCB.

Pressure amp cable misaligned.

Check pressure amp cable connections.

Short on Pressure Amp PCB.

Replace Follower Housing Assembly.

Err.2

Logic PCB component malfunction (rate error).

Replace Logic PCB.

Err.3

Speaker disconnected or malfunctioning; speaker driver malfunction.

Check speaker connections. Replace Speaker. Replace Power Regulator PCB.

Err.4

Watchdog malfunction. Logic PCB circuitry malfunction.

Replace Power Regulator PCB. Replace Logic PCB.

Err.5

Motor drive on Power Regulator PCB disabled.

Replace Power Regulator PCB.

Interconnect cable problem.

Replace cable connecting Power Regulator PCB and Logic PCB.

Watchdog alarm failure on Logic PCB

Replace Logic PCB.

EEPROM blank due to replacement, (calibration error).

Recalibrate before returning for patient use.

Logic PCB component failure (ROM data error)

Replace Logic PCB.

Err.6

Err.7

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Perform 'Door Calibration Procedure' and 'Pressure Calibration Procedure'.

1000SM00016 Issue 9

Troubleshooting

Error Messages (continued) Message

Code

Failure

Action/Replace

Err.8

Logic PCB (RAM failure or low VRAM voltage)

Replace Logic PCB.

Err.11

E11

Logic PCB component failure (calculation error)

Replace Logic PCB.

Err.a

Volume or tack flag error.

Check that the encoder disk in the CAM Housing Assembly is not loose. Replace Optical Sensor PCB. Run test 08. See also Err.h.

Err.A

Err.b

Err.C

Logic PCB component failure (software error).

Replace Logic PCB.

Door sensor error.

Run test 11.

Logic PCB signal malfunction.

Replace Logic PCB.

Err.d

Logic PCB problem (CPU error).

Replace Logic PCB.

Err.e

Motor too fast. Motor drive circuit failure.

Run test 02 and test 05. Replace mechanism. Replace Power Regulator PCB. Replace Logic PCB. See also Err.n.

Err.E

Watchdog malfunction error. Watchdog alarm (WDAL) does not activate. Replace Logic PCB.

Err.F

Err.h

Foreground overrun error. Logic PCB component failure. Motor too slow. Mechanism sticking or have high friction.

Err.H

Run test 02 and test 05. Replace mechanism. Replace Power Regulator PCB. Replace Logic PCB.

Motor stall at power- up. Motor open or disconnected.

Err.J

Run test 02 and test 05. Replace mechanism. Replace Power Regulator PCB. Replace Logic PCB.

Air-in-line electronics.

Run test 04.

Air-in-line frequency (R22) on Power Regulator Board misadjusted.

Verify correct air-in-line frequency and adjust if necessary. See procedure below. Replace Power Regulator PCB.

Err.L

Logic PCB circuitry or A/D converter malfunction (ADC error). Weak battery (if error only occurs on switching to battery power).

Replace Logic PCB. Charge battery. Note: Recharge time with pump off is approximately 24 hours from discharge to 100%. Measure battery voltage. If less than 6.0V replace battery. If error persists after charging then suspect weak battery or battery charge circuit out of adjustment/ malfunction: Check mains outlet power, verify battery charge voltage is 7.02 ± .0.05 VDC (see procedure below). If error still persists, replace battery, replace Power Regulator PCB.

Err.n

Err.o

Dried spillage in mechanism. Misaligned Follower Housing Assembly.

Remove and clean mechanism.

Induced electrical noise in pressure signal.

Check Pressure amp cable connections. Check that Pressure amp connector and Follower Housing Assembly are free of moisture. Check for sources of external EMI, RFI, ESD noise.

Start-up or CPU running tests failed.

Replace Logic PCB.

Logic PCB failure.

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1000SM00016 Issue 9

Troubleshooting

Error Messages (continued) Message

Code

Failure

Action/Replace

Err.P

EEPROM read/write error (calibration error).

Run test 19. Replace EEPROM.

Err.u

Pressure sensor electronics error.

Run test 03. Check cable into Follower Housing Assembly is securely connected, is not pinched, cut or has solution contamination. Clean mechanism. If error persists, replace Follower Housing Assembly.

Err.U

Pressure sensor software error.

Check that the encoder disk in the CAM Housing Assembly is not loose. Replace Optical Sensor PCB. Run test 08. See also Err.h.

Err.Y

Battery error. Battery charger circuit malfunction/failure.

Charge battery. Note: Recharge time with pump off is approximately 24 hours from discharge to 100%. Measure battery voltage. If less than 6.0V replace battery. Replace fuse(s). Replace fuse on Power Regulator PCB. If error persists after charging then suspect weak battery or battery charge circuit out of adjustment/ malfunction: Check mains outlet power, verify battery charge voltage is 7.02 ± .0.05 VDC (see procedure below). If error still persists, replace battery, replace Power Regulator PCB.

Battery Charge Circuit Voltage Test (bat. batt. or Err Y) Equipment required: Test cable (135740), Digital volt meter. 1.

Connect the Test cable to the digital volt meter, red to (+) and black to (-). Ensure the meter is set to the DC voltage setting. Set the meter to the 20 volt range.

Disconnect the battery from the pump.

Connect the Test cable to the battery connector (J3) on the Power Regulator PCB.

Connect the pump to AC mains. If the pump turns on, turn the pump off.

With the pump off, check that the voltage reading 7.02 ±00.05 VDC (6.97 to 7.07 volts). If not, adjust R53 accordingly and reseal.

Disconnect the pump from AC mains. Disconnect the Test cable and reconnect the battery.

Air-in-line Frequency Test (Err J) Equipment required: Frequency counter cable 1. Connect the frequency counter cable to the test connector (J6) on the Power Regulator PCB. Note: pin 2 is GND, pin 1 is signal. 2. Turn the pump on. 3. Check that the frequency value is 3.3 ±0.1MHz. If not, adjust R22 accordingly and reseal.

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1000SM00016 Issue 9

Troubleshooting

General Fault Diagnosis



No battery power



No AC mains power



Delivery rates out of tolerance



Scrambled or frozen Display



 

Fuse(s) blown



 



 



No Display



Transformer



Fuses



Mains Lead



Battery



Display PCB



Power Regulator Board

Exposed to fluids

Logic PCB



CAM Follower Assembly



Mechanism

Rear Case

Dropped or damaged

Labels

Fault

Front Case

Parts to Check/Test



 



Low audio problem If the audio transducer installed is a sealed part, ensure that it has been installed with its lead polarities opposite to that indicated on the Power Regulator Board assembly. If the audio transducer installed is an unsealed part, ensure that it has been installed with its lead polarities matching that indicated on the Power Regulator Board assembly.

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IVAC Corporation

Infusion Pumps

IVAC 597 and 598 Technical Service Manual Issue 9