Medfusion ™ 3000 Series Technical Service Manual s Table of Contents ii 40-5648-51B Table of Contents Table of Contents I Introduction 1 Important Information 1 Warnings.................................................................................... 1 Cautions..................................................................................... 2 Contents of this manual 3 Authorized use of this manual................................................ 3 About the pump 4 Features and Controls.............................................................. 4 Keypad closeup................................................................... 5 Understanding “Biomed” mode 7 What is biomed?....................................................................... 7 Authorized biomed access....................................................... 7 Biomed software program – major options.......................... 7 Symbols...................................................................................... 8 Glossary of Technical Terms................................................... 9 II Scheduled Maintenance 15 Preventive Maintenance Planning 15 Biomed maintenance tools 15 Using a torque screwdriver................................................... 15 Electrostatic-controlled workstation................................... 15 Service warnings............................................................... 16 Periodic maintenance 17 Installation/quick check-out................................................. 17 Quick check-out test........................................................ 17 Cleaning and care................................................................... 18 Standard cleaning of Medfusion™ 3000 series pumps.. 18 Cleaning cautions............................................................. 18 Mandatory annual maintenance testing 19 General inspection................................................................. 19 Power-up test.......................................................................... 19 Calibration verification.......................................................... 20 Force sensor check............................................................ 20 Syringe size sensor check................................................. 20 Plunger position sensor check........................................ 21 Motor drive & occlusion operational test...................... 21 Flow delivery accuracy test.............................................. 22 AC line leakage test.......................................................... 22 AC line leakage test - Medfusion™ 3500BC............ 23 Battery maintenance.............................................................. 24 Shallow discharge (CPI) record...................................... 24 Battery calibration procedure ........................................ 24 Requirements for battery pack replacement................. 25 Collect Separately......................................................... 25 40-5648-51B III Theory of Operation 27 Overview of operation 27 Controlling motor functions................................................. 27 Infusion control & safety functions..................................... 27 Pump design description 28 Logic core of Medfusion™ 3000 Series pumps.................... 28 Main circuit board.................................................................. 28 Main microprocessor....................................................... 28 Watchdog circuit............................................................... 29 DC power converter......................................................... 29 Real time clock.................................................................. 29 Graphical display circuit board (LCD).......................... 29 Keypad............................................................................... 29 Plunger (driver) travel sensor......................................... 29 Motor rotation sensor...................................................... 29 Stepper motor.................................................................... 29 Syringe flange loaded sensor........................................... 29 Syringe size sensor............................................................ 29 Interconnect printed circuit board................................. 29 AC power input & power supply board......................... 30 DC power input jack........................................................ 30 Speaker............................................................................... 30 Rechargeable battery pack & battery gauge.................. 30 Plunger printed circuit board.......................................... 30 Plunger force sensor.................................................... 30 Plunger Loaded Sensors.............................................. 30 Main Board – Schematic Level............................................. 31 Logic Kernel Description................................................. 31 68HC11K4 Main Microprocessor Interface, U19 . . 31 Flash memory, U22...................................................... 34 Software upgrade method for programming flash memory............................................................ 34 Static random access memory, U17........................... 34 Serial EEPROM, U2 and U4....................................... 34 Time of day, U8............................................................ 34 Infrared transceiver..................................................... 34 Analog to digital converter, U13................................ 35 Digital to analog converter, U20................................ 35 I/O port expansion, U3, U33................................................ 36 Expansion port # 1 (port1_cs)...................................... 36 Expansion port # 2 (port2_cs)...................................... 37 Power control description............................................... 38 Always on supply, U7 ................................................. 38 Backup super capacitor, C11...................................... 38 Backup audio buzzer, XD1.......................................... 38 System reset, U43......................................................... 39 Power management, U39............................................ 39 Power OFF state........................................................... 39 Power ON state............................................................. 39 Watchdog...................................................................... 39 DC to DC converter......................................................... 40 Logic supply, U12......................................................... 40 Motor supply, U34....................................................... 40 Analog supply, U21...................................................... 40 Positive & negative supply, U36................................. 41 LCD backlight supply, U1........................................... 41 iii Table of Contents Front panel interface description................................... 42 LED drive circuit, Q26, Q27, Q40, Q33 - Q37......... 42 Keypad matrix interface.............................................. 42 Power switch interface................................................. 42 Graphic display interface description............................ 43 Data output to LCD, U32 / data input from LCD, U6............................................................................... 43 LCD contrast................................................................ 43 LCD backlight.............................................................. 43 Motor drive description................................................... 44 Coil A & B PWM current references......................... 44 Motor current regulators, U26, U35.......................... 44 Motor current detector, U40....................................... 44 Sensors interface description.......................................... 45 Motor speed detection................................................. 45 Syringe sensing description........................................ 45 Syringe size sensing..................................................... 45 Syringe flange (ear) sensing........................................ 45 Plunger position sensing description............................. 46 Speaker drive description............................................ 46 Speaker control............................................................. 46 Speaker test................................................................... 47 Plunger board – schematic level........................................... 47 Force preamplifier function............................................. 47 Force sensing interface description................................ 47 Plunger flipper sensor function.................................. 48 Interconnect board – schematic level.................................. 49 AC power detection description..................................... 49 External DC power conditioning / detection description.................................................................... 50 Infrared serial data port description.............................. 50 Battery management description.................................... 51 Battery gauge interface................................................ 51 Battery charger............................................................. 51 Charge detector............................................................ 52 Battery switchover........................................................ 52 Battery board – schematic level............................................ 52 Battery gauge function..................................................... 52 Severely depleted battery monitor.................................. 52 IV Troubleshooting 53 Problem solving alarms / alerts 53 Types of alarms / alerts.......................................................... 53 Alarm messages & priorities................................................. 54 System Advisory Alarms.................................................. 60 System Failure Alarms..................................................... 61 General troubleshooting........................................................ 65 Smiths Medical service and support 67 Using Smiths Medical service assistance............................. 67 Returning a pump for repair................................................. 67 Using Biomed for troubleshooting 68 Accessing Biomed.................................................................. 68 Biomed > Calibration . ............................................... 69 Biomed > Diagnostics (screen 1 of 2)........................ 69 Audio Test..................................................................... 69 iv Display Test................................................................... 69 Indicator Test................................................................ 69 Keypad Test................................................................... 70 Monitor Analog Sensors............................................. 70 Monitor Digital Sensors.............................................. 70 Monitor Battery Status................................................ 70 Drive Train Test............................................................ 70 Biomed > Diagnostics (screen 2 of 2)........................ 70 Motor Drive Test.......................................................... 71 Monitor a2d Selftest..................................................... 71 Monitor 6811 a2d Group1.......................................... 71 Monitor 6811 A2D Group2........................................ 71 Biomed > Utilities......................................................... 71 Set/View Last [Next] PM Date................................... 71 Set Time/Date (Current)........................................... 72 View Alarm History..................................................... 72 View Infusion History................................................. 72 View Software CRCs & View Software Versions................................................................... 72 View Service Data........................................................ 72 View EEPROM Size [available only on Medfusion™ 3500 pumps version 4 and higher)........................... 72 Biomed > Update Firmware [not available on Medfusion™ 3500 pumps, version 4 and higher] .... 73 Set Language [Not available on Medfusion™ 3010 and 3010a]..................................................................... 73 V Parts Replacement 75 Maintenance warnings/cautions 75 Service warnings . .................................................................. 75 Service cautions ..................................................................... 75 Opening & closing the pump housing 76 Tools needed........................................................................... 76 Opening the pump housing.................................................. 76 Closing the pump housing.................................................... 76 Battery pack 77 Tools needed........................................................................... 77 Removing the battery pack................................................... 77 Replacing the battery pack.................................................... 77 Verifying battery function after new battery replacement................................................................... 77 Interconnect board 78 Tools needed........................................................................... 78 Removing the interconnect board........................................ 78 Replacing the interconnect board........................................ 78 Verify interconnect board function................................ 78 Speaker 78 Tools Needed........................................................................... 78 Speaker removal..................................................................... 78 Speaker replacement.............................................................. 78 Verifying speaker function ............................................. 78 40-5648-51B Table of Contents AC power supply 79 Tools needed........................................................................... 79 Removing AC power supply................................................. 79 Replacing the AC power supply........................................... 79 Verify AC power supply function................................... 79 AC input assembly 79 Tools Needed........................................................................... 79 Removing AC input module assembly................................ 79 Replacing AC input module assembly................................. 79 Verifying AC input assembly module function............ 80 Bottom housing plastic 80 Tools Needed........................................................................... 80 Removing the bottom housing............................................. 80 Replacing the bottom housing.............................................. 80 Main board 81 Tools needed........................................................................... 81 Removing the main board..................................................... 81 Replacing the main board..................................................... 81 Drive train assembly 82 Tools Needed........................................................................... 82 Motor unit (motor, worm, worm gear)............................... 82 Removal............................................................................. 82 Replacement...................................................................... 82 Reassemble motor unit................................................ 82 Position potentiometer.................................................... 83 Removal......................................................................... 83 Replacement................................................................. 83 Clutch assembly 84 Tools needed........................................................................... 84 Leadscrew................................................................................ 84 Removal............................................................................. 84 Replacement...................................................................... 84 Clutch or clutch cam.............................................................. 84 Tools needed...................................................................... 84 Removal............................................................................. 85 Replacement...................................................................... 85 Plunger cable........................................................................... 85 Removal............................................................................. 85 Replacement...................................................................... 85 LCD and backlight 86 Tools Needed........................................................................... 86 Removing LCD and/or backlight assembly........................ 86 Replacing the LCD and/or backlight assembly.................. 86 Verify LCD & backlight assembly function.................. 87 Keypad 87 Tools needed........................................................................... 87 Removing the keypad............................................................ 87 Replacing the keypad............................................................. 88 Syringe barrel clamp assembly 88 Tools Needed................................................................ 88 40-5648-51B Barrel clamp head................................................................... 88 Removal............................................................................. 88 Replacement...................................................................... 88 Verify Function............................................................ 88 Barrel clamp body assembly ................................................ 88 Removal............................................................................. 88 Replacement...................................................................... 89 Ear clip, handle & guide 89 Tools Needed........................................................................... 89 Ear clip .................................................................................... 89 Removal............................................................................. 89 Replacement...................................................................... 89 Ear clip optical sensor . ......................................................... 89 Removal............................................................................. 89 Replacement...................................................................... 90 Handle...................................................................................... 90 Removal............................................................................. 90 Replacement...................................................................... 90 Tubing guide........................................................................... 90 Removal............................................................................. 90 Replacement...................................................................... 91 Plunger case assembly 91 Tools needed........................................................................... 91 Plunger lever........................................................................... 91 Removal............................................................................. 91 Replacement...................................................................... 91 Plunger case disassembly....................................................... 91 Disassembly....................................................................... 91 Reassembly........................................................................ 91 Cam gear and timing plate.................................................... 92 Removal............................................................................. 92 Replacement...................................................................... 92 Flipper and flipper gear......................................................... 92 Removal............................................................................. 92 Replacement...................................................................... 92 Plunger board......................................................................... 92 Additional tools needed................................................... 92 Removal............................................................................. 92 Replacement...................................................................... 93 Force sensor............................................................................ 93 Additional tools needed................................................... 93 Removal............................................................................. 93 Replacement...................................................................... 93 Left plunger case..................................................................... 94 Additional tools needed................................................... 94 Removal............................................................................. 94 Replacement...................................................................... 94 VI Calibration and Adjustment 95 Using Biomed > Calibration 95 Biomed > Calibration . ..................................................... 95 Calibrate (Syringe) size and position................................... 97 Performing both size & position calibration................. 97 Calibrate force sensor.......................................................... 100 Calibrate pressure sensor (future option)......................... 102 v Table of Contents Calibrate plunger position................................................... 102 Calibrate syringe size sensor............................................... 104 Adjust contrast (voltage) setting......................................... 105 View calibration data........................................................... 106 Save changes and exit........................................................... 107 Exit calibration without saving changes...................... 107 Retest guidelines 108 VII Schematics & PCB Assemblies 111 System layout 111 Main board schematics 112 Main board / logic kernel.................................................... 112 Main Board / Power Control Logic Core......................... 116 Main Board / DC-DC Converter...................................... 118 Main Board / Keypad Interface.......................................... 120 Main Board / Graphic Display Interface........................... 123 Main Board / Motor Drive.................................................. 124 Main Board / Syringe Sensing............................................ 125 Main Board / Position Sensing........................................... 126 Main Board / Force Sensing................................................ 127 Main Board / Pressure Sensing........................................... 128 Main Board / Speaker Drive............................................... 129 Main Board / ACU-ICE Socket.......................................... 130 Main Board Assembly Drawing – Top Side...................... 131 Main Board Assembly Drawing – Bottom Side.......... 132 Main Board Assembly – Parts list ..................................... 133 Plunger Board Schematic Barrel clamp assembly......................................................... 161 Barrel clamp assembly – parts list................................ 162 Drive train assembly............................................................ 163 Drive train assembly – parts list................................... 164 Clutch assembly.................................................................... 165 Accessories – parts list 166 Poleclamp assembly............................................................. 166 Poleclamp parts..................................................................... 167 Rotating poleclamp parts ................................................... 167 Miscellaneous parts.............................................................. 167 Calibration & repair – parts list.......................................... 168 Medfusion™ 3000 series calibration kit........................ 168 Other tools & equipment required to service Medfusion™ 3000 series pumps................................ 168 Notes 169 139 Plunger Board / Force Preamplifier................................... 139 Plunger Board / Flipper Sensor.......................................... 140 Plunger Board Assembly Drawing ............................. 141 Plunger Board Assembly – Parts list . .............................. 142 Battery Gauge Schematic 143 Interconnect Board Schematic 144 Interconnect Board / Power Control................................. 144 Interconnect Board / Battery Management...................... 145 Interconnect Board / Infrared Serial Communications.. 146 Interconnect Board Assembly Drawing .......................... 147 Interconnect board assembly – parts list . ........................ 148 VIII Assembly Drawings & Parts Lists 151 Assembly drawings 151 Medfusion™ 3000 series main pump assembly................. 152 Medfusion™ 3000 series main pump assembly – parts list....................................................................... 153 Case bottom assembly......................................................... 154 Case bottom assembly – parts list................................ 155 Case top assembly w/plunger.............................................. 156 Case top assembly w/plunger – parts list.................... 157 Case top assembly without plunger................................... 158 Case top assembly without plunger – parts list.......... 159 vi 40-5648-51B Introduction Important Information WARNING: Read this entire manual before attempting and service or repair on a Medfusion™ 3000 Series Syringe Infusion Pump. Failure to follow the instructions and important information contained in this manual, or improper/inadequate testing, service, repair or troubleshooting can lead to death or serious injury. Warnings, cautions and other important safety information can be found in this section, and throughout the manual (they are contained within lines at top and bottom). The term WARNING is used to indicate a hazard that has the potential to cause injury or death to a technician, patient or user. The term CAUTION is used to indicate a hazard that has the potential to cause damage to the product or other property. • Note: This manual supersedes all previous revisions. Warnings • • • • • • • Attempts to repair or maintain a pump by personnel without proper qualifications or training may create a major hazard which could result in serious injury or death to the patient or the user. Use only approved parts and procedures for repair and maintenance of this pump. Failure to follow this manual may create a major hazard which could result in serious injury or death to the patient or the user. Repair Pump in ESD Controlled Work Area: The pump case should only be opened at a workstation with Electrostatic controls, including a grounded mat and wrist-strap. Pump Maintenance: Only trained biomedical service personnel may service this pump. Service personnel should disconnect the AC power cord before servicing the pump. AC Power: The only means of removing AC power is to disconnect the AC power cord. While the AC power cord is attached to the pump and plugged into an AC outlet, live mains voltage is present within the pump. Manufacturer Recommended Maintenance: Always maintain this pump following manufacturer recommended instructions in this Service Manual. An improperly maintained pump may cause serious injury to a patient or user. Safety Class II, Type CF Medical Equipment: The 40-5648-51B • • • • pump is listed as Safety Class II, Type CF equipment. Protection against electrical shock does not rely only upon basic insulation, but instead relies on double or reinforced insulation. As such, this equipment does not utilize a third wire ground (earth ground). Therefore, when doing line leakage test it is not necessary to measure leakage in both the open ground and closed ground setting. Nor is it necessary to perform a ground resistance test. Safety Class II with functional earth, Type CF Medical Equipment: The pump is listed as Safety Class II with functional earth, Type CF equipment. Protection against electrical shock does not rely only upon basic insulation, but instead relies on double or reinforced insulation. As such, this equipment utilizes a third wire ground (earth ground) lead of the power cord as earth return for electromagnetic energy and does not serve as a safety function. Therefore it is neither possible nor necessary to perform a ground resistance test. Battery Replacement: Observe ESD handling precautions when replacing the battery. Replace battery only with same Smiths Medical part/model number. Recycle batteries in compliance with applicable local regulations. Collect Separately. There are potential health hazards associated with improper disposal of batteries, electronics, and contaminated (used) infusion sets and syringes. Dispose of used batteries, infusion sets, syringes, and other used accessories, or a pump that has reached the end of its useful life, in an environmentally safe manner, and according to any regulations that may apply. Clean the Pump: Always clean the pump thoroughly before performing maintenance on it. This is recommended by the United States Occupational Safety & Health Administration (OSHA) as a protection from potential biohazard. External DC Power: Any power source connected to the external DC jack must be IEC 60601-1 certified for medical equipment: Type CF, Safety Class II. Connecting external power to the pump creates a medical system; therefore, the user is responsible for compliance with IEC 60601-1 standards. Refer all questions to Smiths Medical Technical Service department. 1 Introduction • While servicing the Medfusion™ 3000 Series infusion pump you should wear safety glasses as it contains springs and other small parts which may be a hazard. Cautions • • • • • • • • • 2 Avoid Organic Solvents: Never use organic solvents (e.g., acetone), quarternary ammonia compounds, strong acids or strong bases to clean any portion of the pump. Not Waterproof: The Medfusion™ 3000 Series is “spray resistant” but not “water proof ”. Never spray cleaning or other fluids directly into openings on the bottom of the pump. Never immerse the pump in water or other fluids. Avoid Spray Oils: Never use light spray oils (e.g., WD40™) to clean or lubricate pump. These chemicals can damage the plastic of the pump. Never Autoclave or Gas Sterilize: Never sterilize the pump in a steam autoclave or gas. Using an autoclave or gas sterilization can seriously damage the Medfusion™ 3000 Series pump and void the warranty. Disconnect AC Mains & External DC Power: Always disconnect the pump from AC Mains and from External DC power before disassembling the pump for maintenance. Handle Batteries with Care: Always handle the pump’s battery pack with care. Don’t Over-tighten Screws: Never over-tighten any screws in the pump. Unless otherwise specified, you should torque all screws to 60 in- oz (0.42 Nm). Battery Disposal: Always dispose of exhausted NiMH batteries in compliance with all pertinent local, state, national, and international regulations. If unsure of correct methods for compliance, you may return battery packs to Smiths Medical for recycling. Keypad is NOT Flexible: Whenever handling the keypad, always ensure it remains flat. Bending the keypad can damage keys or break LED contacts. 40-5648-51B Introduction Contents of this manual This is the technical service manual for Medfusion™ 3000 Series Syringe Infusion Pumps manufactured by Smiths Medical MD, Inc. Its purpose is to provide the technical information necessary for maintenance, troubleshooting and repair of these pumps. This manual does not contain information on operating or configuring various models within the Medfusion™ 3000 Series. Such information is found in manuals specific to each individual model, (e.g., Medfusion™ 3500 Operations Manual and Medfusion 3500 Configuration Manual). The sections of this manual are: Introduction • • Overview of contents and purpose of this manual. Authorized use of this manual This manual is only intended for use by trained biomedical technicians who are authorized by their institution to perform maintenance and repair of critical medical devices. WARNINGS: • Attempts to repair or maintain a pump by personnel without proper qualifications or training may create a major hazard which could result in serious injury or death to the patient or the user. • Use only approved parts and procedures for repair and maintenance of this pump. Failure to follow this manual may create a major hazard which could result in serious injury or death to the patient or the user. Scheduled Maintenance • List of tests for required annual maintenance, and the procedure for completing each test. Theory of Operations • Descriptions of the systems which control the operation of Medfusion™ 3000 Series pump. Troubleshooting • Tables of failure messages together with problem descriptions and possible solutions. Also includes an overview of Biomed Diagnostics & Utilities. Parts Replacement • Detailed procedures for removal and replacement of parts of Medfusion™ 3000 Series pump. Calibration • Detailed procedures for calibration of Medfusion™ 3000 Series pump. Schematics and PCB Assemblies • Contains board level schematics & PCB assembly drawings. Assembly Drawings and Parts Lists • Contains mechanical assembly parts lists and replacement parts lists for repairs. Appendices • Contains technical information relevant to Medfusion™ 3000 Series pumps. 40-5648-51B 3 Introduction About the pump Features and Controls Following are several illustrations showing the various controls, connectors and features of the Medfusion™ 3000 Series pump. C D E F H I G* B G* 1) 1 LCD Display: All pump operating and status information appears on the LCD display. The upper portion of the display provides instructions and alarm information. The middle portion of the display shows the current status of the operation in progress or the state of the data entry for pump programming. The lower portion of the display corresponds with the 4 ‘softkeys’ (their function changes depending on where you are in a pump program) on the keypad. 2 Tubing Holders: Thread infusion set tubing between holders to prevent kinking at syringe tip. 3 Carrying Handle 4 Syringe Barrel Clamp: The clamp holds the syringe barrel securely in place. 5 Syringe Barrel Flange Clip: When loading a syringe, slide the syringe flange into the clip. 4 J 6 Syringe Plunger Holders: Holds the syringe plunger securely in place. 7 Syringe Plunger Driver: Once loaded and delivery is started, the driver pushes the syringe plunger forward at a controlled, precise rate to deliver fluid. 8 Syringe Plunger Release Lever: Squeeze the release lever down to allow placement of the syringe plunger onto the holder during loading, or to remove it during unloading. 9 AC Power Connection Port: Plug the AC power cord into connection socket to allow pump to operate on AC (mains) power. 10 Keypad: See Keypad closeup for identification of the individual keypad buttons and what they are used for. 40-5648-51B Introduction 1@ 1# 1! 11 Optional Poleclamp Mount: If desired, attach the optional poleclamp here. 12 External DC Power Input Jack: Plug approved external DC power supply into jack. 13 RS232 Connection Port: Plug RS232 connector into the port to allow upload of data from and download of data to a pump from a PC. This port is also used to load the pump software. Keypad closeup BOLUS 7 POWER 40-5648-51B START 3 STOP 1 2 3 4 5 6 7 8 9 0 . BACK 5 Introduction Button Alarm Silence (í) Power (ë) Menu buttons Back (â) Numbers & Decimal Stop (á) Start (É) Bolus (è) Indicator ò - Alarm ô - AC Line õ - Battery ö - Lock úù Infusing When pump is paused Silences audible alarm. Allows operator to switch the display backlight from bright to dim or dim to bright. Push and hold to turn pump Off. Set number values or select options. N/A When pump is delivering Silences audible alarm. Allows operator to switch the display backlight from bright to dim or dim to bright. Push and release, then push and hold to turn pump Off. Function is defined on the display. Reverts to a previous step or level if adjusting settings. Set number values or select options. Stops delivery (pump remains On). Starts delivery. N/A Begins priming after confirmation. Begins delivery of programmed bolus after confirmation. Function is defined on the display. Reverts to a previous step or level. What it means The Alarm indicators (yellow or red) are on whenever the pump is in an alarm condition. The specific details of each alarm are covered in the Troubleshooting section later in this manual. The AC Line indicator (green) is On whenever the pump is connected to “mains” line power. It is Off when the pump is not connected to an active AC line. The Battery indicator (green) blinks On & Off whenever the pump is operating on internal battery power, and remains On when the battery is charging. The Lock indicator tells you the pump has been locked into its current operational mode. While this indicator is lighted, the keypad is locked and no changes can be made to settings. Attempting to stop or change an infusion while locked will result in an alarm and an advisory message. The Infusing indicators are 3 green lights, which illuminate in sequence right to left when the pump is delivering fluid (the 4th LED indicator on the far left - on the tubing - is not used at this time). During intermittent delivery mode, a single Infusing indicator lights during the time between infusions. When the pump is Off or stopped, the Infusing indicator is not lit. 6 40-5648-51B Introduction Understanding “Biomed” mode Periodic maintenance and troubleshooting on Medfusion™ 3000 Series infusion pumps are aided by use of the “Biomed” software interface. What is biomed? The Biomed feature is the special utility intended for use only by trained biomedical service technicians. • • • • • • • • Biomed has its own security access code. Biomed is for calibration of the pump’s sensors. Biomed is for diagnosis of digital and analog sensors contained in the pump. Biomed allows access to infusion history log and alarm history log stored in the pump. Biomed is for testing of the pump’s drive systems. Biomed is for monitoring the status of the pump battery. Biomed is for setting the pump’s last (V3) or next (V4) preventive maintenance date. Biomed is for setting the time and date. Authorized biomed access Never use Biomed features unless you are trained in maintenance on the Medfusion™ 3000 Series pumps and have been authorized by your facility to use the Biomed program. Biomed software program – major options The Biomed utility has four major modes on its Select the Mode screen. These are: 1. Calibration to check calibration values, re-calibrate sensors or set display contrast. 2. Diagnostics to examine analog and digital signal readings, or test the speaker, motor or display function. 3. Utilities to review alarm history, to review infusion history, to set time and date, to update periodic maintenance timestamp. 40-5648-51B 4. Update Firmware to reprogram the pump’s software version through the serial interface (only available with service upgrade software diskette and instructions on certain models). The following is an outline of the Biomed software: Calibration Diagnostics • • • • • • • • • • • • cal size and position cal force sensor cal pressure sensor cal plunger position cal syringe size sensor adjust contrast view calibration data Audio test Display test Indicator test Keypad test Monitor analog sensors • Monitor digital sensors • save changes and exit • Monitor battery status • Drive Train Test (V4) • Motor drive test • Monitor a2d self test • Monitor 6811 a2d group1 • Monitor 6811 a2d group2 • Force sensor test (V3) • Pressure sensor test (V3) Utilities Update Firmware • set/view last pm date (Special use only for OR set/view next pm software update - Not date available on all pumps) Set Language • set time/date • view alarm history (Medfusion™ 3500 Only) • view infusion history • view software crcs • view software versions • view service data • view EEPROM size (V4) 7 Introduction Symbols The following is a list of symbols which may appear on the pump (or on it’s labeling or accessories), as well as certain technical terms, along with an explanation of what they mean. > g J K J 6 < Z 9 7 8 @ 5 ó P _ i 8 Serial number Attention, See instructions for use Type CF equipment (protection from electric shock) Equipment in which protection against electric shock relies on double or reinforced insulation instead of basic insulation. Accessible metal components of pump enclosure use this higher level of insulation instead of safety grounding. Medfusion™ 3500BC pumps: The earth ground of the power cord serves the purpose of providing a “functional earth” return for electromagnetic energy. Date of manufacture CAUTION: Federal (USA) law restricts this device to sale by or on the order of a physician. Catalog number Collect Separately Latex free Do not reuse Use by Authorized representative in the European Community Australian representative Indicates the product was designed and manufactured in accordance with applicable standards/guidelines and may be sold in the EU (European Union). UL Mark for Canada and the United States. Indicates the product was manufactured in accordance with the requirements of UL (Underwriter’s Laboratory). Temperature limitation Ü Ö Ñ V~ F2 IPX3 Pins of connectors and other areas identified with this ESD Warning symbol should not be touched. Connections should only be made when ESD precautionary measures are used. External DC jack connection. Tip (negative sign) is for power ground and ring (positive sign) is for positive power connection. (See warning that follows.) Symbol for infrared serial communications port on pump. Operating voltage range for alternating current (i.e. AC or mains) power source Medfusion™ 3500BC pumps: The designation “F2” indicated on the label, which is located on the AC input module connector assembly for the pump, is indicating a non-replaceable fuse that is part of the input module assembly. The fuse is located on the neutral side of the AC line. Medfusion™ 3500BC pumps: The “ground” symbol indicated on the label, which is located on the AC input module connector assembly for the pump, is indicating that the earth ground connection is providing a functional ground and not a safety ground. Equipment that is ingress protected from fluid spraying at vertical angle from above, and from angles to 60° on either side of vertical Infusion Class 4 An infusion pump that combines the functions of continuous infusion flow, intermittent flow, and discrete bolus delivery Infusion Class 5 An infusion pump that functions as a profile pump, providing a programmed sequence of delivery rates Humidity limitation Atmospheric pressure limitation 40-5648-51B Introduction Glossary of Technical Terms This is a glossary of technical terms relating to the Medfusion™ 3000 Series pumps. Term Definition AC Line Leakage Test The pump is listed as Safety Class II, Type CF equipment (Medfusion™ 3500BC pumps are listed as Safety Class II with functional earth, type CF equipment). Protection against electrical shock does not rely only upon basic insulation, but instead relies on double or reinforced insulation. As such, this equipment does not use a third wire ground (earth ground). Therefore, when doing line leakage test it is not necessary to measure leakage in both the open ground and closed ground setting. Nor is it necessary or relevant to perform a ground resistance test. Medfusion™ 3500BC: The third wire ground (earth ground) serves a functional and not a safety purpose. Therefore, it is neither necessary nor relevant to perform a ground resistance test. Protection against leakage current is the concern for any device (be it Class I or Class II) deriving power from AC mains. Leakage current is what flows from mains side to device component(s) that is conductive and accessible by the user or patient. Safety grounding of exposed metal does not protect the user from leakage current. Safety grounding causes a circuit breaker or fuse to open should a short occur between wall AC side and grounded metal. Alarm History Alarm Message Backup Audio Buzzer Backup Super Capacitor Battery Gauge The Medfusion™ 3000 Series pump achieves protection by double-isolating secondary power and exposed metal from AC power. The Medfusion™ 3000 pump satisfies the UL requirement that 4000 volts can be applied between AC side and exposed metal without causing significant current to flow. See “view alarm history”. The onscreen text which appears to indicate situations or circumstances requiring user attention. The backup audio buzzer provides a means of generating an alarm during: • instrument power loss (while the instrument was on) • malfunction of the main microprocessor • or failure of the primary speaker. The backup audio buzzer activates during Watchdog Alarm, anytime there is a malfunction of the main microprocessor. During power-up self-tests, the buzzer function is verified by briefly allowing the watchdog alarm to activate. A one (1) Farad Super Capacitor is part of the power control design to provide backup power to the audio buzzer in the loss of the primary power source. The gauge circuits monitor direction and magnitude of current flowing through the battery. • The battery current is sensed by the gauge. • The gauge then computes capacity. To control charging the battery, the gauge uses battery temperature and battery voltage. The gauge changes to trickle charge in the event the battery temperature exceeds 50°C or if the battery voltage is lower than 5.7 volts. 40-5648-51B 9 Introduction Battery Parameters There are two battery parameters requiring periodic inspection to maintain good battery performance. They can be accessed by selecting Biomed > Diagnostics > Monitor Battery Status. LMD (Last Measured Discharge) − This the learned capacity of the battery by the gauge following a calibration cycle. Replace the battery when this is < 1600 mA-hours. • CPI (Capacity Inaccurate) − This is the number of shallow discharge cycles since the last calibration. Always recalibrate the battery when CPI is > 80 Hex. Refer to the Battery Calibration section of this manual. A set of functions for calibration/adjustment of the sensors within the Medfusion™ 3000 Series pump. • Biomed Calibration Biomed Diagnostics Biomed Utilities Steps and processes for using Biomed > Calibration functions are found in the Adjustment & Calibration section. A set of functions which allow the detailed examination of the pump’s systems, sensors, indicators, and controls. Steps for using Biomed > Diagnostics functions are found in the Scheduled Maintenance and Troubleshooting sections. The set of Biomed > Utilities contain a mixture of adjustment and troubleshooting options. These are: Set / View Last PM Date (or Set / View Next PM Date) − Used to view and set the Preventive Maintenance (PM) date. • Set Time / Date − Used to set date and time for built-in real time system clock. • View Alarm History − Used to view alarm and alert history stored in pump memory. This is a troubleshooting feature. You may page backward and forward through stored alarms in order to identify possible malfunction patterns. • View Infusion History − Used to view programming and infusion information stored in pump memory. This can be a troubleshooting feature. You may page backward and forward through stored record of infusion types in order to identify how the pump has been used. • View Software CRCs − For “factory use” only. Allows view of CRCs for each code bank. • View Software Versions − Used to view both bootbank version and main version of software installed within the pump. Configuration Cloning Two pumps can communicate through their built-in infrared serial communications interface, with one teaching and the other learning, to copy pump configuration settings, and libraries. CPI (Capacity Inaccurate) This is the number of shallow discharge cycles since the last calibration. Always recalibrate the battery when CPI is > 80 Hex. Refer to the Battery Calibration section of this manual. Depleted Battery Monitor The circuitry which measures present battery charge status against stored battery capacity data to determine a “depletion” situation. EN 475 Alarms The EN 475 alarms use tones designed for use by customers following European standards. These generate High, Medium & Low Priority Alarms. • 10 40-5648-51B Introduction External Power Detector Flash Memory High Priority Alarms Infrared Serial Data Port Infusion Class 4 Infusion Class 5 Interconnect Board IPX3 Keypad Test LCD LCD Backlight Limit Priority Alarms Circuitry which determines when and if external power (whether AC or DC) has been or is connected to the pump. The pump uses flash memory, which is re-programmable through the infrared (IR) port and a remote computer. A high priority alarm results from either any condition which halts an ongoing infusion, or any pump system fault which affects infusion. If the front panel controls are locked when a high priority alarm occurs, the pump controls unlock. High Priority alarms are signaled by a flashing red indicator and an audible signal. Press í to pause the audible alarm for the preset alarm silence period. The infrared serial port interfaces directly with the main microprocessor’s asynchronous serial communication pins. The infrared port supports short transmission distances of 2” or less and a maximum baud rate of 9600. An infusion pump which combines the functions of continuous infusion flow, intermittent flow, and discrete bolus delivery. An infusion pump which functions as a profile pump, providing a programmed sequence of delivery rates. The interconnect printed circuit board interfaces to an intelligent NiMH Battery (or NiCad on older model pumps), the system speaker, the internal DC supply and supply conditioning for an external DC supply and the main PCB. Equipment which is ingress protected from fluid spraying at a vertical angle from above, and from angles to 60° on either side of vertical. Verifies individual function of each key on the keypad. Nonfunctioning keys indicate need for keypad replacement. Liquid Crystal Display. The LED fiber optic light source which illuminates the LCD display. A limit priority alarm is generated whenever a preset minimum or maximum limit has been violated. For example: when programming an infusion there are minimum and maximum limits preset rates assigned to syringes by size & manufacturer. • LMD (Last Measured Discharge) Low Priority Alarms The limit priority alarms sound a tone and display an advisory message onscreen for 3 seconds. To re-display the message press í. This the learned capacity of the battery by the gauge following a calibration cycle. Replace the battery when this is < 1600 mA-hours. A low priority alarm indicates any condition not requiring immediate operator intervention. Low Priority alarms are announced with a continuous yellow indicator and an intermittent audible signal. Medium Priority Alarms Pressing í permanently silences this alarm. If the front panel controls are locked when a low priority alarm occurs, the pump controls do not unlock. A medium priority alarm indicates any condition requiring operator intervention but does not halt infusion. Medium Priority alarms are signaled with a flashing yellow indicator and an audible signal. Pressing í will silence the audible alarm for the programmed alarm silence period. • • • 40-5648-51B If the front panel controls are locked when a medium priority alarm occurs, the pump controls do not unlock. 11 Introduction Motor Rotation Sensor A optical sensor on the main board senses the movement of the motor worm shaft. “Neglected Pump” or User The “Neglected Pump” or user call back alarm is a low priority alert which simply Call Back reminds you to finish what you started. Once you begin programming any infusion, the pump expects you to continue until programming is complete. Occlusion Plunger Printed Circuit Board Safety Class II, Type CF Equipment Serial EEPROM If you leave the pump paused too long (30 seconds) on any data entry screen, then the pump begins sounding a low priority alert. The blockage of the infusion line during delivery. Here, the pump detects an occlusion by sensing excessive force on the syringe plunger driver. The plunger PCB provides pre-amplification of the force sensor output to the Main board, and contains two photo-interrupters with supporting circuitry for sensing each plunger flipper. See “AC Line Leakage Test”. A non-volatile storage device (electrically-erasable programmable read-only memory) which is used on the main board to store calibration, configuration, and infusion history. Set / View Last (Next) PM This allows viewing the last (or Next on V4 pumps) recorded preventive mainteDate nance date. This is where you also set the date when completing annual preventive maintenance. Stepper Motor A sequentially stepping motor used to drive the plunger head of the pump. System Failure A high priority alarm indicating that the pump self-tests have detected a failure in pump operation. Primary Speaker The main speaker located in the bottom housing of the pump. All normal alarm/ alert tones are generated through this speaker. Update Firmware The firmware is the software installed in Medfusion™ 3000 Series pumps v3 or lower, and which is used to operate the pumps. The software may only be updated with a software kit provided by Smiths Medical. The Biomed > Update Firmware option is the utility provided for reinstalling software used to operate pumps. This can be used to upgrade to a newer version of system software. (Only available on pumps with the V3 software combined with the V1.6 boot loader provides this option.) View Alarm History View Infusion History View Software CRCs View Software Versions 12 Note: Instructions for updating pump operational software are not included in this technical service manual. Instead, they are part of individual software upgrade kit. This is a troubleshooting feature. In Biomed > Utilities, you may page backward and forward through the stored alarms in order to identify possible malfunctions. This is a troubleshooting feature. In Biomed > Utilities, you may page backward and forward through the stored record of infusions in order to identify how the pump has been used. The history will contain roughly 50 events. For “factory use” only. This is where you identify both the bootbank version and the main version of the operational software installed in the Medfusion™ 3000 Series pump. (Pumps with V4.1.5 software also shows the build number.) 40-5648-51B Introduction Watchdog Circuit While in the power on state, the auxiliary controller prevents the watchdog Alarm State from occurring by maintaining the AC signal, WATCHDOG_STRB. • 40-5648-51B The main microprocessor periodically issues the AC signal, PET_WATCHDOG. 13 Introduction 14 40-5648-51B Scheduled Maintenance Section 1: Scheduled Maintenance of the service manual defines the required preventive maintenance for keeping the Medfusion™ 3000 Series syringe infusion pump in good operating condition. Preventive Maintenance Planning The recommended preventive maintenance plan allows you to service pumps in batches as their anniversary dates arrive. For example, if you have numerous pumps to service over the course of a year you may want to set the date on each pump so that 10 pumps are due for service each week of the year (this will prevent all pumps from giving the alert reminder at the same time). Pumps with V3 software: enter the last PM date (the pump will calculate the next PM date). An example of a plan for the maintenance of pumps with V3 software is shown in the following table: Serial Numbers M001001 to M001010 M001011 to M001020 Scheduled Enter Last PM PM 7/24/2007 7/24/2005 7/31/2007 7/31/2005 Date of Alarm 7/25/2007 8/1/2007 Pumps with V4 software: enter the next PM date. An example of a plan for the maintenance of pumps with V4 software is shown in the following table: Serial Numbers M001001 to M001010 M001011 to M001020 Enter Next PM Date 7/24/2008 Last PM Date of Alarm 7/25/2007 7/25/2008 7/31/2008 8/1/2007 8/1/2008 1 ea − Calibration Kit (see service parts list): Small Calibration Slug, Large Calibration Slug & Force Gauge 1 ea − new 50 or 60 cc syringe (note: the lubrication in syringes evaporates, change “test” syringes monthly) 1 ea − 3-way Stopcock 1 ea − Electrical Safety Analyzer 1 ea − Torque Screwdriver w/Phillips & Standard bits. 1 ea − ¼” open end wrench 1 ea − 6” calipers with resolution of 0.001” Using a torque screwdriver You must always use a Torque Screwdriver when reassembling any Medfusion™ 3000 Series pump. Where screws are used to secure components, over-tightening can strip threads or crack standoffs in the case. • Unless otherwise specified, you should always torque all screws to 60 in-oz (approximately 0.8 Nm). Electrostatic-controlled workstation Whenever you work on the Medfusion™ 3000 Series pump − specifically whenever you open the pump for service − you must work in an electrostatic-controlled environment. This ensures you will not damage the electronic components in the pump. WARNING: Repair Pump in ESD Controlled Work Area: The pump case should only be opened at a work-station with Electrostatic controls, including a grounded mat and wrist-strap. The best approach is to set the date so that the alarm occurs only if a pump is missed in the normal PM schedule. Biomed maintenance tools In order to complete maintenance, parts replacement, diagnosis and calibration of Medfusion™ 3000 Series infusion pumps, you will need the following: 40-5648-51B 15 Scheduled Maintenance Service warnings WARNINGS: • Pump Maintenance: Only trained biomedical service personnel may service this pump. Service personnel should disconnect the AC power cord before servicing the pump. • AC Power: The only means of removing AC power is to disconnect the AC power cord. While the AC power cord is attached to the pump and plugged into an AC outlet, live mains voltage is present within the pump. • Manufacturer Recommended Maintenance: Always maintain this pump following manufacturer recommended instructions in this Service Manual. An improperly maintained pump may cause serious injury to a patient or user. 16 40-5648-51B Scheduled Maintenance Periodic maintenance This maintenance is required for the continued safe operation of Medfusion™ 3000 Series pumps. The Medfusion™ 3000 Series pump must be tested annually, or whenever the pump has been damaged or dropped. Always check all sensor calibrations as a standard part of annual maintenance. No calibration is required to maintain pump flow delivery accuracy. Installation/quick check-out Each pump is inspected and tested prior to shipment from the factory. Some institutions require that devices entering a hospital be functionally checked before being placed into service. The following procedure is provided to meet this need. Quick check-out test c 1) c 2) c 3) c c 4) 5) Plug AC power cord into AC receptacle on side of pump, then plug pump into an AC power (100 to 240 VAC) source. Verify AC indicator and battery charge indicator are lit. Press Power. Verify the following on power-up: • Verify alarm beeps. • Verify all the LED indicators are turned on & off (except AC and battery). • Verify that no self-tests fail. • Verify the display is legible and contrast is acceptable. Unplug the AC power cord and verify that within several seconds the battery indicator begins to flash and AC indicator goes off. Re-plug the AC power cord into the unit. Perform the “Flow Delivery Accuracy Test” from Annual Maintenance (which follows). From the pump’s Main screen, use the number buttons to choose Biomed (press More for second page, if needed). Use the number buttons to enter passcode “2580”, then use the number buttons to choose Utilities. Then: Set/view Last PM Date. Pumps with V3 software: Set the PM date to today’s date. (Setting this PM date means that an advisory message will appear on the pump two years from this date.) - OR - Set/view Next PM Date. Pumps with V4 software: Set the date to the date you want the PM alert to occur. c c 6) c 8) 7) 40-5648-51B This message does not prevent normal operation of the pump, but advises the user that maintenance is recommended.) [Note: pumps are shipped from the factory with the date/time set to USA Central Standard Time; use the Set Time/Date utility to modify this if desired.] Perform the “AC Line Leakage Test” from Annual Maintenance (which follows). Consult the troubleshooting guide or contact Smiths Medical should the pump fail any steps in this test. After the completion of these tests the pump be should plugged into AC power to recharge the battery. [This is recommended when the battery capacity is less than 90% – look at battery gauge displayed on the bottom of the power-up screen.] 17 Scheduled Maintenance Cleaning and care Standard cleaning of Medfusion™ 3000 series pumps Follow your institution’s guidelines for cleaning and disinfecting of devices. The syringe pump can be safely cleaned with the following agents: Common chlorine bleach diluted with water. Mild detergent mixed with water. Isopropyl alcohol 70% solution. Other surface disinfectants which are compatible with plastic materials. For best results: Clean by spraying or pouring cleanser directly onto a soft cloth (not directly onto the pump) and then wiping surfaces until dry. • • • • 18 Cleaning cautions Below are standard cautions you should follow when cleaning Medfusion™ 3000 Series pump: CAUTIONS: • Avoid Organic Solvents: Never use organic solvents (e.g., acetone), quarternary ammonia compounds, strong acids or strong bases to clean any portion of the pump. • Not Waterproof: The Medfusion™ 3000 Series is “spray resistant” but not “water proof ”. Never spray cleaning or other fluids directly into openings on the bottom of the pump. Never immerse the pump in water or other fluids. • Avoid Spray Oils: Never use light spray oils (e.g., WD40™) to clean or lubricate pump. These chemicals can damage the plastic of the pump. • Never Autoclave or Gas Sterilize: Never sterilize the pump in a steam autoclave or gas. Using an autoclave or gas sterilization can seriously damage the Medfusion™ 3000 Series pump and void the warranty. 40-5648-51B Scheduled Maintenance Mandatory annual maintenance testing All tests on this Required Annual Maintenance List must be performed annually in order to ensure the continued safe operation of the Medfusion™ 3000 Series pump. General inspection c 1) If not already performed, clean and disinfect the pump as described in the “Cleaning and Care” secc 2) c 3) c 4) c 5) c 6) c 7) c c c c c 8) tion (see previous page). Inspect for obvious physical damage, including cracked housings or torn keypads. Repair any physical damage. Verify smooth operation of syringe plunger driver, syringe release lever, syringe flange clip, and syringe barrel clamp. Clean and/or repair any damaged components. Verify the three tubing guides (hooks) on top left side are intact, and fully secured to pump housing. Replace any damaged guides. Verify force sensor seal, located behind flippers on plunger driver head, is intact and not punctured. Replace damaged seal. Inspect power cord for damage and wear. Replace damaged or worn power cord before performing any leakage current testing. Inspect pole clamp for proper operation. Verify that the screws holding pole clamp components are tight. Verify the Serial Number label is legible and intact. Replace if label is damaged. 9) Verify the Warning label is legible and intact. Replace if label is damaged. 10) Verify four rubber feet are attached to the bottom housing of the pump. Replace missing feet. 11) Turn the pump on all sides and check for any loose parts internally and externally. 12) Plug AC power cord into AC receptacle on side of pump, then plug pump into an AC power (100 to 240 VAC) source. Verify AC indicator and battery charge indicator are lit. Consult troubleshooting for any failed indicator. Power-up test Ensure that no syringe is loaded in the pump and the barrel clamp is fully down. Press ë. Verify the following on power-up: c c c c c c 1) Verify alarm beeps. 2) Verify all the LED indicators are turn on and off (except AC and battery). 3) Verify that battery capacity shown on screen is greater than 0%. 4) Verify that no self-tests fail. 5) Verify the display is legible and contrast is acceptable. 6) Unplug the AC power cord and verify that within several seconds the battery indicator begins to flash and AC indicator goes off. Re-plug the power cord into the unit. Consult troubleshooting for any failed steps in this test. 40-5648-51B 19 Scheduled Maintenance Calibration verification From the pump’s Main menu, use the number buttons to choose Biomed (press More to find it, if needed). Enter the passcode (numbers 2580), then press Enter. Use the number buttons to choose Diagnostics, then Monitor Analog Sensors. Force sensor check c 1) Ensure that no syringe is loaded in the pump. Verify that the force reading on the screen is between –0.2 and +0.2 pounds. c 2) Load the force gauge with the foot of the gauge positioned towards the head of the plunger driver. Zero the force gauge. Using the thumbscrew of the force gauge bracket, increase the force applied until the force gauge reads 15 pounds (6.8 kilograms). Verify that the force reading on the screen is between 14.0 and 16.0 pounds. If either reading is out of specification, re-calibrate the sensor and then retest readings. Syringe size sensor check c Load the small Calibration Slug into the barrel clamp (do not load the plunger driver). Keeping the barrel clamp perpendicular to the slug, move the barrel clamp head slightly back and forth to find the lowest size reading. Verify that the size reads between 0.256” and 0.272”, inclusive. c 2) Load the large Calibration Slug into the barrel clamp (do not load the plunger driver). Keeping the barrel clamp perpendicular to the slug, move the barrel clamp head slightly back and forth to find the lowest size reading. Verify that the size reads between 1.244” and 1.260”, inclusive. If either reading is out of specification, re-calibrate the sensor and then retest readings. 20 1) 40-5648-51B Scheduled Maintenance Plunger position sensor check c 1) Load the small Calibration Slug into the barrel clamp. Load the plunger driver onto the end of the slug with flippers open, and about 0.1 lbs. applied to force sensor (as read from the screen). Verify that the position reads between 0.680” and 0.720”, inclusive. Unload the slug. c 2) Load the large Calibration Slug into the barrel clamp. Load the plunger driver onto the end of the slug with flippers open, and about 0.5 lbs. applied to force sensor (as read from the screen). Verify that the position reads between 4.680” and 4.720”, inclusive. Unload the slug. If either reading is out of specification, re-calibrate the sensor and then retest readings. Note: Use a new syringe for the following tests as the lubrication within syringes evaporates. Change “test” syringes at least monthly. Plunger travel test Return the pump to the Main menu (press â to exit Biomed mode). Load an air-filled 50 or 60 cc syringe into the pump. Use the number buttons to choose ml/hr delivery mode and set the flow rate to 20 ml/hr. Clear the total infused. Press É. c 1) c c 2) Verify the three green infusing indicators are lit in a repeating sequence from right to left. Continue running until at least 0.033 ml has been infused. Press Lock and verify the Lock indicator lights. Press Unlock and verify the Lock indicator turns off. Press CHG Rate and set a rate to the maximum rate available on the ml/hr control screen. Allow the unit to drive for the full length of the syringe. c 4) When the syringe is empty, verify the Syringe Empty alarm message is displayed and the red alarm indicator lights. Verify the alarm tone quality. Press í to silence alarm. If other alarms or system failures occur during this test use the troubleshooting guide for corrective actions. 3) Motor drive & occlusion operational test Connect a three-way stopcock to an empty 50cc or 60cc Luer-lock syringe. Load the syringe with the syringe filled with approximately 30cc of air. c 1) c 2) c 3) 40-5648-51B Use the number buttons to choose ml/hr mode and set the flow rate to the maximum rate as displayed on the ml/hr entry screen. From the Begin Delivery screen, press è to access the Prime screen. Press and hold è to prime the tubing set for at least 0.2 ml priming volume. Press Exit. Close the stopcock to the syringe. Press Options, use the number buttons to choose Override Occl Limit, choose High, then press Enter. Press Options, then use the number buttons to choose Disable Rapid Occl Detect, if available. (If not available, press â.) 21 Scheduled Maintenance c c 4) Press É to begin the infusion. 5) Verify the pump operates until an occlusion alarm occurs. Open the stopcock to release the pressure, then remove the syringe. If any alarm other than occlusion occurs during this test, see troubleshooting for corrective action. Flow delivery accuracy test Return the pump to the Main menu. Use the number buttons to choose ml/hr. Select a syringe manufacturer. Load a 50/60 cc Luer-lock syringe (air-filled) into the pump – use a syringe from the table below. Enter a rate of 300 ml/hr. c 1) From the Begin Infusion screen, press Options and use number buttons to choose Volume Limit. Enter a volume limit of 50 ml. (Note: if volume limit is not configured, press á when TVD reaches 50.0 ml.) From the Begin Infusion screen, press è to access the Prime screen. Press and hold è to prime the tubing set for at least 0.2 ml priming volume. Press Exit. Use calipers to measure the distance from the outside of the syringe flange to the inside of the syringe plunger. Record this measurement as the starting position. _________________ c 2) c 3) Press É and ensure delivery begins. Wait until the pump volume limit is reached in 10 minutes. (Press á if volume limit is not active.) Press í to silence the audible alarm. Use a set of calipers to measure the distance from the outside of the syringe flange to the inside of the syringe plunger. Record this measurement as the ending position. _________________ Subtract the ending position from the starting position. Verify that this result is between 3.473” and 3.615” (inclusive) for a B-D 60cc syringe, consult table below for other syringes. Manufacturer B Braun Perfusor 50cc B Braun Ominifix 50cc B-D 60cc Fresenius 50cc Monoject 60cc Terumo 60cc Minimum travel 3.146” (79.92mm) 3.146” (79.92mm) 3.473” (88.22mm) 2.904” (73.76mm) 3.473” (88.22mm) 2.901” (73.70mm) Nominal travel 3.211” (81.55mm) 3.211” (81.55mm) 3.544” (90.02mm) 2.964” (75.27mm) 3.544” (90.02mm) 2.961” (75.20mm) Maximum travel 3.275” (83.18mm) 3.275” (83.18mm) 3.615” (91.82mm) 3.023” (76.77mm) 3.615” (91.82mm) 3.020” (76.70mm) Table of acceptable syringe travel for 50 and 60 cc syringes. If this test fails use the troubleshooting guide for corrective action. AC line leakage test c 1) c 2) 22 Connect the AC power cord to the Safety Analyzer. Set Safety Analyzer to Line Leakage mode of operation. Press ë to turn the pump on. Using the ground reference probe of the Analyzer, make contact with either the plunger driver tube or the center post of the DC input jack. Verify the leakage in the normal setting is less than 100 micro-amps [note, this is equivalent to BF rating for this device]. 40-5648-51B Scheduled Maintenance If you wish to verify the CF rating of the pump, then fill a beaker with normal (0.9%) saline solution and load the pump with a syringe and tubing filled with normal saline. The saline-filled tubing should be in contact with the saline in the beaker. Place the ground reference of the leakage current Analyzer in contact with the saline in the beaker and verify the leakage current in the normal setting is less than 10 micro-amps. [This procedure is specified in IEC 60601-2-24, clause 19.] Turn off pump and disconnect from safety analyzer. WARNING: Safety Class II, Type CF Medical Equipment: The pump is listed as Safety Class II, Type CF equipment. Protection against electrical shock does not rely only upon basic insulation, but instead relies on double or reinforced insulation. As such, this equipment does not utilize a third wire ground (earth ground). Therefore, when doing line leakage test it is not necessary to measure leakage in both the open ground and closed ground setting. Nor is it necessary to perform a ground resistance test. AC line leakage test - Medfusion™ 3500BC c 1) c 2) c 3) Connect the AC power cord to the Safety Analyzer. Set Safety Analyzer to Line Leakage mode of operation. Press ë to turn the pump on. Enclosure Leakage - Using the ground reference probe of the Analyzer, make contact with the center post of the DC input jack. Verify the leakage in the normal setting is less than 100 micro-amps [note, this is equivalent to BF rating for this device]. Earth Leakage - Use the Safety Analyzer, to measure the leakage current flowing through the earth conductor of the AC power cord. Verify the leakage in the normal setting is less than 100 micro-amps [note, this is equivalent to BF rating for this device]. If you wish to verify the CF rating of the pump, then fill a beaker with normal (0.9%) saline solution and load the pump with a syringe and tubing filled with normal saline. The saline-filled tubing should be in contact with the saline in the beaker. Place the ground reference of the leakage current Analyzer in contact with the saline in the beaker and verify the leakage current in both the normal and reversed settings is less than 10 micro-amps. [This procedure is specified in IEC 60601-2-24, clause 19.] Turn off pump and disconnect from Safety Analyzer. WARNING: Safety Class II with functional earth, Type CF Medical Equipment: The pump is listed as Safety Class II with functional earth, Type CF equipment. Protection against electrical shock does not rely only upon basic insulation, but instead relies on double or reinforced insulation. As such, this equipment utilizes a third wire ground (earth ground) lead of the power cord as earth return for electromagnetic energy and does not serve as a safety function. Therefore it is neither possible nor necessary to perform a ground resistance test. 40-5648-51B 23 Scheduled Maintenance Battery maintenance This chapter discusses battery maintenance as recommended to ensure good battery performance. 1. The battery pack contains six 2100 mAH Nickel Hydride (NiMH) cells (older pumps may have Nickel Cadmium [NiCad] batteries) with a smart gauge for monitoring battery charge information. Notes: • The gauge is built into the battery pack, and the pump reads the battery capacity from the gauge on the pack. • The battery pack has a shelf life of 4 months, after which it will require recharging. Once installed into a pump, the shelf life is 2 months, after which it will require recharging. 2. There are two measured battery parameters that must be reviewed to maintain good battery performance and accuracy of the battery gauge. From the Main menu, use the number buttons to choose Biomed; use the number button to choose Diagnostics; use the number buttons to choose Monitor Battery Status option. a) LMD (Last Measured Discharge) − This the learned capacity of the battery by the gauge following a calibration cycle. It is recommended the battery be replaced when this value is < 1600 mA-hours. b) CPI (Capacity Inaccurate) − This is the number of shallow discharge cycles since the last calibration. It is recommended that you recalibrate the battery when CPI is > 80 hex (i.e. >128 decimal). Refer to the battery calibration section below. Shallow discharge (CPI) record The battery gauge records the number of shallow discharges. A shallow discharge happens whenever the battery is partially discharged and then returned to AC power. The number of the shallow discharges appears on page two of the Monitor Battery Status menu in the Biomed > Diagnostics menu. • • 24 This displays CPI as 0×DD, where 0×DD is a hexadecimal number representing the number of shallow discharges cycles. The value is reset to zero each time the battery is calibrated. It increments to a maximum count of 0×FF hex (255 decimal). During the annual periodic maintenance if the number of shallow discharges, CPI, is 0×80 hex or higher [e.g. 0×90, 0×A5, 0×BB, etc.], then the battery should be re-calibrated. Battery calibration procedure The battery calibration procedure ensures the battery calibrates (or “re-learns”) the battery capacity. It does this by measuring the actual charge & discharge rates to determine the true capacity of the battery. With this correct information, the pump calculates “percentage of battery charge” and determines “low battery alarm”. 1. Connect the pump to AC power. 2. Turn the pump on and select Biomed > Diagnostics > Monitor Battery Status. 3. After the Charge Level gauge reaches 99 to 100%, wait at least 1 more hour, then remove AC power. 4. Using one of the methods listed here, fully drain the battery pack, until the pump sounds the Battery Depleted alarm (not the Low Battery alarm). You can interrupt the discharge test by turning the pump off and continue discharge at a later time – as long as you do not plug the pump into AC power during the discharge cycle. a) The battery can be discharged by operating the pump on battery power and infusing at 5 ml/hr using a 60cc syringe. This takes approximately 10 hours from a full charge. b) A quicker method is holding open the clutch lever with an a clamp or vise grips to prevent the plunger flipper and clutch from closing. Then use Biomed > Diagnostics > Motor Drive Test, and set motor step period to 2 msec, and press É. This should deplete the battery within approximately 3 hours . c) A third method is to disconnect AC power, turn the pump on, and run Biomed > Diagnostics > Monitor Battery Status. This discharges the battery at about 130 ma, and takes approximately 13 hours from full charge. 5. Once the Battery Depleted alarm sounds, turn the pump off and plug into AC. This begins recharging the battery. [Do not unplug AC power until charging is complete.] If left in “Depleted” alarm condition, the pump will draw power from the battery until its voltage drops 40-5648-51B Scheduled Maintenance 6. 7. 8. 9. to a level which disconnects the battery gauge. The pump then loses all its calibration information. From the time the Battery Depleted alarm occurs, the pump has approximately 5 minutes of operation on battery before the “fully-depleted disconnect” condition occurs. At this point, the audible alarm continues running from the super-capacitor on the main board. After several minutes of recharging the gauge will show the learned capacity of the battery. Turn the pump on and select Biomed > Diagnostics > Monitor Battery Status. Verify LMD (last measured discharge) value is greater than 1600 ma-hours. Press More and verify CPI is 0×00 or 0×01. 10. Turn the pump off and continue to charge pump until battery charge is complete (approximately 10 hours). 11. Turn on pump and select Biomed > Diagnostics > Monitor Battery Status. 12. Verify the LMD is greater than 1600 mA-hours. At 1600 mA-hours battery, the pump’s battery life is approximately 7-8 hours. It is recommended that the battery be replaced if its capacity is less than 1600 mA-hours. In accordance with Directive 2002/96/EC Waste Electrical and Electronic Equipment, residents of the European Union must follow specific disposal or recycling instructions for this product. Contact your local distributor, or visit the following web site for specific instructions: http://www.smiths-medical.com/recycle/index.html Non-European Union residents must dispose of or recycle this product (including batteries) in accordance with the local laws or regulations that apply. WARNING: Collect Separately. There are potential health hazards associated with improper disposal of batteries, electronics, and contaminated (used) infusion sets and syringes. Dispose of used batteries, infusion sets, syringes, and other used accessories, or a pump that has reached the end of its useful life, in an environmentally safe manner, and according to any regulations that may apply. Requirements for battery pack replacement The battery must be replaced only by a trained Biomedical or service technician. Always dispose of depleted or defective batteries in compliance with all applicable regulations or you may return the battery pack to Smiths Medical for recycling. WARNING: Battery Replacement: Observe ESD handling precautions when replacing the battery. Replace battery only with same Smiths Medical part/model number. Recycle batteries in compliance with applicable local regulations. Collect Separately This product contains electrical and electronic components (including batteries) that may contain materials, which if disposed of with general waste, could be damaging to the environment. 40-5648-51B 25 Scheduled Maintenance 26 40-5648-51B Theory of Operation Section 2: Theory of Operation of the manual contains definitions and descriptions of standard operation of the Medfusion™ 3000 Series pumps. Overview of operation The Medfusion™ 3000 Series pump design allows the precise control of the infusion rates over a wide range of syringe sizes and manufacturers as specified in the Operation Manual. Controlling motor functions A stepper motor driving the plunger driver controls the infusion rate. The motor receives electrical pulses from microcontroller with pulse frequency determined from the programmed flow rate. • • • ence and syringe size. d) A force sensor in the plunger driver head detects and reports the amount of force exerted on syringe plunger head. A large amount of force indicates an occlusion in the patient line to the microcontroller. A Watchdog device checks for microcontroller malfunction including timebase errors, and can shutdown the motor and generate an alarm independent of the microcontroller operation. An internal power source (i.e., 1 Farad super-capacitor) allows the pump to alarm should failure occur in the pump’s power system or internal battery. Forty-eight motor pulses turn the motor one full revolution. Five hundred and sixty full motor revolutions move the plunger driver one inch. Therefore, 26,880 motor steps move the plunger driver 1 inch (or 0.000037 inches per motor step) − providing very good flow continuity and precise delivery. Infusion control & safety functions Two sensors are used to verify that the infusion proceeds at the programmed rate. Specifically, the microcontroller uses: a) the motor rotation sensor to verify proper motor speed; b) the position sensor to verify proper syringe plunger driver motion over time. If the microcontroller determines either motor or syringe plunger driver is running at a speed not equivalent to the programmed flow rate, then the infusion stops and a system fault alarm warns the user. Four additional sensors verify the syringe parameters: a) The plunger sensor, in the head of the plunger driver, detects proper engagement of syringe plunger with syringe plunger driver. b) The flange clip detects the proper position of the syringe flange. c) The syringe barrel clamp detects both syringe pres40-5648-51B 27 Theory of Operation Pump design description Listed in this chapter are descriptions of each functional block and its role in pump operation and system safety. Logic core of Medfusion™ 3000 Series pumps The block diagram below shows interrelation between the different assemblies of the Medfusion™ 3000 Series pump. Force Transducer & PreAmp Board 240x64 Graphical Display Board Syringe Plunger Loaded Sensor Keypad & Indicator Lights Speaker Main System Board (Logic Core) Rechargeable Battery Pack & Battery Gage Plunger Travel Sensor Syringe Ear Loaded Sensor WatchDog Syringe Size Sensor Motor Rotation Sensor Interconnect Board DC Power Input Jack AC Power Input & Power Supply IR Serial Comm Link Stepper Motor Buzzer Block Diagram for Medfusion™ 3000 Series Infusion Pump Main circuit board Main microprocessor The main circuit board has one main microprocessor, 68HC11, with responsibilities for the following tasks: a) Controlling the graphical display of information. b) Responding to the keypad and controlling visual indicators on the keypad. c) Controlling the primary speaker. d) Controlling the stepper motor which drives the syringe plunger. e) Monitoring syringe sensors: syringe size, syringe flange (ear) loaded, syringe plunger loaded, syringe plunger position, and syringe plunger force. f) Communicating with the smart battery gauge. g) Controlling the external serial communication. 28 40-5648-51B Theory of Operation Watchdog circuit A watchdog circuit has a separate power supply and separate (PIC) microcontroller/clock which monitors the main microprocessor. The watchdog circuit detects microprocessor timing failures and initiates a watchdog alarm through a dedicated “back-up” audible alarm which is separate from the primary speaker. If a watchdog or “System Failure” alarm is generated, then watchdog circuit turns on the red alarm indicator and backup audible alarm, and turns off the motor current. The microprocessor uses sensor output to verify plunger travel against set flow delivery rate. The sensor output is not used for rate correction. Motor rotation sensor The motor rotation sensor is an optical reflective sensor which senses 4 pulses per motor rotation. The microprocessor measures the frequency of this signal to: • Verify rotation speed against the set flow delivery rate. It is not used for speed correction. Stepper motor DC power converter The stepper motor drives the syringe plunger driver. The DC Power Converter generates required system DC voltages from the available power source coming from the interconnect board. This power source can be either battery power, or AC power, or external DC power. The main microprocessor monitors these voltages and will detect failures in any system voltages. • Real time clock • A separate Real Time clock source provides the microprocessor with date and time information. The date and time are used for time-stamping records in alarm history and infusion history, and for determining the next recommended Periodic Maintenance date. Graphical display circuit board (LCD) A 240 × 64-pixel liquid crystal display provides the primary visual interface for pump operation. • An always on LED driven back light in the LCD enhances viewing in low light areas. Keypad The keypad is a multi-layer polyester laminate providing buttons for controlling the pump, and indicator lights for identification of pump status. Plunger (driver) travel sensor The plunger travel sensor is a precision potentiometer producing a change in voltage (resistance) with the motion of the syringe plunger driver. This allows the microprocessor to determine: • • • plunger speed near end of plunger travel (i.e,. near empty alarm) end of plunger travel (i.e., empty alarm) 40-5648-51B Each motor step is controlled by the microprocessor using an open loop control method. Syringe flange loaded sensor The syringe flange sensor requires the flange be installed in the flange locating device on the pump. • Reports a logic state to the microprocessor to indicate proper syringe flange loading. Uses self test signal to verify the sensor is not in an electrically “stuck” state. Syringe size sensor The syringe size sensor is a precision potentiometer which produces a voltage (resistance) proportional to the outside barrel diameter of the syringe loaded into the pump. This allows the microprocessor to measure: • Voltage proportional to syringe barrel outside diameter to determine the syringe size (e.g. 10cc, 20cc etc.) or syringe not loaded. Interconnect printed circuit board Receives and directs the power source, either internal 12VDC power supply, internal battery, or external DC power to the “Main” board. a) Generates status signals to “Main” board indicating source of power supplied. b) Contains battery charger for charging the battery. c) Contains an infrared drivers for serial communication interface with the pump. d) Supplies the audio drive signal, originating from the “Main” board, to power the speaker. 29 Theory of Operation AC power input & power supply board This AC Power Input provides a receptacle for connecting an IEC 320-type AC power cord to the internal, universal input power supply. This Power Supply Board provides 12 VDC to operate the pump and charge the batteries. • ringe plunger (i.e. occlusion detection). Uses self test control line to verify force sensor and circuitry are operating properly. DC power input jack Plunger Loaded Sensors The two plunger loaded sensors are located on the plunger PCB, and sense the state of each “flipper” on the plunger driver. The DC Power Input Jack connects external DC power into the pump from external DC sources. This input is protected from over-voltage and reverse polarity. • • Always observe all cautions and warnings for connecting DC power to this input. • Reports a logic state to the microprocessor to indicate proper syringe plunger loading. Uses self test signal to verify the sensor is not in an electrically “stuck” state. Speaker The primary speaker serves as the primary audio source for generating alarms. • The microprocessor senses speaker current to determine if speaker is operational. Rechargeable battery pack & battery gauge A rechargeable NiMH battery pack (NiCad battery pack on older model pumps) allows operation on battery, which also serves to provide backup power with the loss of externally applied AC or DC power A gauge residing on the battery pack maintains present battery capacity during charge and discharge conditions. The gauge monitors battery temperature and controls the battery charger in setting the charge rate. The pack contains a resettable fuse which limits the current flowing through the battery. Plunger printed circuit board This plunger printed circuit board (PCB) provides connection and pre-amplification of sensors in the plunger driver to the main microprocessor board. The plunger PCB contains the force sensor amplifier and the plunger loaded sensors. Plunger force sensor The plunger force sensor is a full bridge strain gauge which generates a voltage proportional to the force applied by the plunger driver to push the syringe plunger. The allows the microprocessor to measure: • 30 Voltage proportional to force applied to the sy40-5648-51B Theory of Operation Main Board – Schematic Level The Main printed circuit board design has the following sub-circuits: • • • • • Logic kernel • Motor speed detection Power control • Syringe sensing DC-DC Converter • Plunger position sensor Front panel interface • Force sensing Graphic display • Speaker drive interface • Motor drive Each of the sub-circuit descriptions is presented in the order of the schematic pages of the Medfusion™ 3000 Series “Main Printed Circuit Board”. The signal names marked with the asterisk symbol on the schematic indicate that those signals are “active-low”. In the block diagrams for each section, the arrows indicate data flow direction referenced to the main microprocessor. In some cases, the arrows will identify a device other than the microprocessor to which the signal directly interfaces, (e.g., analog to digital converter). Logic Kernel Description The Medfusion™ 3000 Series Logic Kernel Main PC flowchart is below. It shows linkage between the 68HC11K1 microprocessor and the main components of the system: 32Kb Serial EEPROM Time of Day IC 4 Mb Flash Memory Infrared X-Ceiver T×D, R×D PH6, SPI PA4, SPI $8000 - $FFFF PG6, SPI 10 Bit A/D Converter 68HC11K1 Main Processor 32Kb Static RAM PG1, SPI $0 - $7FFF I/O $1000 24 1/O Bit Port 1 Expansion (82C55) I/O $1200 8 Bit D/A Converter 24 1/O Bit Port 2 Expansion (82C55) Flowchart of Logic Kernel for Medfusion™ 3000 Series infusion pump 68HC11K4 Main Microprocessor Interface, U19 The main microprocessor’s direct signal interfaces are described in clockwise order taken from the Medfu40-5648-51B 31 Theory of Operation sion™ 3000 Series Main PC Schematic of the microprocessor. The following table summarizes some of the microprocessor input / output signals. Signal name ir_xmt_data ir_rcv_data speaker_frequency speaker_volume mtrpha_iref mtrphb_iref adc_cs* dac_cs* reset_pio power_strobe plunger_detect1 plunger_detect2 acu_pwr_strb_on async_battery_ data io_cs* ram_cs* eeprom1_cs* flash_cs* 32 Processor port Description PD1/TxD The ir_xmt_data is used for transmitting asynchronous serial data. PD0/RxD The ir_rcv_data is used for receiving asynchronous serial data. PH0/PW1 Sets the audio frequency of the main speaker. Generated as a fixed 50% duty cycle (square wave) with a variable frequency. PH1/PW2 Fixed frequency variable pulse widths signal that the speaker- driver hardware converts into a DC voltage for volume control. PH2/PW3 Pulse-width modulated output transformed by hardware into a DC level representing motor current for coil “A” of the motor. PH3/PW4 Pulse-width modulated output transformed by hardware into a DC level representing motor current for coil “B” of the motor. PG6 Chip select signal for SPI communication to the 10-bit analog to digital converter. This signal is active low. PG1 Chip select signal for SPI communication to the 8-bit digital to analog converter. This signal is active low. PG0 Allows the main processor to independently reset the two 24 bit I/O expansion devices. The reset is active high. PD5 Controls the power state of the system. Must be an AC signal to maintain the power on state. A stuck state of either logic high or low, is one of the conditions for enabling the power off state. PA6/OC2 Logic sense signal for detecting the respective plunger flipper state. A logic high indicates a syringe is loaded. PA5/OC3 Logic sense signal for detecting the respective plunger flipper state. A logic high indicates a syringe is loaded. PA4/OC4 This feedback signal to check that ACU is still controlling power to the system. When power is on, acu_pwr_strb_on measures > 4.0 volts nominally. PA3/IC4/OC5 The single wire asynchronous data communication between the main processor and the battery gauge located on the battery pack. This port pin is bi-directional, both input & output. CSIO Chip select for the two 24 bit I/O expansion devices. This signal is active low. CSGP1 Chip select for the main processor’s external random access memory (RAM). This signal is active low. PH6 Chip select for SPI communication to the serial E2 PROM #1. This signal is active low. Chip select for access to the main processor’s programmed memory (Flash). This signal is active low. 40-5648-51B Theory of Operation Signal name Processor port write*, e_clock, R/w*, E, XADxaddr[15:18], DR15 - XADaddr[0:14], data[0:7] DR18, ADDR0 - ADDR14, and DATA0 - DATA7 spi_clock, spi_mosi, SCK, MOSI, and spi_miso MISO atod_ref_bfrd AN0 supercap_detect AN1 pwr_strb_on AN2 motor_sply_meas AN3 analog_sply_meas AN4 force_psv_adj AN5 speaker_detect AN6 vpos_sply_meas AN7 mtr_timer PA7/OC1 motion_detect PA2/IC1 buzzer_detect PA1/IC2 tod_intrpt PA0/IC3 MOD_A, MOD_B 40-5648-51B Description The main processor control bus signals that route to the memory and I/O expansion devices. The address line addr15 is not used. These signals are used for SPI bus communication to the Serial EEPROM, Time of Day Clock, Analog to Digital Converter, and the Digital to Analog Converter. Input for main processor to verify the reference voltage used by the 10-bit analog to digital converter and system reference. The nominal measured reference voltage is 2.048 volts. Analog signal proportional to the Super Capacitor voltage. When fully charged, supercap_detect measures 2.5 volts nominally. The main processor read supercap_detect to verify the Super capacitor is present. Feedback signal is to check the proper operation of the power control circuit. When power is on, pwr_strb_on measures > 4.0 volts nominally. Signal is proportional to the motor supply voltage. The nominal DC voltage for this signal is 1.09 volts, exactly a sixteenth of the motor supply voltage. Signal is proportional to the analog supply voltage. The nominal DC voltage for this signal would be 2.5 volts nominally, exactly one half of the analog supply voltage. Feedback signal proportional to the offset voltage used on the force sensor pre-amplifier. Its voltage range dependent upon the offset voltage setting (a calibration value). Feedback signal proportional to the current through the main speaker. Its level depends on the volume setting for the speaker. Signal is proportional to the positive supply voltage. The nominal DC voltage for this signal is 2.397 volts, exactly one fourth of the vpos_sply supply voltage. Time base used by the main processor to control motor step timing and an input to the highest, maskable interrupt source. Signal is the encoded output from the optical motor rotation detector. Feedback signal from the audio buzzer detection circuit. This signal is logic high whenever the audio buzzer is active. An independent time base provided by the time of day clock. This is a 1 Hz frequency signal. These inputs configure special processor operational modes. 33 Theory of Operation Signal name reset* Processor port Description Reset Provided from the system-reset circuit located in the Power Control Logic section of the Main PCB. VRH 4.096V A/D reference. AVDD, AVSS, The main processor’s analog to digital conversion supply and referand VRL ence pins. Flash memory, U22 Flash program memory is 512 K × 8. It is addressed as 16 pages of 32 K × 8 each. Flash memory can be reprogrammed within the system. Software upgrade method for programming flash memory The re-programmable feature of Flash Memory provides for software upgrades. The pump is placed in a special Biomed mode which allows reprogramming of the software through the infrared serial port. Static random access memory, U17 Static RAM is 32 K × 8 bit. Serial EEPROM, U2 and U4 The serial EEPROMs are used for storing manufacturing, calibration, configuration, libraries, the history event log, the PharmGuard® Safety Data, and the service data requiring non-volatile random access. Medfusion™ 3000 series pumps may have two 8K x 8 bit EEPROMs, two 16K x 8 EEPROMs, or two 32K x 8 EEPROMs. Time of day, U8 The time of day, including calendar, is maintained by the RS5C316B which is continually powered as long as AC, external DC voltage, or internal battery is present, or the super capacitor is charged. Infrared transceiver An IR transceiver, located on the Interconnect board, provides an electrically isolated asynchronous serial communication link between the pump and an external system. The infrared link is intended for short distances of less than a few inches. 34 40-5648-51B Theory of Operation Analog to digital converter, U13 A four channel, unipolar, 10-bit converter obtains high resolution analog measurements. The high resolution measurements in ascending channel order are: • pressure sensing amplifier • plunger force sensing amplifier • syringe size sensing amplifier • plunger travel sensor. The converter uses precision 4.096-volt reference equating to a bit resolution of 4 millivolts. The converter interfaces to the Serial Peripheral Interface of the 68HC11. Digital to analog converter, U20 A dual channel 8 bit digital-to-analog converter: • Generates the contrast voltage for the Liquid Crystal display, • Generates an offset to the force sensing amplifier. Uses precision 4.096-volt reference equating to a nominal bit resolution of 16 millivolts. Channel A is the source for the force amplifier, and channel B is the contrast voltage reference. 40-5648-51B 35 Theory of Operation I/O port expansion, U3, U33 There are two 82C55 input/output port devices providing the additional input/output requirements for the microprocessor. They are accessed through the I/O chip selects port1_cs* and port2_cs*. Expansion port # 1 (port1_cs) Signal name eeprom2_cs* pet_watchdog Port location PB7 PB6 supercap_test PB5 tod_cs tod_wr_enbl* speaker_envelope3 PB4 PB3 PB2 speaker_envelope2 PB1 speaker_envelope1 PB0 warning_led_on* infusing_ledl_on* PC7 PC6 infusing_ledm_on* infusing_ledr_on* pcell_led_on* battery_led_on caution_led_on* lockout_led_on* keypad_in_col(0-5) PC5 PC4 PC3 PC2 PC1 PC0 PA0-PA5 pwr_sw_mcu PA6 mtr_current_detect* PA7 36 Description A logic low enables accessing the 2nd serial EEPROM. A logic signal used as a handshake for indicating valid operational status to the auxiliary controller. A logic high enables testing the super-capacitor, (i.e., backup power source). A logic high enables accessing the time of day IC. A logic low enables writing data to the time of day IC. A logic high selects the audio envelope time constant of 35 milliseconds. Refer to the Main Speaker Drive description section. A logic high selects the audio envelope time constant of 11 milliseconds. Refer to the Main Speaker Drive description section. A logic high selects the audio envelope time constant of 2.5 milliseconds. Refer to the Main Speaker Drive description section. A logic low turns the “Caution” LED indicator on. A logic low turns the left most (when viewing the keypad) “Infusing” LED indicator on. A logic low turns the middle “Infusing” LED indicator on. A logic low turns the right most “Infusing” LED indicator on. A logic low turns the “Pressure Cell” LED indicator on. A logic high turns the “Battery” LED indicator on. A logic low turns the “Caution” LED indicator on. A logic low turns the “Tamper Feature Active” LED indicator on. Senses 1 of 6 columns of the keypad matrix. When the sense value is logic low, the indication is the corresponding button for the column is being pressed. Sense signal for the power switch. The signal is at a logic high when the power switch is being pressed. Sense signal from the motor current detector circuit. If the motor is energized with sufficient current in any coil, this signal is at logic low. 40-5648-51B Theory of Operation Expansion port # 2 (port2_cs) Signal name set_in_snsr_enbl* Port Location PB6 syringe_ear_snsr_ enbl plunger_snsrs_enbl PB5 motion_snsr_enbl PB3 force_snsr_test* PB2 pressure_snsr_test* PB1 lcd_reset* PB0 mtr_phb_dir PC7 mtr_phb_enbl* mtr_pha_dir PC6 PC5 mtr_pha_enbl* keypad_sel_row3* PC4 PC3 keypad_sel_row2* PC2 keypad_sel_row1* PC1 keypad_sel_row0* PC0 buzzer_armed PA0 watchdog_alarm extrnl_pwr_detect PA1 PA2 ac_pwr_detect PA3 syringe_ear_detect PA5 set_in_detect PA6 vlow_battery PA7 40-5648-51B PB4 Description Set to logic low to enable the “set in” detector to sense the pressure cell being installed. Set to logic high to enable the “syringe” detector to sense the syringe flange (ears) being installed. Set to logic high to enable the “plunger” detectors to sense the plunger flippers being properly engaged. Set to logic high to enable the motion sensor monitoring the motor speed. Set to logic low to activate the force sensor test circuit. This signal causes the sensor to generate a known offset if the sensor is operating properly. Set to logic low to activate the pressure sensor test circuit. This signal causes the sensor to generate a known offset if the sensor is operating properly. Allows the main processor to reset the LCD display independently of other system devices. The reset signal is active low. Controls the direction (phase) of motor current in coil “B” of the stepper motor. Set to logic low to enable motor current in coil “B”. Controls the direction (phase) of motor current in coil “A” of the stepper motor. Set to logic low to enable motor current in coil “A”. Control signal to select row 4 of the four-row keypad matrix. To select the row requires a logic low and only one row at a time. Control signal to select row 3 of the four-row keypad matrix. To select the row requires a logic low and only one row at a time. Control signal to select row 2 of the four-row keypad matrix. To select the row requires a logic low and only one row at a time. Control signal to select row 1 of the four-row keypad matrix. To select the row requires a logic low and only one row at a time. A logic high indicates the backup audio buzzer is ready to alarm should the “watchdog” alarm state become true. A series resistor is provided to prevent latching. A logic high indicates the “watchdog” alarm state is true. A logic high indicates an external power source is connected to the pump. A series resistor is provided to prevent latching. A logic high indicates AC line power is connected to the pump. A series resistor is provided to prevent latching. A logic high indicates the syringe flange (ears) are installed properly in the pump and syringe_ear_snsr_enbl is active. A logic high indicates the pressure cell is installed and set_in_ snsr_enbl is active. A logic high indicates the battery voltage has fallen below a fixed voltage level, independent of the battery being charged. 37 Theory of Operation Power control description The power control logic provides two functions, power management, and triggers alarms when the main microprocessor fails. Refer to the Power Control Logic section of the Main PC Schematic for details. Test Supercap Mains Supply Battery External DC 5 Volt Always On Supply Super Capacitor Processor Reset to Processor Reset Circuit Logic Supply Monitor Super Capacitor Processor A/D Channel AN1 Watchdog Alarm Circuit Auxiliary Controller Audio Buzzer Buzzer Detector Watchdog Alarm Power Control Main Power On Flowchart of Power Control Description. Always on supply, U7 A 5-volt linear regulator provides power to the time of day clock and auxiliary controller, while maintaining a charge on the super capacitor. • This supply is always active provided a power source is present be it the regulated mains AC power, battery, or external DC. Backup super capacitor, C11 This device provides backup power to the audio buzzer in the loss of the primary power source, a 1 Farad Super Capacitor is part of the power control design. • The super capacitor voltage supercap_detect, is monitored through the microprocessor’s A/D converter channel by the microprocessor asserting supercap_test when the pump is turned on. Backup audio buzzer, XD1 The audio buzzer provides a means to generate a backup audible alarm during: • • • 38 instrument power loss (while the instrument was on) malfunction of the main microprocessor or failure of the primary speaker. 40-5648-51B Theory of Operation The audio buzzer is enabled when the pump is turned on, and when the watchdog_alarm signal activates. The watchdog_alarm signal (from the auxiliary controller) activates anytime there is a malfunction of the main microprocessor. The main microprocessor can activate this buzzer indirectly by not providing the pet_watchdog strobe to the auxiliary controller which causes a watchdog alarm. • During power-up, the buzzer is tested by the watchdog alarm state being active, and the buzzer response verified through the buzzer_detect signal. System reset, U43 On startup, the microprocessor comes out of reset when the logic supply exceeds 4.6 volts plus the builtin delay of the reset IC. Power management, U39 An embedded Auxiliary controller oversees the power control management, and serves as the main microprocessor watchdog. The behavior of the power management system depends on pump states: • • • • Power Off Power On Watchdog Alarm and a Battery Disconnect. Power OFF state You must press, hold, and release the power switch to turn OFF the power. In normal operation, both the auxiliary controller and the main microprocessor control power-off. Power ON state To enter the power on state the power_enbl signal is initially set active by the auxiliary controller. This requires the auxiliary controller provide an AC strobe to the power_enbl circuit. This power_enbl signal also arms the backup audio buzzer. The power_enbl signal is verified by the main microprocessor monitoring the buzzer_armed signal. Watchdog During a watchdog alarm, the auxiliary controller has sole control of power-off. 40-5648-51B 39 Theory of Operation DC to DC converter The circuits for the DC-DC Converter provide all regulated voltages required by the hardware sub-circuits. • • • A switched DC source, (battery, regulated mains supply, or external DC) powers the converter section under the control of the Power Control circuitry. The converter design provides stable supply operation from an unregulated DC source, simplifying the requirements for the switched sources. Refer to the DC-DC Converter section of the Main PCB schematic for details. Positive Supply + 10 volts Switched DC Source Logic Supply 5 volt Buck / Boost Converter Main Supply 17 volt Boost Converter Negative Supply – 10 volts Inverter LCD Contrast Supply LCD Backlight Control Analog Supply 5 volts Linear Flowchart of DC & DC Converter Operation Logic supply, U12 The Logic Supply current-mode switching regulator provides a regulated output voltage of 5 volts (±5%) for the system logic. Motor supply, U34 The Motor Supply is a current-mode switching regulator provides a regulated output voltage of 17 volts for the motor current regulators. Analog supply, U21 The Analog Supply is provided specifically for low noise signal processing circuits. Being a linear supply, inherent noise rejection removes source input switching noise from it’s regulated output. 40 40-5648-51B Theory of Operation Positive & negative supply, U36 The negative supply is a charge pump DC-DC converter doubles the input voltage, then inverts the doubled voltage. • • • Provides the contrast voltage to the graphic LCD display. The low current load for the contrast voltage allows use of an operation amplifier controlled by the D/A converter through the SPI bus. Provides negative supply for the amplifiers used in force and pressure sensing. The charge pump doubles the “Logic Supply” voltage to achieve a 10V nominal positive supply voltage. This supply is used for analog circuits needing a supply voltage higher than the “Analog Supply”. LCD backlight supply, U1 A constant current regulator controls the primary LED back light for the LCD display. On the Medfusion™ 3500 pump, the secondary LED for the backlight is controlled by Q45. 40-5648-51B 41 Theory of Operation Front panel interface description The keypad interface has two circuits: • • the interface to the LED’s the interface to the keypad switch matrix, and power switch. Enable I/O Exp #2, PC0-PC7 Row Scan I/O Exp #1, PA0-PA5 Column Select I/O Exp #2, PC0-PC3 LED(s) Drive Circuits Front Panel (Keypad) LCD Input Data Control Circuits Flow Chart of Front Panel Function LED drive circuit, Q26, Q27, Q40, Q33 - Q37 Each LED drive circuit has a logic controlled switch providing a pseudo-current source to the LED when activated. • All LED’s except the “Warning”, “Battery Charge”, and “AC Power” LEDs, are controlled exclusively by the main microprocessor. Keypad matrix interface A 4 row by 6 column scan matrix senses the front panel keys: • • A pressed button is read from column signals, keypad_in_colx, through the 82C55 port expander #1. A button press is sensed as a logic low. The keypad row signals are output from port C of the 82C55 port expander #2. Power switch interface The power switch has a circuit separate from the keypad matrix because it is monitored by both the main microprocessor and the auxiliary controller. 42 40-5648-51B Theory of Operation Graphic display interface description The graphic display interface circuits have the main microprocessor control signals, read write, the device select signal lcd_cs*, a data output latch, a data input buffer, and a device reset. Data output to LCD, U32 / data input from LCD, U6 The data from the LCD to the main microprocessor is buffered by U32 and U6. LCD contrast The contrast control is created from the 8-bit digital to analog converter buffered with a 2.5 gain amplifier to provide minus contrast voltage. • The full scale range of 255 (FF hexadecimal) counts equals approximately minus 10 volts. LCD backlight The primary backlight for the LCD is an LED driven by a constant current source. This backlight is always on whenever the pump is on. The secondary backlight is not present on Medfusion™ 3010 and 3010a pumps. Its on-off state is controlled by the CPU. During normal conditions, it is off when the pump is powered via the internal battery. 40-5648-51B 43 Theory of Operation Motor drive description A two-phase bipolar stepper motor drives the syringe plunger. The motor control interface drives the stepper motor. ø Direction ø Enable Coil “A” Motor Current Control Motor Current Phase A/A* ø Count Reference Motor Current Phase B/B* ø Direction ø Enable* Motor Coil “B” Motor Current Control ø Current Reference Motor Current Detect Motor Current Detector Flowchart of Motor Drive Description The main microprocessor controls which motor winding is active, designated as A or B, the direction of current in each winding, and the magnitude of the current. Coil A & B PWM current references The pulse-width modulated signals from the main microprocessor are low pass filtered to create an analog voltages for control of motor current in each coil. Motor current regulators, U26, U35 Two regulator ICS independently regulate the current for windings A and B. • The watchdog_alarm signal activates the N-channel mosfet to disable the motor current in both windings through the “BRAKE” pin of the regulator IC. Motor current detector, U40 The watchdog alarm function is tested at power-up by verifying the mtr_current_detect* signal is at a logic high when the watchdog alarm condition is active. • 44 Similarly, the mtr_current_detect* signal should be at a logic low when either motor winding has sufficient current and the watchdog alarm condition is not present. 40-5648-51B Theory of Operation Sensors interface description Motor speed detection The digital sense signal is created by using a reflective infrared optical sensor to sense a motor-coupled encoder as the motor rotates. The microprocessor measures the period of the signal created by the encoder. Syringe sensing description The syringe sensing system senses the syringe barrel size, senses the plunger end cap is secured by the mechanical flippers, and the syringe flange (ears) are located in the pump’s syringe flange locating device. • The circuit for sensing the plunger flippers is part of the plunger printed circuit function. Syringe size sensing Syringe sensing is accomplished by using a potentiometer which changes its resistance with the barrel diameter. The potentiometer is excited with a precision 4.096v voltage reference and the potentiometer’s output is monitored through channel 2 of the system A/D. • The sensing system requires calibration to determine offset and gain. Calibration values are stored in non-volatile (serial EEPROM) memory. Syringe flange (ear) sensing Syringe flange (or ear) sensor is used to detect if the syringe flange is installed in the flange-holder on the side of the pump. An infrared optical interrupter detects when the flange-locating device is in a valid position. A properly loaded flange causes the optical path to become uninterrupted allowing a direct path from the infrared emitter to the detector. • • • The emitter is enabled by the signal syringe_ear_ snsr_enbl when set to logic low. The sensor output, syringe_ear_detect, produces a high logic state when the flange is properly loaded. The state should be logic low anytime the syringe ear (flange) is not installed or syringe_ear_snsr_ enbl is inactive. 40-5648-51B 45 Theory of Operation Plunger position sensing description Sensing syringe plunger position is required for the detection of an incorrect plunger speed, detecting near end of plunger travel, and detecting end of plunger travel. The travel sensing circuits perform excitation and signal processing of the travel sensor. The travel sensor uses a linear potentiometer which produces a change in resistance with the motion of the syringe plunger. • The sensing system requires calibration to determine offset and gain. Calibration values are stored in non-volatile (serial EEPROM) memory. Speaker drive description The speaker sounds the warning and caution alarm tones for the pump. The interface circuit controls the frequency and amplitude of the signal driving the speaker, and provides feedback for verifying speaker function. Amplitude Envelope Control I/O Exp #1 PD0-PD2 Frequency, PW1 Volume, PW2 Speaker Amplitude + Envelope Control Circuit A/D Channel 6 Speaker Amplification Speaker Test Circuit Illustration of Speaker Drive Speaker control • Tone duration is controlled by the interval the amplitude level is applied. • The speaker_frequency signal is a fixed 50% duty cycle (square wave) with a variable frequency to 1 kHz. • • 46 The speaker_volume is a pulse-width modulated signal converted by hardware to an analog voltage which controls the speaker volume. The rise and fall times of the volume are controlled by input signals from: speaker_envelope_1, speaker_envelope2, and speaker_envelope_3. 40-5648-51B Theory of Operation Speaker test The return signal from the speaker detects whether current is flowing in the Speaker from analog conditioning circuitry. The half-wave rectifier circuit uses the negative half-cycle of the sense signal to invert and amplify it. • • The amplified output is demodulated by the analog switch which creates a peak and hold circuit. The speaker_detect output signal from the conditioning circuitry goes to the microprocessor’s analog input. Plunger board – schematic level The plunger PCB provides pre-amplification of the force sensor output to the Main system PCB, and contains two photo-interrupters with supporting circuitry, one for each plunger flipper. The referenced schematic signals of the main board electronics are identified using names in Smallcaps. Force preamplifier function The force sensing system provides a measurement of the force required in moving the syringe plunger. The interface to the force sensor has an excitation source, test signal, and pre-amplification. • The Main printed circuit board provides a fixed 4.096-volt excitation to the force sensor. • The Main printed circuit board trims this offset range using the signal force_preamp_osadj. The Main PCB provides additional gain to maximize measurement resolution. • Force sensing interface description The force sensing element is a full bridge strain gage, and the plunger PCB pre-amplifies and filters the output of this bridge. The interface has: sensor excitation, electronic zero-offset adjustment, amplification and filtering, and a sensor test control signal • • • • • 40-5648-51B force_snsr_exh provides a constant voltage excitation of 4.096 volts DC to the sensor. Auto-Zero Adjustment Circuit provides a voltage to zero the pre-amplifier, force_osv_adj, from the 8 bit system D/A converter. Sensor Post Filter Amplifier is a second order lowpass filter with a 3.68x gain. The signal force_snsr_test* when set active low causes Q2 to apply a resistance parallel to the force sensor’s bridge resulting in a positive shift of the sensor output. The sensing system requires calibration to determine zero adjustment, offset, and gain. Calibration values are stored in non-volatile (serial EEPROM) memory. 47 Theory of Operation Plunger flipper sensor function Plunger flipper sensing requires each sensor detect its respective flipper position. Each infrared optical interrupter provides a high logic state when the flipper is in a valid position determined by a loaded syringe plunger. The transmitters for both photo-interrupters are driven in series; however, the optical receivers are read in parallel. • • • 48 Output from each photo-interrupter is monitored individually so each sensor is independently checked. When a syringe plunger is correctly loaded, both plunger_snsr1_out and plunger_snsr2_out are at a logic high. The transistor Q1 allows the sensor output to be tested by turning the transmitter from both sensors on and off. This is controlled by the signal plunger_snsrs_enbl from the Main PCB. 40-5648-51B Theory of Operation Interconnect board – schematic level The interconnect printed circuit design interfaces to an intelligent rechargeable Battery, the system speaker, the internal DC supply, connection for an external DC supply and the main PCB. To MAIN PCB Speaker Decoupling AC Power Detector DC Power Supply External Power Detector External DC Jack + Filtering Smart Battery Smart Charger Infrared Serial Data Port Flowchart of Interconnect Board at Schematic Level Each sub-circuit description is presented in the order of the schematic pages of the Medfusion™ 3000 Series “Interconnect Printed Circuit”. AC power detection description The AC power detector uses a zener diode regulator to provide a constant voltage to the signal ac_pwr_detect anytime AC power is provided to the pump. The regulated voltage is required for logic detection of AC power and is used to regulate the current through the AC LED indicator and the battery charge LED indicator. • For ac_pwr_detect to be active, requires the DC input voltage (from the AC power supply) exceed 10 volts. The ac_pwr_detect signal is also used to generate the signal battery_swx_on* which controls a battery switch to turn ON using battery power when AC power and external DC power are removed. • The other effect of battery_swx_on* is delaying the battery charger from starting until the internal DC power supply reaches 10 volts. A transient voltage suppressor protects the detection circuitry on the reg_dc_intrnl. 40-5648-51B 49 Theory of Operation External DC power conditioning / detection description The external DC power input section limits current through a resettable fuse, both common and differential mode noise suppression and transient voltage protection. The resettable fuse limits current into the pump from an external DC source. Noise filtering is performed by input and output capacitors on the conditioning circuit together with a common mode choke. The external power detector uses a zener diode to provide a valid logic high level when external DC power is applied. The active voltage for extrnl_pwr_detect is nominally 5 volts. The threshold detector U3 provides immediate detection, through the signal battery_swx_on*, of the external DC source being removed. • • A battery switch toggles to internal battery if both AC and external DC power are removed. The threshold detector also prevents the battery charger from charging the internal battery until the external DC power exceeds 5 volts. Infrared serial data port description The infrared serial port interfaces directly with the main microprocessor’s asynchronous serial communication pins. The infrared port supports short transmission distances of approximately 3” or less and a maximum baud rate of 9600. The Infrared Receiver signal from U1 is conditioned by the comparator circuit of U4 to generate a valid logic state to the microprocessor. The Infrared Transmitter signal ir_xmt_data is at a logic high during its inactive state. A logic low on ir_ xmt_data enables the transmitting IR diode through the transistor Q3. 50 40-5648-51B Theory of Operation Battery management description The battery management circuits are a 2-stage constant current battery charger, a charge detector, and a battery switch over control circuit. The interconnect board interfaces to a 6 cell NiMH battery pack (NiCad battery pack on older model pumps) with a “smart” battery gauge. 2-Step Constant Current Battery Charger Smart Battery Switch Battery + Gauge Charge Detector Battery Communication Very Low Battery Battery Board Interconnect Board Main Processor Main Board Flowchart of Battery Management Description Battery gauge interface The main microprocessor communicates to the battery through Battery_Data − a single bi-directional serial data line. A very low battery capacity status, vlow_battery*, signal protects the battery pack by disconnecting the battery. This signal is at a logic low when the battery is depleted. Battery charger The battery charger allows charging a battery with an input supply voltage either above or below the battery voltage. Battery charging takes place when either the internal DC supply or external DC is present. The charger provides a charge current determined from three conditions: • In normal operation the charge current is controlled by the gauge, providing two levels of constant charge current. If the battery capacity is less than 94% of its known capacity, the gauge will set charge* to a logic low. This results in a charge current rate of C/6, approximately 270 milliampere giving a 6-8 hour recharge time. 40-5648-51B 51 Theory of Operation • • The gauge sets charge* to logic high when the battery has been charged to 94% (or greater) of the battery’s capacity, this lowers the charge rate to 65 milliampere, or C/25. A separate charge control circuit is the voltage limit for the battery; here a battery voltage monitoring circuit in the charger limits the charger to a voltage limit of 1.55 volts per cell (nominal). The charger keeps reducing the charge current in order to remain below this voltage limit. This prevents damage to the cells from excessive battery voltage. Battery gauge function The gauge IC, BQ2012, monitors direction and magnitude of current flowing through the battery. • The current is sensed by the gauge as a voltage across R4. • The gauge computes capacity. To control charging the battery, the gauge uses battery temperature and battery voltage to update the battery capacity − which is a function of current and temperature. Charge detector A charge detector circuit generates the control signal Charge_Detect to control the illumination of a battery charge LED indicator and to reset the very low battery detector circuit located within the battery pack. The charge* signal from the gauge controls the battery charger, located on the Main PC board, to charge at different rates depending on the state of the battery. • Severely depleted battery monitor The main microprocessor does not monitor the Charge_Detect signal. However, the main microprocessor communicates with the gauge to determine charge status. Battery switchover A smart switch selects a reliable source of power for the system power supplies. This switches to internal battery power when AC power and external DC power are removed from the pump (or when these sources are below acceptable thresholds detailed above). • In normal operation, the battery voltage can be at a higher voltage than the external DC − especially during battery charging. The gauge terminates standard charge in the event of the battery temperature exceeding 50°C or if the battery pack voltage is less than 5.7 volts. The depleted battery monitor IC senses the battery voltage to prevent an over-discharged battery. When the battery pack voltage reaches a nominal voltage of 5 volts, the IC sets the vlow_battery signal to a logic low, which disconnects all battery loads with the exception of the battery monitor circuit. The battery charger provides the signal charge_detect, which resets this monitor IC reconnecting the battery back to the system. Battery board – schematic level The battery reports to the “Main” system microprocessor present status and controls battery charge from the Interconnect PCB. The battery PCB has: • a 3-volt Linear Regulator • a Gauge IC • and a Depleted Battery Monitor IC. The local circuit allows the battery to maintain its current capacity regardless of where the battery resides. The referenced schematic signal nets of the main board electronics are identified using names in smallcaps. 52 40-5648-51B Troubleshooting Problem solving alarms / alerts This section defines basic problems and provides some standard problem solving procedures. Types of alarms / alerts The following table defines the alarms and alerts generated by the Medfusion™ 3000 Series pumps, with suggested remedies and solutions. Type High priority Definition and Remedy A high priority alarm results from any condition which halts an ongoing infusion, or any pump system fault which affects infusion. High Priority alarms are signaled by a flashing red indicator and an audible signal. Press í to pause the audible alarm for the preset alarm silence period. Medium priority A medium priority alarm indicates any condition requiring operator intervention but does not halt infusion. Medium Priority alarms are signaled with a flashing yellow indicator and an audible signal. Low priority Pressing í silences the audible alarm for the programmed alarm silence period. A low priority alarm indicates any condition not requiring immediate operator intervention. Low Priority alarms are signaled with a continuous yellow indicator and an intermittent audible signal. Pressing í permanently silences this alarm. A limit alarm occurs whenever an invalid entry is attempted on a numerical enLimit priority try screen. The invalid entry alarm sounds a brief tone with an advisory message onscreen. Neglected pump The Neglected Pump alarm is a medium priority alarm. It is simply reminding you to finish what you started. Once you begin programming any infusion delivery setting, the pump expects you to continue until setup is complete. If you leave the pump paused too long (>30 seconds) on a data entry screen, then the pump sounds a medium priority alarm tone with the yellow indicator flashing. Note: The Neglected Pump alarm, the Periodic Callback alarm, the Improper Shutdown alarm, the Check Syringe Barrel Clamp alarm, and all Limit Priority alarms are not recorded in the pump’s alarm history record. 40-5648-51B 53 Troubleshooting Alarm messages & priorities The following table defines alarm message, alarm priority, and cause for each alarm condition: Alarm message Alarm priority programming infusing Battery Communication Timeout (System Advisory) Low Low Battery Not Charging (System Advisory) Low Low Battery Not Working (System Advisory) Calculated Rate Out of Range Check Clutch / Plunger Lever Medium Medium High – – High Check Syringe Barrel Clamp Medium – Check Syringe Flange Sensor High – 54 Cause or corrective action Pump has sensed battery current present, but the battery gauge on the battery pack is not communicating. Check connections from main board, to interconnect, to battery pack. Pump has sensed AC or DC external power is present, but the battery is not charging. Use Biomed > Diagnostics and run Monitor Battery Status to review battery function. Check battery connections and battery charge circuit on the interconnect board. Pump has found no battery present – no charge current and no battery gage communication. Battery may be unplugged. The calculated rate is not valid. Verify that all infusion parameters have been entered correctly. Normal alarm message. Software uses position potentiometer to monitor motion of the plunger driver during delivery. If the motion is not correct this alarm is generated. May be caused because pump was not primed and clutches took too long to engage, or may occur when user squeezes the plunger lever and moves plunger head. May also occur if position pot is not calibrated or is contaminated – use Biomed > Utilities and run View Alarm History to check if failure occurs at same position reading. Certain syringe brands and sizes may cause the barrel clamp sensor to have difficulty in verifying the clamp is in position. Use Biomed > Diagnostics and run Monitor Digital Sensors to check function of barrel sensor. At power-up, software has sensed the flange is loaded when no syringe is loaded in the pump (as sensed by the barrel clamp size sensor). Use Biomed > Diagnostics and run Monitor Digital Sensors to check function of flange sensor. 40-5648-51B Troubleshooting Alarm message Alarm priority programming infusing Check Syringe Plunger Sensor High – Clear TVD to Start Infusion Limit – Completing System Initialization Limit – Data Does Not Match Previous Entry Limit – Depleted Battery (System Failure) High High Force Sensor Bgnd Test High High Infusion Complete – High Input Out of Range Greater Than Max Value Limit – 40-5648-51B Cause or corrective action At power-up, software has sensed the plunger is loaded when no syringe is loaded in the pump (as sensed by the barrel clamp size sensor). Use Biomed > Diagnostics and run Monitor Digital Sensors to check function of both plunger sensors. Normal advisory message. Total volume delivered (TVD) or total dose delivered (TDD) needs to be cleared to start an infusion when TVD/TDD exceeds the volume limit setting. Normal advisory message. At power-up, if all settings are entered by the user and É is pressed before background self-tests are completed, then this message appears. Wait a few seconds until selftesting is completed and then press É to begin infusion. Normal advisory message. In cases where confirmation of user entered data is required, the confirmation value did not match. Re-enter the value. Normal alarm message. Battery voltage measured by the gauge on the battery pack is too low. Software then stops delivery and allows watchdog to generate alarm. Plug pump into AC power, cycle power on the pump, then use Recall Last Settings to recall delivery settings and resume delivery. If problem is chronic, check battery pack function or perform battery calibration. Normal alarm message. Press ë to turn the pump off. Background self-test has found the force sensor signal out-of-range or the force sensor signal did not change when bridge-test signal was asserted. Use Biomed > Diagnostics > Monitor Analog Sensors to check operation of plunger force sensor. Open plunger head and check plunger cable and force sensor cable on the plunger board. Replace plunger board, plunger cable or force sensor. Normal alarm message. Infusion has reached the set volume limit and delivery has stopped. Normal advisory message. User attempted to enter a number greater than the maximum value allowed. (See also “maximum rate” in general problems below). Try a lower value. 55 Troubleshooting Alarm message Alarm priority programming infusing Input Out of Range Less Than Min Value Limit – Invalid Infusion Parameter Combination Low – Invalid Library Entry Limit – Invalid Syringe Size High High Invalid Rate for Syringe Size (V3 pumps only) High – KVO in Progress – Medium Limits Adjusted - Cannot Delivery All Doses Limit – Low Battery (each 1% drop Low Low Low Battery (initial signal) Medium Medium Motor Rate Error High High in capacity following initial signal if power cord is not plugged in) 56 Cause or corrective action Normal Advisory Message. User attempted to enter a number less than the minimum value allowed. Try a higher value. Normal advisory message. The user has attempted to set a combination of infusion values that does not allow a valid flow rate to be calculated. Press â and enter a different set of values. Normal advisory message. The library entry was not defined correctly when it was created. Review the library entry using the PharmGuard® Toolbox and correct the problem. Syringe size (barrel clamp potentiometer sensor) does not match selected manufacturer or when barrel clamp is lifted during delivery, this alarm occurs. If there is any question about this sensor’s function perform PM check of barrel clamp calibration. Normal advisory message. When using E-plates library entries, the library stores syringe size. Changing this size may cause this message to appear (refer to the Operation Manual for syringe size/rate tables). Normal alarm message. Infusion has reached the set volume limit and delivery changed to KVO rate. Normal alarm message. The limits on the parameter to be entered were adjusted to keep the resulting rate inside allowable limits. Normal advisory message. Battery gauge has measured the capacity of the battery is less than 10%. The infusion rate will determine the run time remaining on the battery. Normal advisory message. Plug in the power cord and run the pump on AC Mains while recharging battery. Normal advisory message. The stepper motor moving at the wrong speed. Clear any obstructions to proper motor operation. If the message reoccurs, you may need to replace the motor. 40-5648-51B Troubleshooting Alarm message Alarm priority programming infusing Occlusion - Check Infusion Line – High Outside Range Limit - Silence Alarm to Continue Medium - Periodic Callback - Silence Alarm to Continue PharmGuard Data Transfer is Recommended – Medium Medium Medium Pressure Increasing - Check Infusion Line – Medium Profile Does Not Match Last Settings Profile Limit – Pump is Locked – Limit Rate Below Recommended Min for Syringe Size Limit – Restricted Flow - Bolus Cancelled – Medium 40-5648-51B Cause or corrective action Normal alarm message. The force sensor in the plunger driver has sensed occlusion of the infusion line when the force value exceeds the set limit. If this is a chronic problem review: (a) the configured occlusion limit – the setting appears on graph on delivery screen as VL, L, N, H - pumps with v3 software: use Configuration Manual to change settings; pumps with v4 software: use the PharmGuard® Software to change settings or (b) change the infusion set up (high rates through micro-bore tubing can cause high backpressures). Normal alarm message. The user entered a rate which is outside of the library limits. The user has the option to override the limit and use the questioned value or press â and change values so that the infusion stays inside the established limits. Normal alarm message. User programmed callback alarm - no remedy required. Normal alarm message. PharmGuard® Safety Data on the pump is nearly full, and continued use may result in lost PharmGuard® event data. Use the PharmGuard® software to download the event data to computer. This alarm can be enabled or disabled using the PharmGuard® Toolbox. Normal alarm message. Backpressure in the infusion line is increasing. User should attempt to clear blockage in infusion line. If blockage is not cleared occlusion alarm will result. Normal alarm message. The “Recall Last Settings” feature only works for the profile under which the settings were programmed. Change the profile and try again. Normal advisory message. Press Unlock before changing settings during delivery. Normal advisory message. Reminds user that the programmed rate is below that recommended for the syringe size. No remedy required. Normal alarm message. During bolus rate reduction, the rate fell below the main infusion rate or the time was extended past the maximum bolus time of 59 minutes. The bolus dose has been cancelled. 57 Troubleshooting Alarm message Alarm priority programming infusing Restricted Flow - Loading Cancelled – Restricted Flow - Rate Reduced – Set Volume Limit Before KVO Limit Syringe Does Not Match Library Entry Limit Syringe Empty – Syringe Empty - Manual – Syringe Flange Not in Place High Syringe Near Empty – Cause or corrective action Medium Normal alarm message. During loading dose rate reduction, the rate fell below the main infusion rate or the time was extended past the maximum loading dose time of 59 minutes. The loading dose has been cancelled. Medium Normal alarm message. Due to high backpressure during delivery of a bolus dose or loading dose, the Medfusion™ 3500 software reduces the infusion rate in an attempt to successfully delivery the bolus. If the user presses Silence, the audible tone will not reactivate, even though the software may continue to reduce the rate. If the software cannot successfully overcome the backpressure, the bolus dose or loading dose will be cancelled. – Normal Alarm Message. In order to set a KVO rate, you must first set a volume limit. – Normal advisory message. When using E-plates library entries, the library stores syringe size. Here, this is advisory message that syringe does not match the library entry. High Normal alarm message. The plunger driver position potentiometer has sensed that the syringe is empty. This position (in a software table) is different for each syringe manufacturer and syringe size. High Normal alarm message. After reaching Syringe Empty position, the user can press É to resume infusion – in cases where there is a small amount of fluid left in the syringe. Here, the pump delivers until the force sensed on the plunger driver reaches the set occlusion limit – as the plunger pushes against the end of the syringe barrel. High Pump has sensed the flange is not loaded when syringe is loaded in the pump (as sensed by the barrel clamp size sensor). User may not have loaded syringe correctly. If necessary, use Biomed > Diagnostics and run Monitor Digital Sensors to check function of flange sensor. Medium or Normal advisory message. Notice that only a few Low* minutes of fluid remain in the syringe. This alarm is configurable for the number of minutes notice or may be turned off entirely. *The alarm priority is configurable using the PharmGuard® Toolbox software. 58 40-5648-51B Troubleshooting Alarm message Alarm priority programming infusing Syringe Plunger Not in Place High High System Advisory – “Description” System Failure – “Description” Neglected Pump (User Call-back) Low – High High Medium Medium 40-5648-51B Cause or corrective action Pump has sensed the plunger is not loaded when syringe is loaded in the pump (as sensed by the barrel clamp size sensor). User may not have loaded syringe correctly. If necessary, use Biomed > Diagnostics and run Monitor Digital Sensors to check function of both plunger sensors. See detailed descriptions in section below. See detailed descriptions in section below. If pump is left in a user input screen (e.g. set rate or titrate rate) for more than 30 seconds the pump alarms. Go to pause screen or main screen to get longer alarm silence intervals. 59 Troubleshooting System Advisory Alarms This section explains the system advisory alarms in the Medfusion™ 3000 Series pump, and suggests possible causes and remedies for these alarms. System advisory alarm Backup Critical Data Corrupted Default Configuration Restored History Data Corrupted Improper Shutdown Invalid Interrupt & System Advisory: Improper Shutdown Non Critical Data Corrupted PharmGuard Data Corrupted Primary Critical Data Corrupted Set Time and Date Maintenance Is Recommended 60 Cause or remedy Configuration and library settings are stored redundantly in nonvolatile serial EEPROM on the main board. This message will occur if backup data was lost, and primary data was used to restore backup values. No action is required. Configuration settings are stored redundantly in non-volatile serial EEPROM on the main board. If both primary and backup are lost, the configuration is defaulted. Use pump Custom Program > Teach/Learn to copy configuration from a known good pump to restore settings. If problem persists, there may be a problem with the main board. This message may appear when a new main board is installed. Infusion history log is stored in non-volatile serial EEPROM on the main board. This message will occur if this data is lost. No action is required. This alarm is recorded to history when the pump is turned on if the last power-down did not occur through pressing the power key. Check for possible causes for a pump power failure. Replace the Main PCB. Other settings are stored in non-volatile serial EEPROM on the main board. This message will occur if this data was lost. No action is required. The PharmGuard® Safety Data is stored in non-volatile serial EEPROM on the main board. This message will ocur if this data is lost. No action is required. Configuration and library settings are stored redundantly in nonvolatile serial EEPROM on the main board. This message will occur if primary data was lost, and backup data was used to restore primary values. No action is required. Advisory message that real time clock has reset on the pump. This may occur if the battery is depleted and the main board supply totally discharged – the super-capacitor on main board should keep up the clock for many days after a depleted battery is reached. Use Biomed > Utilities and run Set Time/Date to restore date and time settings. No functionality of pump is affected by date/time setting. This is a reminder to the user to conduct the Annual Maintenance Testing (section 1, page 19). To clear this alarm, reset the PM Maintenance date (see section 5, Quick Maintenance Check-out Test and follow the instructions). 40-5648-51B Troubleshooting System Failure Alarms This section discusses the diagnosis of system failure alarms in the Medfusion™ 3000 Series pump, and suggests possible causes and remedies for these alarms. System failure alarm A2D Reference Voltage BGND Test ACU Power Strobe Failure ACU Watchdog Failure Analog Supply BGND Test Aux Controller Unit Post Background CRC Test Timeout Background Self Test Timeout Backup Audible Alarm Post Calibration Required Control Key Switch BGND Test Control Key Switch Post Critical Data Block BGND Test 40-5648-51B Cause or remedy Background self-test measured an invalid range on analog-to-digital converter reference voltage. Use Biomed > Diagnostics to check the voltage. Replace the main board if invalid voltage found. Self-test has found that the ACU processor is not maintaining its power strobe. If this failure repeats, then try full reset of main board – disconnect AC power, open pump, disconnect battery, short super-cap through ~100 ohm load; then reassemble pump and retest. Replace main board if problem persists. Self-test has found that the ACU watchdog alarm signal active. This alarm may occur if processor failed to pet watchdog within allotted time (e.g. a software failure occurred). If problem recurs, replace the main board. Background self-test measured an invalid range on analog supply voltage. Use Biomed > Diagnostics to check the voltage. Replace the main board if invalid voltage found. Power-up self-test has found that the ACU processor failed to shut down motor current during the watchdog alarm test. If problem recurs, replace the main board. Software timing failure. A transient failure may have occurred in the software; if problem recurs, replace the main board. Software timing failure. A transient failure may have occurred in the software; if problem recurs, replace the main board. Power-up self-testing has found that the backup audible alarm (controlled by ACU) is not working at correct power (current) or frequency. Replace the alarm buzzer on the main board or replace the main board. Calibration values stored in non-volatile serial EEPROM memory are invalid. This message appears whenever a new main board is installed. Calibrate all the sensors in the pump. Key on keypad was found stuck on during continuous background selftest. Use Biomed > Diagnostics to determine which key is stuck. If stuck key is found, replace keypad. Key on keypad was found stuck on during power-on self-test. Use Biomed > Diagnostics to determine which key is stuck. If stuck key is found, replace keypad. Delivery settings are stored in a critical data block of RAM on the main board. This message will occur if background self-test showed the critical data block was corrupted (i.e. a RAM cyclic redundancy test failed). Run power-on self test which executes extensive RAM testing – if problem recurs, replace the main board. 61 Troubleshooting System failure alarm Critical Data Block Post Critical Data Failure D2A Offset Voltage BGND Test Depleted Battery Display Controller Post External COM Task Timeout Flash Memory BGND Test Flash Memory Post Force Sensor BGND Test Force Sensor Bridge Test 62 Cause or remedy Configuration and library settings are stored redundantly in non-volatile serial EEPROM on the main board. This message will occur if backup data and primary data are both good, but fail to agree. Use pump Custom Program > Teach/Learn to copy configuration from a known good pump to restore settings. Replace main board if serial EEPROM has failed. After settings are programmed into the pump, the pump performs a reverse calculation to ensure all settings are correct. Using incompatible ranges of settings may cause this alarm (e.g. using concentration of 1000 mg/ml and trying to set a rate of 0.1 microgram/hour). Review pump settings. Alternatively, this alarm may indicate a software data failure where critical flags are found invalid. If problem recurs, replace the main board. Background self-test found failure in force sensor offset signal. Probably a failure in the main board digital-to-analog converter or a failure in the plunger cable/board. Use Biomed > Diagnostics to check force sensor voltage readings. Battery is fully discharged below low voltage threshold. Plug in the pump to AC power or external DC power to recharge the battery. Failure detected in testing the LCD display. Check cabling between main board and display. Replace LCD display. External computer or device connected to the pump is sending too many commands too quickly, or sending too many invalid commands and this causes the software to timeout. Remove the Medfusion™ 3000 Series external RS232 adapter and observe if the problem is corrected. CRC failure found in program memory during background self-tests. Failure may occur during external re-programming of the pump software. Otherwise failure is in flash memory of the main board, and main board should be replaced. CRC failure found in program memory during power-up self-tests. Failure may occur during external re-programming of the pump software. Otherwise failure is in flash memory of the main board, and main board should be replaced. Background self-test has found the force sensor signal out-of-range or the force sensor did not change when the bridge-test signal was asserted. Use Biomed Diagnostics monitor analog sensors to check operation of plunger force sensor. Open plunger head and check plunger cable and force sensor cable on the plunger board. Replace plunger board, plunger cable or force sensor. Software sensed no voltage change when sensor test signal was asserted. The force sensor bridge (strain gage) may be unplugged or have an open connection. Use Biomed > Diagnostics > Monitor Analog Sensors to check operation of plunger force sensor. Open plunger head and check plunger cable and force sensor cable on the plunger board. Replace plunger board, plunger cable, or force sensor. 40-5648-51B Troubleshooting System failure alarm Force Sensor Test Input Task Timeout Internal A2D Failure Invalid Interrupt LED Task Timeout Logic Supply Voltage BGND Test MCU Power Strobe Failure Monitor Task Timeout Motor Failed to Stop Error Motor Not Running Error Motor Rate Error Motor Supply Voltage BGND Test Motor Volume Limit Error Plunger Sensor Failure Positive Supply BGND Test 40-5648-51B Cause or remedy Power-up self test found that the force sensor output did not change when the DAC offset voltage was changed. May be problem on main board offset circuit, plunger board, plunger cable, or force sensor. Check cabling first. Software timing failure. A transient failure may have occurred in the software; if problem recurs, replace the main board. Software self-test identified a failure in the 10-bit analog to digital converter. Use Biomed > Diagnostics > Check Analog Sensor readings. If they are abnormal, replace the main board. Software/hardware failure. Software attempted to execute invalid interrupt, may be caused by main processor hardware failure, bus failure, or software flash memory failure. Software timing failure. A transient failure may have occurred in the software; if problem recurs, replace the main board. Background self-test measured an invalid range on logic supply voltage. Use Biomed > Diagnostics to check the voltage. Replace the main board if invalid voltage found. Failure in self-test of power strobe (output port) signal from the main processor. Replace the main board if problem recurs. Software timing failure. A transient failure may have occurred in the software; if problem recurs, replace the main board. Software sensed motor rotation after stop pump motor was executed. This could be caused by failing motor rotation (photo-reflective) sensor on the back of the main board. Use Biomed > Diagnostics to run motor drive test (set motor step period to ~100 msec) then use monitor digital sensors to check motor rate sensor. Stop motor and rate sensor should stop changing. Replace the main board if sensor has failed. Motor sensor did not detect any rotation of the stepper motor. Sensor (on main board) may have failed, or worm/gear/leadscrew may be jammed. Motor sensor did not measure the correct rotation rate for the stepper motor. Sensor (on main board) may have failed, or the force sensor may be inoperative and the stepper motor stalled when an occlusion occurred. Background self-test measured an invalid range on motor supply voltage. Use Biomed > Diagnostics to check the voltage. Replace the main board if invalid voltage found. The motor has run more steps than should have been required to deliver the set volume limit. Software sensed plunger sensor voltage out of range. The plunger position sensor (potentiometer) may be unplugged or have an open connection. Use Biomed > Diagnostics > Monitor Analog Sensors to check operation of plunger position sensor. Open pump case and check connections to plunger sensor. Replace plunger position sensor. The power supply has malfunctioned. Check the outputs of the supply. 63 Troubleshooting System failure alarm Primary Audible Alarm BGND Test Primary Audible Alarm Post Pump Motor Drive Off Post Pump Motor Drive Phase A Post Pump Motor Drive Phase B Post RAM BGND Test Serial EEPROM Timeout SPI BUS Timeout Supercap Post Syringe Flange Sensor Failure Time Base BGND Test Time of Day Clock Post Time of Day Clock Timeout 64 Cause or remedy Background self-test sensed no current flowing in the primary speaker. Speaker may be unplugged or wire came loose from connector. Check connections from main board to interconnect and from interconnect board to speaker. Replace speaker if wiring is intact. Power-up self-test sensed no current flowing in the primary speaker. Speaker may be unplugged or wire came loose from connector. Check connections from main board to interconnect and from interconnect board to speaker. Replace speaker if wiring is intact. Power-up self-test sensed no current in the stepper motor. Motor supply or motor driver circuit may have failed. Verify motor connections are correct, then use Biomed >Diagnostics > Motor Drive Test to check motor operation. If motor does not run replace the motor or the main board. Power-up self-test found the stepper motor winding open. Motor may be unplugged or wire came loose from winding. Replace motor if wiring is intact. Power-up self-test found the stepper motor winding open. Motor may be unplugged or wire came loose from winding. Replace motor if wiring is intact. Software test showed failure of a RAM on the main board. Cycle power and run rerun power-up self test which executes more extensive RAM test. If failure recurs, then check the main board to ensure no cable or contamination is shorting the board, then replace the main board. Software test showed failure of a serial EEPROM on the main board. Check the main board to ensure no cable or contamination is shorting the board, then replace the main board. Software test showed failure of some component on the SPI bus. Check the main board to ensure no cable or contamination is shorting the board, then replace the main board. Power-up self-test sensed insufficient charge in the super-capacitor. This problem can occur with a new main board or when a pump battery is totally dead. Plug pump into AC power for at least two minutes then cycle power. If problem is not corrected, then replace the main board. Software sensed syringe sensor voltage out of range. The sensor (potentiometer) may be unplugged or have an open connection. Use Biomed > Diagnostics > Monitor Analog Sensors to check operation of syringe sensor. Open pump case and check connections to syringe sensor. Replace syringe sensor. Background self-test found the system (MCU) time base did not agree with the time of day clock tick. Problem with oscillator for MCO or oscillatory for real time clock. If problem recurs, replace main board. Power-up self-test found the system (MCU) time base did not agree with the time of day clock tick. Problem with oscillator for MCO or oscillatory for real time clock. If problem recurs, replace main board. Time of day clock failed to communicate. If problem recurs, replace main board. 40-5648-51B Troubleshooting General troubleshooting This section discusses some potential problems which may be encountered with the Medfusion™ 3000 Series pump, and suggests remedies for those problems. Problem Alarms do not sound (either loudly or at all) Problem: No charge light Remedy or solution a) If the alarms sound faintly, they may have been configured to their lowest level. Use Custom Program to change the audio alarm volume to a higher level. b) Use Biomed > Diagnostics and run the Audio Test on Speaker and Alarm Style. Replace speaker if audio alarm does not work correctly. a) Connect to AC power. Turn on pump and allow to complete startup self-testing. If both AC indicator and charge lights are off then see “Indicators Do Not Flash” below. Battery Problem: Battery not working message b) Use Biomed > Diagnostics and run the Monitor Battery Status test. Determine whether battery is charging at 50 MA or greater. a) Open the battery door in the case bottom and check the connection of the battery ribbon cable to the interconnect board. Battery Problem: Battery does not hold charge b) Use Biomed > Diagnostics and run the Monitor Battery Status test. If no information appears then replace the battery pack. a) Open the battery door in the case bottom and check the connection of the battery ribbon cable to the interconnect board. b) Connect to AC power. Turn on pump and allow to complete startup self-testing. Use Biomed > Diagnostics and run the Monitor Battery Status test. Check whether battery is charging at least +50 MA (wait at least 1 minute from power-on for charge current reading to stabilize). • Indicator lights do not flash Unplug AC power if pump immediately shuts down then replace battery pack. • If pump continues to operate and gauge shows normal discharge current -100 to -200 ma, then perform a battery calibration. If the indicator lights do not flash during startup, or along with their appropriate function or alarm, then: • Keyclick (Beep) is faint or not present Open the case and check the keypad connection to the Main Board. If any connections are loose, reconnect and re-test. • Otherwise, replace keypad. If the keyclicks (beeps) sound faintly, or not at all, they may have been configured to their lowest level or turned off. Use Custom Program to reset the audio to a higher level. Keypad button does not work Use Biomed > Diagnostics and run the Keypad Test. If any keys do not pass this test, open the case and check connections for the keypad. Liquid Crystal Display (LCD) has Use Biomed > Calibration and run the Adjust Contrast. poor contrast If the LCD contrast cannot be adjusted, then check LCD negative supply, and consider replacing display or main board. 40-5648-51B 65 Troubleshooting Problem Libraries not available Maximum rate not available Occlusion alarms occur frequently Pump won’t turn on Remedy or solution Libraries may have been turned off or cleared in pump configuration. Use Custom Program, Teach mode or Learn mode to copy the Libraries from a correctly configured pump. See Configuration Manual. Maximum rate may be set low in pump configuration. Use Custom Program, Set Max Flow Rate to configure the pump’s maximum flow rate. See Configuration Manual. Occlusion alarm limit may be set too low in pump configuration. Use Custom Program, Set Occlusion Limit to configure the pump’s occlusion alarm level. See Configuration Manual. Plug into AC power (pump will not turn on with a dead battery) then push and hold power key to turn on. Otherwise, open case and check: • Syringe Manufacturer not available 66 Connections of main to interconnect ribbon cable • AC power connections. • Battery connections. • Keypad cable connections. Syringe manufacturer may have been turned off or cleared in pump configuration. See Configuration Manual (if available) or Operations Manual. 40-5648-51B Troubleshooting Smiths Medical service and support Using Smiths Medical service assistance Use the following steps to make use of Smiths Medical technical service assistance: 1. Contact Smiths Medical Technical Service Department at one of the following telephone numbers: Toll-free in the United States Outside the continental United States In Europe, Contact: 1 800.258.5361 OR 1 800.848.1757 1 651.633.2556 Your local distributor or: Smiths Medical International Ltd. +44 (0)1923 246434 2. When calling any of these numbers, please have the following ready: • • • • Model name / number of pump Pump serial number Purchase date if pump is within warranty period Description of problem in as much detail as possible 3. The service representative will give suggestions in an attempt to help solve the problem. 2. Clean and decontaminate the pump and accessories prior to returning items to Smiths Medical. This is required before shipment according to United States Occupational Safety & Health Administration (OSHA) regulations. 3. Remove the power cord and poleclamp assembly before shipping the pump. Return ONLY the pump, not the accessories. Smiths Medical will not be responsible for lost poleclamp parts or power cords. 4. Package the infusion pump carefully for shipment. 5. Smiths Medical will not accept returns for service without the assigned RA number clearly printed on the shipping package. Mark the Return Authorization (RA) number clearly on the outside of the shipping package used to return the pump. 6. The shipment method must meet the environmental conditions of: Shipping Temperature –40° to 60° C (–40° to 140° F) 5 to 95% nonRelative condensing humidity Atmospheric 50 to 108 kPa (7.3 to 15.4 pressure psia) 6. Ship the carefully packaged infusion pump to either of the addresses listed below: United States Service Returning a pump for repair When a pump problem cannot be solved, it becomes necessary to return the infusion pump for service. Note: The following instructions apply primarily to product within the United States. If you are outside the United States, contact your local distributor for specific instructions. If you are unsure of who your local distributor is, contact Smiths Medical International Ltd. at the address and/or phone number listed below. 1. If the problem cannot be resolved through the assistance of the Technical Service Department, then you will be assigned a Return Authorization (RA) number. 40-5648-51B Storage –20° to 50° C (–4° to 122° F) 5 to 95% noncondensing 50 to 108 kPa (7.3 to 15.4 psia) European Service Smiths Medical MD, Inc. 1265 Grey Fox Road St. Paul, Minnesota 55112 1 800.848.1757 www.smiths-medical.com Your local distributor or: Smiths Medical International Ltd. WD24 4LG UK +44 (0)1923 246434 67 Troubleshooting Using Biomed for troubleshooting The primary tools for troubleshooting the Medfusion™ 3000 Series pumps are available through the Biomed menu which contains Diagnostics, Calibration, Utilities and for all version below 4.1.x, Update Firmware features. All version of the Medfusion™ 3500 pump also contains Set Language, which allows you the ability to change the displayed language. Two features within Utilities are very useful for investigating user complaints on the pump: View Infusion History and View Alarm History. View Infusion History allows review of infusion pump settings, delivery information, and alarms with each entry date and time stamped. View Alarm History allows review of pump alarms (together with sensor data) with each entry date and time stamped. There are many features under Diagnostics which allow the examination of various sensors and components within the pump. The speaker, motor, keypad, indicators and display may be tested individually through this program. The battery gauge status information and charging/discharging current may be viewed. Numerous digital and analog inputs may also be viewed. GENERAL PRESS THE NUMBER TO SELECT 1 MISCELLANEOUS 5 VOLUME / TIME 2 DOSE / KG / MIN 3 DOSE / MIN 4 DOSE / HR CHG PROFILE MORE QUICK CAT 2. Press More until the Biomed appears onscreen. (If E-Plates/Libraries are enabled, you will have to press Main Menu before using More to locate Biomed.) (For v4 software, if Profiles are displayed you must select a profile then choose Biomed - you may need to press More to find it.) PRESS THE NUMBER TO SELECT THE MODE 1. CUSTOM PROGRAM 2. BIOMED BEGINNING PRESS THE NUMBER TO SELECT 1 PROFILE SETTINGS 2 BIOMED QUICK CAT ENTER BIOMED PASSCODE - PRESS ENTER TO CONTINUE MAX: MIN: 68 PRESS THE NUMBER TO SELECT THE MODE ML/HR VOLUUME / TIME MICROGMS / KG / MINUTE RECALL LAST SETTINGS MORE 9999 0 CLEAR BACKSPACE ENTER Now you may select: PRESS THE NUMBER TO SELECT THE MODE CALIBRATION 5. SET LANGUAGE DIAGNOSTICS UTILITIES UPDATE FIRMWARE 1. 2. 3. 4. 1. Turn the pump on and allow the power-on, selftesting to complete. (If there is a system failure detected in power-on testing, then the pump will directly go to Enter Biomed Passcode screen see item 4.) 1. 2. 3. 4. BEGINNING 3. Use the number button to choose Biomed. 4. Use the number buttons to enter the Biomed Passcode (2580) then press Enter. Accessing Biomed Note: The following screens are slightly different depending on the version you have. For this reason, version 3-type screens are shown first, followed by version 4-type screen (if they are different). Also, depending on the personalization performed on your pump, the items listed in some of the menus may be different than those shown. CHG PROFILE GENERAL 1 2 3 4 • • PRESS THE NUMBER TO SELECT CALIBRATION DIAGNOSTICS UTILITIES SET LANGUAGE Calibration to check calibration values, recalibrate sensors or set display contrast. Diagnostics to examine analog and digital signal readings, or test the speaker, motor or display function. 40-5648-51B Troubleshooting • • • Utilities to review alarm history, to review infusion history, to set time and date, to update periodic maintenance timestamp. Update Firmware to reprogram the pump’s software version through the serial interface (only available with service upgrade software diskette and instructions). [Not available on Medfusion™ 3500 pumps version 4.1 and above.] Set Language to change the national language displayed. [Available on Medfusion™ 3500 pumps.] Biomed > Calibration Within Biomed > Calibration the following selections are available. See the Calibration section of this manual for further details. PRESS THE NUMBER TO SELECT THE MODE 1. 2. 3. 4. CAL CAL CAL CAL SIZE AND POSITION FORCE SENSOR PRESSURE SENSOR PLUNGER POSTITION 5. 6. 7. 8. CAL SYRINGE SIZE SENSOR ADJUST CONTRAST VIEW CALIBRATION DATA SAVE CHANGES AND EXIT Audio Test Use the number buttons to select the test. Set Alarm Style allows testing of the various alarm tones. Test Speaker is a factory/engineering test. PRESS THE NUMBER TO SELECT THE MODE 1. SET ALARM STYLE 2. TEST SPEAKER PRESS THE NUMBER TO SELECT 1 SET ALARM STYLE 2 TEST SPEAKER Display Test Display Test repeats blank, all pixels on, vertical lines, horizontal lines, and checkerboard patterns across the LCD display. This test may only be exited by use of the Stop button. PRESS THE NUMBER TO SELECT 1 2 3 4 CAL CAL CAL CAL SIZE AND POSITION FORCE SENSOR PLUNGER POSITION SYRINGE SIZE SENSOR STARTING THE DISPLAY TEST PRESS STOP TO EXIT 5 ADJUST CONTRAST 6 VIEW CALIBRATION DATA 7 SAVE CHANGES AND EXIT STARTING THE DISPLAY TEST PRESS <STOP> TO EXIT Biomed > Diagnostics (screen 1 of 2) Within Biomed > Diagnostics the following selections are available (one of two screens). Use the number buttons to select the test. PRESS THE NUMBER TO SELECT THE MODE 1. 2. 3. 4. AUDIO TEST DISPLAY TEST INDICATOR TEST KEYPAD TEST 5. MONITOR ANALOG SENSORS 6. MONITOR DIGITAL SENSORS 7. MONITOR BATTERY STATUS MORE PRESS THE NUMBER TO CHANGE LED STATE PRESS THE NUMBER TO SELECT 1 2 3 4 AUDIO TEST DISPLAY TEST INDICATOR TEST KEYPAD TEST 5 6 7 8 Indicator Test The Indicator Test allows the individual control and testing of each indicator on the front panel (except battery and AC). Use the number button for the indicator to toggle on or off. MONITOR ANALOG SENSORS MONITOR DIGITAL SENSORS MONITOR BATTERY STATUS DRIVE TRAIN TEST 1. 2. 3. 4. RED ALARM YELLOW ALARM PRESSURE CELL LEFT INFUSE OFF OFF OFF OFF 5. MID INFUSE 6. RIGHT INFUSE 7. LOCK OFF OFF OFF MORE PRESS THE NUMBER TO CHANGE LED STATE 1 2 3 4 40-5648-51B RED ALARM YELLOW ALARM PRESSURE CELL LEFT INFUSE OFF OFF OFF OFF 5 MID INFUSE 6 RIGHT INFUSE 7 LOCK OFF OFF OFF 69 Troubleshooting Keypad Test The Keypad Test allows each key to be tested (except ë; pressing ë turns the pump off) to be tested. The only exit from this test is to press Exit. PRESS < BACK > TO STOP SYRINGE PLUNGER SENSOR R:TRUE SYRINGE EAR SENSOR :TRUE MOTOR RATE SENSOR :FALSE F:TRUE PRESS THE KEY YOU WISH TO TEST RELEASED : NUMBER FOUR EXIT Monitor Analog Sensors Monitor Analog Sensors allows viewing the high resolution analog signals in the pump. These are force, pressure (future option), plunger position, and syringe size. The first data column is analog to digital converter counts (0 to 1023), the second column is the voltage equivalent to counts, and the third column is the reading with calibration values applied. PRESS < BACK > TO STOP FORCE 64 CNTS 0.256V 0.50LBS PRESSURE 0 CNTS 0.000V PLUNGER POS 375 CNTS 1.500V 1.898IN SYRINGE SIZE 632 CNTS 2.528V 0.853IN Monitor Battery Status Monitor Battery Status shows the information from the battery gauge. It may take up to 1 minute for current readings to stabilize when changing from charge to discharge or visa versa. If current is positive the battery is charging; thus negative is discharging. See schedule maintenance for discussion of battery gauge. CAPACITY CURRENT LMD PRESS < BACK > TO 0.0 MA-HOURS MA 0 MA-HOURS 1600.0 STOP 0x00 0x00 0x00 TMPGG FLGS1 FLGS2 64% MORE Drive Train Test This feature is for factory/engineering use. Biomed > Diagnostics (screen 2 of 2) PRESS < BACK > TO STOP FORCE COUNT: 0 PLUNGER POS COUNT: 957 SYRINGE SIZE COUNT 902 0.00LBS 5.002IN 1.167IN Monitor Digital Sensors Monitor Digital Sensors allows viewing the state of the digital sensors in the pump. Syringe plunger sensor is the state of the flippers on the plunger head where open is true. Syringe ear (flange) sensor indicates true when the ear clip (flange) is pulled out. Pressure cell is future option. The motor rate sensor with show true or false depending upon the position of the reflective surface on the end of the motor/worm shaft. PRESS < BACK > TO STOP SYRINGE PLUNGER SENSOR R:TRUE SYRINGE EAR SENSOR :TRUE PRESSURE CELL SENSOR :FALSE MOTOR RATE SENSOR :FALSE 70 Within Biomed Diagnostics the following selections are available (second of two screens). Use the number buttons to select the test. 1. 2. 3. 4. 1 2 3 4 PRESS THE NUMBER TO SELECT THE MODE MOTOR DRIVE TEST MONITOR A2D SELT TEST MONITOR 6811 A2D GRP1 MONITOR 6811 A2D GRP2 BEGINNING PRESS THE NUMBER TO SELECT MOTOR DRIVE TEST MONITOR A2D SELT TEST MONITOR 6811 A2D GRP1 MONITOR 6811 A2D GRP2 BEGINNING F:TRUE 40-5648-51B Troubleshooting Motor Drive Test The Motor Drive Test allows running the motor without any alarms (position, rotation, etc.) being active. Only use the Set Motor Step Period feature. Enter a motor step period where 2 millisec is the fastest rate and 1000 millisec is the slowest rate, then press É to start the motor and á to stop. All other features are for factory/engineering use. 1. 2. 3. 4. 1 2 3 4 PRESS THE NUMBER TO SELECT THE MODE SET MOTOR STEP PERIOD 5. REVERSE MOTOR SET MOTOR MAX CURRENT SET MOTOR MAX RUN TIME REVERSE MOTOR STEPS PRESS THE NUMBER TO SELECT SET MOTOR STEP PERIOD 5 REVERSE MOTOR SET MOTOR MAX CURRENT SET MOTOR MAX RUN TIME REVERSE MOTOR STEPS Monitor a2d Selftest These are self-test values within the high-resolution analog to digital converter. This feature is for factory/ engineering use. The normal readings are full scale equals 1023, midrange equals 512, and zero equals 0. Monitor 6811 a2d Group1 This Monitor Analog Sensors allows viewing the low resolution analog signals in the pump. These are analog supply, positive supply, motor supply, and a2d reference. The first data column is analog to digital converter counts (0 to 255), the second column is the “normalized” voltage equivalent to counts multiplied by the resistor divider feeding that channel. See Main Board theory of operation for definition of signals and values. ANALOG SUPPLY POS SUPPLY MOTOR SUPPLY A2D REFERENCE PRESS < 68 0 152 125 ANALOG SUPPLY POS SUPPLY MOTOR SUPPLY A2D REFERENCE PRESS < BACK > TO STOP COUNT: 156 4.992V COUNT: 148 9.472V COUNT: 68 17.408V COUNT: 127 4.064V 40-5648-51B BACK > TO STOP CNTS 2.176V CNTS 0.000V CNTS 38.912V CNTS 4.000V Monitor 6811 A2D Group2 This Monitor Analog Sensors allows viewing the low resolution analog signals in the pump. These are supercap detect, speaker detect, power strobe, and force offset. The first data column is analog to digital converter counts (0 to 255), the second column is the “normalized” voltage equivalent to counts multiplied by the resistor divider feeding that channel. See Main Board theory of operation for definition of signals and values. PRESS < SUPERCAP DETECT 0 SPEAKER DETECT 0 POWER STROBE 0 FORCE OFFSET 0 BACK > TO STOP CNTS 0.000V CNTS 0.000V CNTS 0.000V CNTS 0.000V PRESS < BACK > TO STOP SUPERCAP DETECT COUNT: 0 SPEAKER DETECT COUNT: 0 POWER STROBE COUNT: 255 FORCE OFFSET COUNT: 137 0.000V 0.000V 4.080V 2.192V Biomed > Utilities Within Biomed > Utilities the following selections are available. Use the number buttons for selection. PRESS THE NUMBER TO SELECT THE MODE 1. 2. 3. 4. SET/VIEW LAST PM DATE SET TIME/DATE VIEW ALARM HISTORY VIEW INFUSION HISTORY 1 2 3 4 SET/VIEW NEXT PM DATE SET TIME/DATE VIEW ALARM HISTORY VIEW INFUSION HISTORY 5. VIEW SOFTWARE CRCS 6. VIEW SOFTWARE VERSIONS 7. VIEW SERVICE DATA PRESS THE NUMBER TO SELECT 5 6 7 8 VIEW VIEW VIEW VIEW SOFTWARE CRCS SOFTWARE VERSIONS SERVICE DATA EEPROM SIZE Set/View Last [Next] PM Date Depending on your pump version, this feature will either be Set/View Last PM Date or Set/View Next PM Date (Medfusion™ 3500 software version 4 and above). This feature should be used every time that Periodic Maintenance is performed on the pump. Use the number keys to enter the date of the current or next maintenance date into the pump, then this value is stored in non-volatile memory. When two years elapse from this date, or when it reaches this date, an advisory message (low priority alarm) appears on-screen for annual maintenance to be performed. 71 Troubleshooting [Note: ensure current date and time are correct in Set Time/Date.] ENTER LAST PM DATE - PRESS ENTER TO CONTINUE YYYY-MM-DD CLEAR BACKSPACE ENTER ENTER NEXT PM DATE - PRESS ENTER TO CONTINUE YYYY-MM-DD CLEAR BACKSPACE ENTER Set Time/Date (Current) This feature allows setting the current date and time. This setting is stored in a clock/calendar chip on the main board. [Note: if all power is removed from the main board and the super-capacitor is drained, the clock will be reset to 1998 and PM advisory message may appear until the clock is set.] ENTER CURRENT TIME – PRESS ENTER TO CONTINUE 13:52 CLEAR HR : MIN BACKSPACE ENTER ENTER CURRENT TIME – PRESS ENTER TO CONTINUE 24:00:00 00:00:00 13:52 :00 HR : MIN : SEC CLEAR BACKSPACE ENTER View Alarm History This feature allows review from the most recent alarm backwards in time. Each alarm is date and time stamped. [Note: see latest power-on record in view infusion history to check current clock/calendar settings.] ALARM EVENT 2007-01-28 13:32:34 SYSTEM ADVISORY – BATTERY NOT WORKING TVD = 0.000ML PRESSURE = 0 CNTS TRAVEL POS = 375 CNTS SYRINGE DIA = 632 CNTS FORCE = 0 CNTS ANALOG SUPPLY= 68 CNTS PREV ALARM NEXT ALARM ALARM EVENT 2007-04-04 07:19:23 SYSTEM ADVISORY – BATTERY NOT WORKING PVD = 0.000ML TRAVEL POS = 957 CNTS FORCE = 0 CNTS ANALOG SUPPLY = 0 CNTS SYRINGE DIA = 902 CNTS PREV ALARM NEXT ALARM 72 STOP INFUSION TVD = RATE = TRAVEL POS = PREV PROG 2007-03-28 12:11:45 0.0046M 0.0000 ML/HR 374 CNTS PREV ENTRY NEXT ENTRY STOP THE INFUSION PREV ENTRY NEXT PROG 2007-04-04 12:08:48 PVD = 1.4230ML TRAVEL POS RATE = 0 ML/HR FORCE SYRINGE DIA PREV PROG MAX: 24:00 MIN: 00:00 MAX: MIN: View Infusion History This feature allows the review of infusion history from the most recent time backwards. Each entry is date and time stamped. The infusion history is “event” driven with entries made for start infusion, stop infusion, change rate, alarms, etc. Depending upon complexity of infusions, the infusion history stores approximately 8 or more complete infusions. Press Prev Entry to step backwards one event at a time, or press Prev Prog to step back one infusion at a time. Here, Next Entry and Next Prog step forwards in time one event or one infusion respectively. NEXT ENTRY = 938 CNTS = 0 CNTS = 902 CNTS NEXT PROG View Software CRCs & View Software Versions These features are for factory/engineering use. View Service Data This feature is for factory service allows the service department to review the data on pump usage. PRESS < BACK > TO STOP ON TIME: 0 HOURS 1 MINUTES ON TIME SINCE LAST CAL: 0 HOURS 1 MINUTES INFUSE TIME: 0 HOURS 0 MINUTES MOTOR REVS: 0 THOUSAND View EEPROM Size [available only on Medfusion™ 3500 pumps version 4 and higher) This feature allows you to view the size (in kilobytes) of the EEPROM installed on the pump. PRESS < BACK > TO STOP EEPROM INSTALLED SIZE: 16 kILOBYTES 40-5648-51B Troubleshooting Biomed > Update Firmware [not available on Medfusion™ 3500 pumps, version 4 and higher] Do Not Use this feature unless specifically authorized by Smiths Medical to update the software of the pump. Review the documentation provided with the software update. Follow the instructions provided with the software update and ensure the update is compatible with the pump model before performing a software update. ENTER FIRMWARE UPDATE MODE? YES NO [Note: pressing Yes does not erase any software in the pump. The pump must be connected to a host personal computer running a Medfusion™ 3000 Series download program and a download must be initiated on the PC in order to update the pump’s software.] Set Language [Not available on Medfusion™ 3010 and 3010a] Selecting this option permits changing the displayed language on the pump. All messages are displayed using the new language. 1. 2. 3. 4. 1 2 3 4 PRESS THE NUMBER TO SELECT THE MODE ENGLISH 5. PORTUGUESE FRENCH 6. SPANISH GERMAN ITALIAN ENTER ENGLISH FRENCH GERMAN ITALIAN PRESS THE NUMBER TO SELECT 5 PORTUGUESE 6 SPANISH ENTER To select a language, press the number button corresponding to the language, and press Enter. The display will immediately change to the selected language. Some pumps may not have all languages implemented; selecting an unimplemented language will result in English being selected. Note: Do not select a language unless you know how to read and understand that language. 40-5648-51B 73 Troubleshooting 74 40-5648-51B Parts Replacement Section 4: Parts Replacement provides procedures for disassembly, parts replacement & re-assembly of the pump. Maintenance warnings/ cautions • Observe the following warnings and cautions while disassembling, replacing parts, and reassembling any Medfusion™ 3000 Series pump. After reassembling pump, use Retest Guidelines listed in the Calibration and Adjustment section to find any re-calibration or re-testing required before returning pump to use. Service cautions • Service warnings • • • • • • • AC Power: The only means of removing AC power is to disconnect the AC power cord. While the AC power cord is attached to the pump and plugged into an AC outlet, live mains voltage is present inside the pump. Battery Replacement: For continued protection against fire hazard, always replace battery pack with same type and model of battery specified in the labeling on the pump. Clean the Pump: Always clean the pump thoroughly before performing maintenance on it. This is recommended by the United States Occupational Safety & Health Administration (OSHA) as a protection from potential biohazard. Pump Maintenance: Only trained biomedical service personnel may repair, calibrate, and maintain this pump. Follow Manufacturer’s Maintenance Procedures: Always repair and maintain this pump following the manufacturer’s recommended instructions in this Service Manual. Repair Pump in ESD Controlled Work Area: The pump case should only be opened at a workstation with Electrostatic controls, including a grounded mat and wrist-strap. External DC Power: Any power source connected to the external DC jack must be IEC 60601-1 certified for medical equipment: Type CF, Safety Class II. Connecting external power to the pump creates 40-5648-51B a medical system; therefore, the user is responsible for compliance with IEC 60601-1 standards. Refer all questions to Smiths Medical Technical Service department. Collect Separately. There are potential health hazards associated with improper disposal of batteries, electronics, and contaminated (used) infusion sets and syringes. Dispose of used batteries, infusion sets, syringes, and other used accessories, or a pump that has reached the end of its useful life, in an environmentally safe manner, and according to any regulations that may apply. • • • Disconnect AC Mains & External DC Power: Always disconnect the pump from AC Mains and from External DC power before disassembling the pump for maintenance. Handle Batteries with Care: Always handle the pump’s battery pack with care. Don’t Over-tighten Screws: Never over-tighten any screws in the pump. Unless otherwise specified, you should torque all screws to 60 in- oz (0.42 Nm). Battery Disposal: Always dispose of exhausted NiMH batteries in compliance with all pertinent local, state, national, and international regulations. If unsure of correct methods for compliance, you may return battery packs to Smiths Medical for recycling. 75 Parts Replacement Opening & closing the pump housing Tools needed For this disassembly procedure you will need: • Torque screwdriver with a #1 Phillips head Always work at an electrostatic-controlled work station when disassembling the pump. Opening the pump housing 1. Unplug the AC power cord (also disconnect any external DC power, if in use). 2. If the poleclamp is attached to the pump, you must remove it before disassembling the pump. Remove the 2 flat head screws attaching the poleclamp bracket to bottom housing of the pump. 3. Remove the 2 flat head screws from the battery compartment cover, and then remove the cover. 4. Carefully remove battery pack from its compartment, and disconnect its cable from the interconnect board. 5. Remove the 2 pan head screws from the bottom housing of the pump. 6. Carefully separate the two halves of the pump housing (there are three snap tabs across the back). 7. Unplug the ribbon cable from J9 on the main board (in most cases the other end of this ribbon cable is glued or soldered into the interconnect board). top & bottom housings. Torque these screws to 60 in oz (0.8 Nm). 6. Orient the battery pack with the circuit board and cable facing the rectangular cutout in the battery compartment. 7. Connect battery cable to the interconnect board. Slide the battery into the compartment. 8. Replace battery cover and secure it with 2 flathead screws. Torque these screws to 60 in oz (0.8 Nm). 9. If using the pole clamp, reattach it to the pump with the 2 flathead screws. Torque these screws to 160 in oz (2.3 Nm). Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. Closing the pump housing 1. Before closing the pump housing, be sure the AC and external DC power are disconnected, and the battery pack is removed. 2. Reconnect the ribbon cable joining the interconnect board and the main board at J9. 3. Be sure all wires are clear of pinch points when rejoining the housing halves. 4. There are 3 snap fit tabs and slots along the backside of the housing. Align them and close the top & bottom housings together. 5. Screw in the 2 pan head screws which connect the 76 40-5648-51B Parts Replacement Battery pack This section defines the steps for removing and replacing the battery pack for the Medfusion™ 3000 Series pump. Tools needed For this disassembly procedure you will need: • Torque screwdriver with a Phillips head Always work at an electrostatic-controlled work station when disassembling the pump. Removing the battery pack 1. Before removing the battery pack, be sure the AC mains and external DC power are disconnected. greater than 95%, then charge current is reduced to 50 ma or greater). 4. If < 0 ma, then check connections to AC power. [Note: negative current means the battery is discharging.] 5. If there is no battery information on the Monitor Battery Status screen, then check battery connection on battery pack, or connection on the interconnect board. 6. Turn off the pump, but leave it connected to AC power. Allow pump to recharge battery for at least 10 hours. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. 2. Remove the 2 flat head screws from the battery compartment cover, and then remove the cover. 3. Carefully remove battery pack from the compartment, and gently disconnect (pull) its ribbon cable from the interconnect board. Replacing the battery pack 1. Unpack and carefully inspect the battery pack for physical damage. 2. Orient the battery pack with the circuit board and cable facing the rectangular cutout in the battery compartment. 3. Connect battery cable into the interconnect board. Slide the battery into the compartment. 4. Replace battery cover and secure it with 2 flathead screws. Torque these screws to 60 in oz (0.8 Nm). Verifying battery function after new battery replacement Before returning the Medfusion™ 3000 Series pump to service, you must verify the new battery is functioning nominally. 1. Connect the pump to AC power and verify the battery charge indicator is on. 2. Turn ON the pump. From the Main screen, select Biomed program Diagnostics and go to Monitor Battery Status. 3. Wait several minutes from power-on for readings to stabilize and then verify battery charge current is greater than 160 ma (if battery charge reading is 40-5648-51B 77 Parts Replacement Interconnect board This section defines the steps for removing and replacing the interconnect board for the Medfusion™ 3000 Series infusion pump. Tools needed Adjustment section to verify pump functionality before returning it to use. Speaker This section defines the steps for removing and replacing the speaker for the Medfusion™ 3000 Series pump. For this disassembly procedure you will need: Tools Needed • Torque screwdriver with a Phillips head Always work at an electrostatic-controlled work station when disassembling the pump. For this disassembly procedure you will need: • Torque screwdriver with a Phillips head Always work at an electrostatic-controlled work station when disassembling the pump. Removing the interconnect board 1. Disconnect the pump from AC power source. 2. Open the pump housing, remove battery pack, and separate the top and bottom halves. 3. Unplug the ribbon cable from J9 on the main board (in most cases the other end of this ribbon cable is glued or soldered directly into the interconnect board). 4. Disconnect the speaker cable from the interconnect board at J2. 5. Disconnect power supply cable from interconnect board at J3. 6. Remove the 2 pan head screws holding the board, and carefully remove the interconnect board from housing. Replacing the interconnect board [Torque all screws to 60 in oz (0.8 Nm).] 1. Align the interconnect board with the threaded bosses, and press firmly into place. 2. Secure it with the 2 pan head screws. 3. Attach the speaker cable to connector J2, and the power supply cable to connector J3. 4. Close the housing and secure with 2 pan head screws. 5. Replace the battery pack, battery cover, and secure with 2 flat head screws. Verify interconnect board function Follow retest guidelines listed in the Calibration and 78 Speaker removal 1. Disconnect the pump from AC power source. 2. Open the pump housing, remove battery pack, and separate the top and bottom halves. 3. Disconnect the speaker cable from the interconnect board at J2. 4. Remove the 2 pan head screws & shoulder (or flat) washers holding the speaker to the case, and remove the speaker from housing. Speaker replacement [Torque all screws to 60 in oz (0.8 Nm).] 1. Align the speaker on the round holder, and orient the cable to run toward the interconnect board. 2. Insert the 2 pan head screws & shoulder (or flat) washers and secure the speaker to the housing. 3. Close the housing and secure with 2 pan head screws. 4. Replace the battery pack, battery cover, and secure with 2 flat head screws. Verifying speaker function After installing the new speaker, you only need to execute power-up testing to verify speaker function. 1. Connect the pump to AC power. 2. Turn ON the pump. 3. Listen for power-on tones. Allow power-on selftests to complete. If no system failure messages appear, then the speaker is good. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. 40-5648-51B Parts Replacement AC power supply This section defines the steps for removing and replacing the AC Power Supply for the Medfusion™ 3000 Series infusion pump. Tools needed For this disassembly procedure you will need: • Torque screwdriver with a Phillips head & small flat blade • 5mm open end wrench • ¼” nut driver Always work at an electrostatic-controlled work station when disassembling the pump. Removing AC power supply 1. Disconnect the pump from AC power source. 2. Open the pump housing, remove battery pack, and separate the top and bottom halves. 3. Remove the power supply shield. 4. Disconnect the interconnect board cable from power supply board at J2. 5. Use small flat blade screwdriver to loosen the terminals on the AC input wires, and disconnect the AC input wires from the power supply board at J1. 6. Remove the 2 pan head screws securing board to bottom housing, and remove AC Power Supply Board. Replacing the AC power supply 1. Align the AC Power Supply Board over the threaded bosses, with J1 in line with the AC input cable. 2. Secure the board with 2 pan head screws. Medfusion™ 3500BC: The earth wire from the AC inlet is to be secured at the AC supply mounting post furthest from the AC inlet. Torque to 60 in oz (0.8 Nm). 3. Connect the AC Input Wires to J1 and tighten the 2 terminal screws. Torque to 32 in oz (0.4 Nm). 4. Reconnect the interconnect board cable to J2. 5. Reinstall the Power Supply Shield by sliding it into the notched tabs. 6. Close the housing and secure with 2 pan head screws. Torque to 60 in oz (0.8 Nm). 40-5648-51B 7. Replace the battery pack, battery cover, and secure with 2 flat head screws. Torque to 60 in oz (0.8 Nm). Verify AC power supply function After you replace the AC Power Supply, you must verify its function with the following steps: 1, Plug the pump into AC power. 2. Verify the AC power indicator lights. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. AC input assembly This section defines the steps for removing and replacing the AC Input Assembly. Tools Needed For this disassembly procedure you will need: • • ¼” open end wrench Torque screwdriver with a Phillips head & small flat blade Always work at an electrostatic-controlled work station when disassembling the pump. Removing AC input module assembly 1. Disconnect the pump from AC power source. 2. Open the pump housing, remove battery pack, and separate the top and bottom halves. 3. Remove power supply shield. 4. Use small flat blade screwdriver to loosen the 2 screws on the Terminal Block of the power supply. 5. With screwdriver & open end wrench, remove the 2 flathead screws & Nylock nuts. Medfusion™ 3500BC: Remove screw holding earth ground connection. 6. Slide the AC Input Module Assembly from the case. Replacing AC input module assembly 1. Install AC Input Module Assembly with 2 power 79 Parts Replacement 2. 3. 4. 5. 6. 7. wires oriented toward the bottom of the housing. Medfusion™ 3500BC: Install AC Input Module Assembly with 3 wires, mains wires oriented toward the bottom of the housing, earth wire oriented toward the top. Insert the 2 wires into the Terminal block on the power supply. Tighten the 2 screws of the Terminal block. Torque to 32 in oz (0.4 Nm). Secure with the 2 flathead screws & Nylock nuts. Medfusion™ 3500BC: Reinstall the earth wire from the A/C inlet to the A/C supply mounting post furthest from the A/C inlet. Torque to 60 in oz (0.8 Nm). Reinstall the Power Supply Shield by sliding it into the notched tabs. Close the housing and secure with 2 pan head screws. Torque to 60 in oz (0.8 Nm). Replace the battery pack, battery cover, and secure with 2 flat head screws. Torque to 60 in oz (0.8 Nm). Verifying AC input assembly module function 1. After you replace or repair the AC Input Assembly Module, you must verify its nominal function with the following steps: 2. Plug the pump into AC power. 3. Verify the AC power indicator lights. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. 80 Bottom housing plastic Tools Needed For this disassembly procedure you will need: • • ¼” open end wrench Torque screwdriver with a Phillips head and small flat blade Always work at an electrostatic-controlled work station when disassembling the pump. Removing the bottom housing 1. Disconnect the pump from AC power source. 2. Open the pump housing, remove battery pack, and separate the top and bottom halves. 3. Unplug the ribbon cable from J9 on the main board (in most cases the other end of this ribbon cable is glued or soldered directly into the interconnect board). 4. Remove the Interconnect Board, the speaker, the Power Supply Shield, the AC Power Supply, and the AC Input Assembly using the procedures listed above. Replacing the bottom housing 1. The new case bottom should have rubber feet, and IR lens already installed; however, new labels (included) need to be applied. 2. Record the serial number from the old case bottom. Take the new serial number label and type the serial number into the blank field on this label. Take the overlay supplied with the label, remove the backing and apply this overlay to cover/protect the typed serial number label. 3. Remove the backing on the typed serial number label, and apply this to the new case bottom. 4. Attach all new labels to the new case bottom, use the old bottom as a guide for label application. 5. Install the AC Power Supply, the AC Input Assembly, the Power Supply Shield, the speaker, and the Interconnect Board into the replacement housing using the procedures listed above. 6. Reconnect the ribbon cable to J9 on the main board in the top housing. 7. Close and secure the two halves of the housing, 40-5648-51B Parts Replacement and reinstall the battery pack. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. Main board This section defines the steps for removing and replacing the Main Board for the Medfusion™ 3000 Series pump. Tools needed For this disassembly procedure you will need: • Torque screwdriver with Phillips head & small flat head Always work at an electrostatic-controlled work station when disassembling the pump. Removing the main board 1. Disconnect the pump from AC power source. 2. Open the pump housing, remove battery pack, and separate the top and bottom halves. 3. Disconnect the interconnect ribbon cable from the main board at J9. 4. Loosen the 2 terminal block screws connecting the fiber optic back light to the main board, then pull the fiber cable assembly from the terminal block. 5. Disconnect all cable connections on the main board. These include: • • • • • • • Keypad ribbon cables at J10. Motor cable at J3. Position pot cable at J6. Display cable at J12. Ear clip sensor cable at J2. Barrel clamp flex circuit at J4. Plunger cable at J11 and unscrew the cable clamp. 6. If present, clip the wire tie securing the 2nd backlight cable. 7. Remove the 2 pan head screws securing main board, and carefully remove the main board from housing. Replacing the main board 1. Place the new main board into the housing. It should rest in the slot on the extrusion, and align the mounting holes with the 2 stand-offs. 2. Secure the main board with the 2 pan head screws. Torque to 60 in oz (0.8 Nm). 40-5648-51B 81 Parts Replacement 3. Reconnect all cable and wire connections on the main board. These include: • • • • • • • Keypad ribbon cables at J10. Motor cable at J3. Position pot cable at J6. Display cable at J12. Ear clip sensor cable at J2. Barrel clamp flex circuit at J4. Plunger cable at J11. Install the cable clamp over the exposed braid of the plunger cable and secure with small pan head screw. Torque screw to 16 in oz (0.2 Nm). 4. If a 2nd fiber optic tail is present on the backlight, connect its cable to J8 on the main board. If you are replacing an older main board (with a black connector at J8), you can discard the backlight adapter cable. After completing the next step, anchor both fiber optic tails to the main board with a wire tie. 5. Insert the backlight wires into the main board terminal block. Screw the terminal connector onto the leads with the flat edge of the LED lens toward the outside edge of the board. Torque terminal block screws to 32 in oz (0.4 Nm). Note: If you reverse the leads during installation, the backlight will not turn on. You may wish to loosely reassemble the case halves, plug in the battery, and power up pump to check the backlight. 6. Close and secure the two halves of the housing and reinstall the battery pack. 7. Complete recalibration and reconfiguration is required when replacing main board. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. Drive train assembly Tools Needed For this disassembly procedure you will need: • Torque screwdriver with a Phillips head & ¼” nut drive • ¼” wrench • .002” (.051mm) shim Always work at an electrostatic-controlled work station when disassembling the pump. Motor unit (motor, worm, worm gear) Removal 1. Open pump housing per pump housing section above, and set up the case top section with the handle down and main board facing up. 2. Remove the main board per section above. 3. Squeeze the plunger lever and fully extend the plunger head away from the case. 4. Remove pan head screws and standoffs holding the extrusion (drive train assembly). Remove pan head screws and Nylock nuts holding barrel clamp assembly to extrusion. 5. Partially slide extrusion out of case until motor mount screws are accessible. Disassemble motor unit as required: 1. For motor or worm, remove two pan head screws and Nylock nuts holding the motor. Remove motor and worm. Worm pulls straight off of motor shaft. 2. For worm gear (plastic gear on leadscrew), remove e-clip. Pull gear straight off of leadscrew shaft. Replacement Reassemble motor unit 1. For motor/worm, slide worm onto motor shaft. Rotate motor to align mounting holes with holes in motor plate. Ensure the motor is positioned for the wires to properly reach the main board. Secure motor with two pan head screws and Nylock nuts. Torque to 100 in oz (1.2 Nm). 82 40-5648-51B Parts Replacement 2. For worm gear, align “D” with shaft and press onto leadscrew until centered over worm. Attach e-clip. 3. Carefully slide the extrusion (drive train assembly) back into case. 4. Ensure right end plate on extrusion does not damage ear clip sensor. 5. Ensure plunger cable comes out between middle boss and boss by the motor. 6. Slide keypad ground tab (black side toward extrusion) between boss by the motor and extrusion. 7. Secure extrusion with 3 standoffs and 3 pan head screws. Torque to 100 in oz (1.2 Nm). 8. Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts. Torque to 100 in oz (1.2 Nm). 9. Reinstall main board per main board section above. 10. Close pump housing per housing section above. Position potentiometer Removal 1. Open pump housing per pump housing section above, and setup the case top section with the handle down and main board facing up. 2. Remove the main board per section above. 3. Squeeze the plunger lever and fully extend the plunger head away from the case. 4. Remove pan head screws and standoffs holding the extrusion (drive train assembly). Remove pan head screws and Nylock nuts holding barrel clamp assembly to extrusion. 5. Partially slide extrusion out of case until flat head screw in right end plate is accessible. 6. Remove small flat head screw holding position potentiometer (pot). 7. On the carriage remove pan head screw, washer, and Nylock nut holding the post of the pot. (It may be necessary to reposition carriage by moving the plunger head.) 8. Remove three flat head screws holding motor assembly on extrusion and rotate out of way. 9. Slide position pot out of the extrusion. 40-5648-51B Replacement 1. Slide new position pot into extrusion. 2. Clean small flat head screw (or use a new screw), apply Loctite 242 (mild thread-locking adhesive) to screw, and secure pot to right end plate of extrusion assembly. Torque only to 16 in oz (0.2 Nm). 3. Secure motor assembly on extrusion with three flat head screws. Torque to 100 in oz (1.2 Nm). 4. Slide post of position pot up to carriage. Insert pan head screw through hole in carriage arm, then through washer. Start the Nylock nut onto the screw. Insert 0.002” shim between pot’s post and the washer, then tighten the nut until slack is removed. Do not over-tighten nut. Remove shim and check if flat washer can move (spin) freely, if not loosen nut slightly. 5. Carefully slide the extrusion (drive train assembly) back into case. 6. Ensure right end plate on extrusion does not damage ear clip sensor. 7. Ensure plunger cable comes out between middle boss and boss by the motor. 8. Slide keypad ground tab (black side toward extrusion) between boss by the motor and extrusion. 9. Secure extrusion with 3 standoffs and 3 pan head screws. Torque to 100 in oz (1.2 Nm). 10. Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts. Torque to 100 in oz (1.2 Nm). 11. Reinstall main board per main board section above. 12. Close pump housing per housing section above. 83 Parts Replacement Clutch assembly Tools needed For this disassembly procedure you will need: Torque screwdriver with a Phillips head & ¼” nut drive • ¼” wrench • .002” (.051mm) shim Always work at an electrostatic-controlled work station when disassembling the pump. 2. • 3. Leadscrew Removal 1. Open pump housing per pump housing section above, and setup the case top section with the handle down and main board facing up. 2. Remove the main board per section above. 3. Squeeze the plunger lever and fully extend the plunger head away from the case. 4. Remove pan head screws and standoffs holding the extrusion (drive train assembly). Remove pan head screws and Nylock nuts holding barrel clamp assembly to extrusion. 5. Partially slide extrusion out of case until Nylock nut holding leadscrew on right end plate is accessible. 6. Pull the plastic worm gear off the end of leadscrew near motor. 7. Remove three flat head screws holding motor assembly on extrusion, and pull off motor assembly. 8. Slide carriage rod out of the carriage. 9. Move the plunger head/carriage in about 1” (2.5cm) from the right end plate. Hold onto the “D” side of the leadscrew and use ¼” wrench to remove Nylock nut holding leadscrew and the flat brass washer. 10. Slide extrusion in slightly until leadscrew clears right end plate, then pull off the thrust bearings. 11. Squeeze the plunger lever to open clutch and pull leadscrew out of carriage. Replacement 1. Apply light coating of STP poly-plus (lithium) 84 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. grease to leadscrew. Squeeze plunger lever to open clutch and insert leadscrew until it sticks slightly through the carriage. Install thrust bearing assembly (flat washer, bearings, flat washer) onto end of leadscrew and pull on plunger head to feed leadscrew through the right end plate. Ensure nylon shoulder washer is still in place on right end plate. Place brass washer over the leadscrew and start Nylock nut. Insert .002” shim between the brass washer and shoulder washer and tighten the nut. Do not over-tighten nut. Remove shim and check if brass washer can move (spin) freely, if not loosen nut slightly. Slide carriage rod through carriage and seat into hole in right end plate. Slide motor assembly over leadscrew and align carriage rod with motor assembly bracket. Secure motor assembly on extrusion with three flat head screws. Torque to 100 in oz (1.2 Nm). Align “D” of worm gear with leadscrew shaft and press onto leadscrew until gear is centered over the motor worm. Carefully slide the extrusion (drive train assembly) back into case. Ensure right end plate on extrusion does not damage ear clip sensor. Ensure plunger cable comes out between middle boss and boss by the motor. Slide keypad ground tab (black side toward extrusion) between boss by the motor and extrusion. Secure extrusion with 3 standoffs and 3 pan head screws. Torque to 100 in oz (1.2 Nm). Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts. Torque to 100 in oz (1.2 Nm). Reinstall main board per main board section above. Close pump housing per housing section above. Clutch or clutch cam Tools needed For this disassembly procedure you will need: • Safety glasses 40-5648-51B Parts Replacement • Needle nose pliers plunger head. Removal Replacement 1. Remove leadscrew per procedure above. 2. Use needle nose pliers (or hemostats) to remove e-ring from cam in carriage plate. 3. Using ¼” open end wrench and Phillips screw driver, remove three pan head screws with Nylock nuts holding the carriage plate. 4. Use needle nose pliers to remove either: 1. Take the new plunger cable, with the smaller exposed braid area towards the carriage, turn connector in line with the cable, then thread the cable through the plunger tube. 2. Plug the cable into the plunger board, then press the braided portion into the slot of the force mount and plunger tube. This should leave about 2” (5cm) of cable sticking out the notched end of the plunger tube. 3. Press the square shaft on the cam, the cam through the carriage plate (check orientation of plate) and snap the e-ring on the cam. • • the clutches, use caution in separating clutches because of spring. the cam, pull straight out and separate from square shaft. Replacement 1. For replacement of: • • 2. 3. 4. the cam, first ensure the shaft is seated to the plunger lever, then press the cam gear on the shaft. the clutches, put the clutch halves together (closed) and press the spring into place, then slide the clutch halves into the carriage. Feed the pan head screws though the carriage then the carriage plate, then secure with nylon nuts. Nuts should be on top of the carriage plate not the carriage. Torque to 100 in oz (1.2 Nm). Snap e-ring over cam sticking through carriage plate. Replace leadscrew per procedure above. 4. Slide carriage plate with clutch cam and shaft into plunger tube. 5. Feed the pan head screws though the carriage then the carriage plate, then secure with nylon nuts. Nuts should be on top of the carriage plate not the carriage. Torque to 100 in oz (1.2 Nm). 6. Close plunger case per procedure below. 7. Replace lead screw per procedure above. Plunger cable Removal 1. Remove leadscrew per procedure above. 2. Using ¼” open end wrench and Phillips screw driver, remove three pan head screws with Nylock nuts holding the carriage plate. Pull plate with cam and square shaft attached. 3. Open plunger case right per procedure below. 4. Unplug the plunger cable from plunger board and pull cable out of slot in force mount and plunger tube. 5. At the carriage, turn plunger cable connector in line with the cable, and pull cable out through 40-5648-51B 85 Parts Replacement LCD and backlight This section defines the steps for removing and replacing the LCD Display and Backlight for the Medfusion™ 3000 Series pump. Tools Needed For this disassembly procedure you will need: • • ¼” open end wrench Torque screwdriver with Phillips head & small flat head Always work at an electrostatic-controlled work station when disassembling the pump. Removing LCD and/or backlight assembly 1. Disconnect the pump from AC power source. 2. Open the pump housing, remove battery pack, and separate the top and bottom halves. 3. Disconnect the display cable from the main board at J12. 4. Use small flat blade screwdriver to loosen the 2 screws connecting the fiber optic back light to the main board. Then pull the fiber cable assembly from the terminal block. 5. If the back light has a 2nd fiber optic tail, cut the wire tie anchoring its connecting cable and separate the 2nd tail from the connecting cable. 6. With ¼” open end wrench, remove the 2 Nylock nuts securing the display. 7. Carefully lift the display assembly from the top housing. 8. Slide the back light and spacer from the display assembly. Replacing the LCD and/or backlight assembly 1. Remove the protective plastic film from the new display’s glass. 2. Remove the tape which holds the plastic spacer inside the new display, and slide out the spacer. Discard the white plastic spacer. 3. If the backlight has one fiber optic tail, then you will use two clear plastic spacers in the next step. 86 4. 5. 6. 7. 8. 9. 10. If your backlight has two fiber optic tails, then you will use only one clear plastic spacer in the next step. Place the clear plastic spacer(s) on top of the backlight with the white side of the back light facing up and the silver side down. Gently slide the back light and spacer together into the display with the clear plastic spacer toward the display glass. Orient the display with the back light tail on the side with the keypad cables. Verify there is not lint or dirt on the display. Slide the display onto the ribs in the top of the top housing and over the spacers/studs. Secure the display assembly with the 2 Nylock nuts and tighten with ¼” wrench. Reconnect the display cable to the main board at J12. If a 2nd fiber optic tail is present on the backlight, clip the lead on the LED of the shorter fiber optic tail to match the length of the shorter tail’s LED on the removed backlight. Note: the longer fiber optic tail’s LED requires longer leads. Connect the shorter fiber optic tail to the round connector on the cable. Be sure to orient the lead closest to the flat edge of the LED into the terminal touching the MELF resistor embedded in the round connector. After completing the next step, anchor both fiber optic tails to the main board with a wire tie. Insert the back light wires into the main board terminal block. (When replacing the back light, trim the LED leads to about ½” in length.] Screw the terminal connector onto the leads with the flat edge of the LED lens toward the outside edge of the board. Torque terminal block screws to 32 in oz (0.4 Nm). Note: If you reverse the leads during installation, the backlight will not turn on. You may wish to loosely reassemble the case halves, plug in the battery, and power up pump to check the backlight. 11. Close and secure the two halves of the housing and reinstall the battery pack. 40-5648-51B Parts Replacement Verify LCD & backlight assembly function 1. Plug the pump into AC power and turn it ON. 2. Watch the screen during startup and self-testing. [Note: you may wish to adjust the display contrast, see chapter on calibration and adjustment.] 3. After self-testing completes, set the pump in a darkened area and verify the back light is functioning. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. Keypad This section defines the steps for removing and replacing the Keypad. Tools needed For this disassembly procedure you will need: • • ¼” open end wrench Torque screwdriver with a Phillips head & small flat blade Always work at an electrostatic-controlled work station when disassembling the pump. Removing the keypad 1. Disconnect the pump from AC power source. 2. Open the pump housing, remove battery pack, and separate the top and bottom halves. 3. Disconnect the interconnect ribbon cable from J9 on the main board. 4. Loosen the 2 terminal block screws connecting the fiber-optic backlight to the main board. Then, carefully pull the leads from the connector. If a 2nd backlight LED is present, disconnect its cable at the main board and clip the wire tie securing it to the main board. 5. Disconnect the keypad cables at J10 on the main board. 6. Disconnect the display cable at J12 on the main board. 7. Remove the 2 pan head screws securing the main board, and then loosen the main board. It is not necessary to remove the main board, or disconnect all cables from it, to access the keypad. 8. With ¼” open end wrench, remove the 2 Nylock nuts securing the display board, and remove the display from the top housing. 9. With ¼” open end wrench, remove one hex head standoff nearest to the motor, and carefully slide out the keypad ground tab from between the top housing boss and the extrusion. 10. Press on inside of clear lens (window) to loosen keypad and peel keypad from top housing. 40-5648-51B 87 Parts Replacement Replacing the keypad CAUTION: Keypad is NOT Flexible: Whenever handling the keypad, always ensure it remains flat. Bending the keypad can damage keys or break LED contacts. 1. Clean the clear lens with a soft cloth. Ensure there is no lint or fingerprints on the lens. 2. Ensure inside of new keypad window is clear of lint or fingerprints. 3. Remove backing from the keypad. Feed the 3 keypad cables through the housing window. Slide the clear lens into the cutout of the case top. 4. Align the keypad and carefully press into recess in the case top. Keep the keypad as flat as possible. 5. Slide the keypad ground tab between the extrusion and the top housing boss. Be sure the black side of the tab faces toward the extrusion. Replace the hex head standoff into the extrusion securing the ground tab. Torque to 100 in oz (1.2 Nm). 6. Slide the display assembly into the ribs on the top housing, and secure it with 2 Nylock nuts. 7. Reposition the main board and secure with 2 pan head screws. Torque to 60 in oz (0.8 Nm). 8. Reconnect display cable to J12, keypad cables to J10. 9. Insert the back light wires into the main board terminal block. (When replacing the back light, trim the LED leads to about ½” in length.] Screw the terminal connector onto the leads with the flat edge of the LED lens toward the outside edge of the board. Torque terminal block screws to 32 in oz (0.4 Nm). If present, connect the 2nd backlight LED’s cable to J8. Note: If you reverse the leads during installation, the backlight will not turn on. You may wish to loosely reassemble the case halves, plug in the battery, and power up pump to check the backlight. 10. If a 2nd backlight LED is present, secure the fiber optic cable to the main board with a wire tie. 11. Close the pump case and reinstall the battery pack. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. 88 Syringe barrel clamp assembly Tools Needed For this disassembly procedure you will need: • Torque screwdriver with a Phillips head & 1/16” hex head • ¼” wrench • Small vise-grip pliers Always work at an electrostatic-controlled work station when disassembling the pump. Barrel clamp head Removal 1. Lift barrel clamp head until screw is accessible then use vise grips to clamp near base of barrel clamp rod to hold it in place. 2. Using a 1/16” hex wrench, remove hex head screw from barrel clamp head. 3. Pull barrel clamp head off of the barrel clamp rod. Replacement 1. Align the hole in the barrel clamp rod with the barrel clamp head, and press the head onto the rod. 2. Secure the barrel clamp head with the 1/16” hex head screw. Torque to 60 in oz (0.8 Nm) Verify Function 1. Verify barrel clamp head moves up and down, and will rotate when fully extended. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. Barrel clamp body assembly Removal 1. Remove barrel clamp head per above. 2, Open pump housing per pump housing section above. 3. Using a ¼” wrench and Phillips screwdriver, remove two pan head screws with Nylock nuts which hold the barrel clamp assembly. These 40-5648-51B Parts Replacement 4. 5. 6. 7. screws are located on the right end plate of the drive train assembly. Unplug the barrel clamp flex circuit from J4 of the main board. Gently slide barrel clamp assembly out of the case avoiding the fingers extending from the right end plate around the plunger tube. Remove small screw holding the pot to the barrel clamp assembly. Carefully lift pot up off alignment bosses and out of fingers on the slide. Replacement 1. Align new pot into fingers of slide on the barrel clamp assembly and press onto bosses. 2. Secure pot with small screw. Tighten until screw is flush with pot. [Do not over-tighten.] 3. Carefully slide barrel clamp body assembly into case. Push the rod through the hole in top of the case. 4. Secure barrel clamp assembly with two pan head screws with Nylock nuts. Torque to 100 in oz (1.2 Nm). 5. Plug barrel clamp flex circuit into J4 of the main board. 6. Close pump housing per housing section above. 7. Replace barrel clamp head and verify function per above. Ear clip, handle & guide Tools Needed For this disassembly procedure you will need: • Torque screwdriver with a Phillips head & ¼” nut drive • Needle nose pliers (two pairs) Always work at an electrostatic-controlled work station when disassembling the pump. Ear clip Removal 1. Open pump housing per pump housing section above, and setup the case top section with the handle down and main board facing up. 2. Use one pair of needle nose pliers to press the ear clip sleeve towards the case wall, then use a second set of pliers (or hemostats) to pull the e-ring off of the ear clip. [Note, on older pumps sleeve is not present, so use 1st set of pliers to pull spring towards the case wall.] 3. Slide the ear clip out of the top housing assembly. Replacement 1. Partially insert new ear clip through side of case, then slide the spring onto shaft of ear clip. 2. Slide sleeve over ear clip with hollow end of sleeve towards the spring. 3. Ensure the ear clip faces the “V” groove in the case top, then press the ear clip into the case. Use one pair of needle nose pliers to compress the sleeve (and/or spring) and use a second set of needle nose (or hemostats) to snap e-ring into groove on the ear clip. 4. Pull on the ear clip and release it. Verify that the ear clip moves smoothly out and is pulled back flush to the case by the spring when released. 5. Close pump housing per housing section above. Ear clip optical sensor Removal 1. Open pump housing per pump housing section above, and setup the case top section with the 40-5648-51B 89 Parts Replacement handle down and main board facing up. 2. Remove the main board per section above. 3. Squeeze the plunger lever and fully extend the plunger head away from the case. 4. Remove pan head screws and standoffs holding the extrusion (drive train assembly). Remove pan head screws and Nylock nuts holding barrel clamp assembly to extrusion. 5. Partially slide extrusion out of case until ear clip sensor is visible. 6. Remove pan head screw holding sensor and remove the ear clip optical sensor. Replacement 1. On the new ear clip sensor, look at the old sensor then use wire cutters to carefully cut a portion of the plastic tab/mounting hole to allow clearance for the display connector. 2. Slide ear clip sensor onto post in case top, with grey side of sensor away from the display. 3. Secure the sensor with the pan head screw. Torque to 100 in oz (1.2 Nm). 4. Carefully slide the extrusion (drive train assembly) back into case. 5. Ensure right end plate on extrusion does not damage ear clip sensor. 6. Ensure plunger cable comes out between middle boss and boss by the motor. 7. Slide keypad ground tab (black side toward extrusion) between boss by the motor and extrusion. 8. Secure extrusion with 3 standoffs and 3 pan head screws. Torque to 100 in oz (1.2 Nm). 9. Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts. Torque to 100 in oz (1.2 Nm). 10. Reinstall main board per main board section above. 11. Close pump housing per housing section above. Handle Removal 1. Open pump housing per pump housing section above, and setup the case top section with the handle down and main board facing up. 90 2. Remove the main board per section above. 3. Squeeze the plunger lever and fully extend the plunger head away from the case. 4. Remove pan head screws and standoffs holding the extrusion (drive train assembly). Remove pan head screws and Nylock nuts holding barrel clamp assembly to extrusion. 5. Partially slide extrusion out of case until two handle screws are visible. 6. Remove two pan head screw holding handle and remove the handle. Replacement 1. Place new handle on case top and secure with two pan screws with washers through the inside of case. 2. Carefully slide the extrusion with plunger tube back into the case. 3. Carefully slide the extrusion (drive train assembly) back into case. 4. Ensure right end plate on extrusion does not damage ear clip sensor. 5. Ensure plunger cable comes out between middle boss and boss by the motor. 6. Slide keypad ground tab (black side toward extrusion) between boss by the motor and extrusion. 7. Secure extrusion with 3 standoffs and 3 pan head screws. Torque to 100 in oz (1.2 Nm). 8. Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts. Torque to 100 in oz (1.2 Nm). 9. Reinstall main board per main board section above. 10. Close pump housing per housing section above. Tubing guide Removal 1. Open pump housing per pump housing section above, and setup the case top section with the handle down and main board facing up. 2. Remove the main board per section above. 3. Squeeze the plunger lever and fully extend the plunger head away from the case. 40-5648-51B Parts Replacement 4. Remove pan head screws and standoffs holding the extrusion (drive train assembly). Remove pan head screws and Nylock nuts holding barrel clamp assembly to extrusion. 5. Partially slide extrusion out of case until three tubing guide screws are visible. 6. Remove pan head screw holding tubing guides and remove the tubing guides. Note orientation of each tubing guide. Replacement 1. Place each tubing guide onto case top and secure with a pan head screw and nylon washer. The bumps on the case top help ensure correct orientation of each guide. Torque to 60 in oz (0.8 Nm). 2. Carefully slide the extrusion (drive train assembly) back into case. 3. Ensure right end plate on extrusion does not damage ear clip sensor. 4. Ensure plunger cable comes out between middle boss and boss by the motor. 5. Slide keypad ground tab (black side toward extrusion) between boss by the motor and extrusion. 6. Secure extrusion with 3 standoffs and 3 pan head screws. Torque to 100 in oz (1.2 Nm). 7. Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts. Torque to 100 in oz (1.2 Nm). 8. Reinstall main board per main board section above. 9. Close pump housing per housing section above. Plunger case assembly Tools needed For this disassembly procedure you will need: • Torque screwdriver with a Phillips head & 2.5mm hex head • Needle nose pliers • Safety glasses Always work at an electrostatic-controlled work station when disassembling the pump. Plunger lever Removal 1. Remove pan head screw from lever. 2. Pull plunger lever off the lever gear. Replacement 1. Position new plunger lever onto lever gear and secure with pan head screw. Torque to 60 in oz (0.8 Nm). Plunger case disassembly WARNING: While servicing the Medfusion™ 3000 Series infusion pump you should wear safety glasses as it contains springs and other small parts which may be a hazard. Disassembly 1. Stand the pump up on its left side so that the plunger assembly points vertically up. Squeeze the plunger lever and position the plunger driver for disassembly. 2. Remove three pan head screws holding the plunger case halves together (do not remove screw on lever). 3. Remove the plunger case right and remove the plunger case seal. The lever gear will be attached to the plunger case right. The square shaft may come out with plunger case right; if so, pull the shaft out of the lever gear and slide the shaft down the plunger tube into gently press into the cam. Reassembly 1. Remove any slack in movement of square shaft by 40-5648-51B 91 Parts Replacement turning counter-clockwise. With plunger lever positioned up against long rib on plunger case right, join the two case halves together pressing the lever gear over the square shaft. 2. Start the three pan head screws into the plunger case halves, with the long screw into the tall rib of the case. 3. Before tightening, press the plunger case seal into the gaps between the case halves. Ensure the seal is positioned properly between the halves then tighten the plunger case screws. Torque to 60 in oz (0.8 Nm). Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality before returning it to use. Cam gear and timing plate WARNING: While servicing the Medfusion™ 3000 Series infusion pump you should wear safety glasses as it contains springs and other small parts which may be a hazard. Removal 1. 2. 3. 4. Open the plunger case halves per above. Lift cam gear off of pin. Remove push block. Press timing plate upward and lift carefully to remove timing plate spring and timing plate. Note, the timing plates are asymmetrical (left and right handed). Replacement 1. Rotate the right flipper until it stops against the “V” groove on the plunger case. 2. Insert the spring into the timing plate right. Slide spring over the post in the side wall of the plunger case. 3. Slowly lower timing plate into the plunger case slot – as far down the slot as possible toward the optical sensor on the plunger board – while lining up the gears. 4. Repeat this process for the left flipper and left timing gear. 5. Place the push block on top of the timing plate 6. Place cam gear over pin (check assembly drawing 92 for orientation) and up against push block. 7. Close plunger case halves per above. Flipper and flipper gear Removal 1. Disassemble plunger case and remove timing plates per above. 2. Use the needle nose pliers to compress the flipper shaft inside the flipper gear. Gently pull on the flipper while compressing the shaft. 3. Slide the O-ring seal off of the flipper. (Inspect the O-ring replace if damaged; otherwise, clean with soap and water.) Replacement 1. Slide O-ring seal over new flipper. 2. Insert flipper through the plunger case and snap onto the flipper gear. (Ensure gear recess faces out from case – if gear is installed incorrectly then flipper will not snap in place. If flipper gear is damaged replace flipper gear.) 3. Install timing plates per above and reassemble plunger case halves. Plunger board Note: Ensure plunger head is fully extended away from pump housing before starting. Additional tools needed For this disassembly procedure you may also need: • .002” (.051mm) shim Removal 1. Disassemble plunger case and remove timing plates per above. 2. Gently pull on the plunger cable unplugging it from connector J2. Unplug force sensor cable from J1 on plunger board. 3. Using a Phillips screwdriver, remove pan head screw with washer from the force mount assembly. 4. On newer assemblies it is not necessary to remove float plate seal and float plate. Gently try to pull plunger case left towards the pump. If it comes apart skip to step 7 below, otherwise remove float plate seal and float plate. 40-5648-51B Parts Replacement 5. Grab float plate seal with pliers (or hemostats) and pull off from plunger case left. (Float plate seal is glued in place and may be damaged in removal.) 6. Using a metric 2.5mm hex wrench , remove the screw holding the float plate. 7. Slide plunger case left toward pump until plunger board is accessible, then remove plunger board. Replacement 1. Insert new plunger board into plunger case left. (Ensure board sits on two guide pins and does not interfere with flipper gears.) 2. Slide the plunger case left up and over the force mount assembly. Secure in place with the flat washer and pan head screw. Torque to 100 in oz (1.2 Nm). 3. Connect force sensor cable to the plunger board at connector J1 and press excess cable flat against board. 4. Connect plunger cable to plunger board connector J2, and check to ensure cable remains in slot through force mount and plunger tube. 5. If you did not remove float plate/seal skip to step 7; otherwise, place float plate into opening in plunger case left and start 2.5mm hex screw into this assembly. Slide a .002” shim between float plate and the wall of the plunger case. Tighten screw and torque to 100 in oz (1.2 Nm), then remove shim. 6. Use sharp tool or knife to clean slot for seal. If seal was damaged, replace with a new seal. Place small drops of Loctite 454 (cyanoacrylate adhesive) at four points in the slot and then press the seal into place. 7. Install timing plates and reassemble plunger case per above. Force sensor Note: Ensure plunger head is fully extended away from pump housing before starting. Additional tools needed For this disassembly procedure you will also need: • .002” (.051mm) shim 40-5648-51B Removal 1. Disassemble plunger case and remove timing plates per above. 2. Gently pull on the plunger cable unplugging it from connector J2. Unplug force sensor cable from J1 on plunger board. 3. Using a Phillips screwdriver, remove pan head screw with washer from the force mount assembly. 4. On newer assemblies it is not necessary to remove float plate seal. Gently try to pull plunger case left towards the pump. If it comes apart skip to step 6 below, otherwise remove float plate seal. 5. Grab float plate seal with pliers or hemostats and pull off from plunger case left. (Float plate seal is glued in place and may be damaged in removal.) 6. Using a metric 2.5mm hex wrench , remove the screw holding the float plate. 7. Slide plunger case left toward pump until the hex head screw is accessible on the force mount assembly. 8. Using a metric 2.5mm hex wrench , remove the screw holding the force sensor onto the force mount. Note the orientation of the cable on the force mount. Replacement 1. Install the new force sensor onto the force mount bracket with the 2.5mm hex screw. (Ensure the cable of the force sensor faces towards the plunger PCB and connector J1.) Torque to 100 in oz (1.2 Nm). 2. Slide the plunger case left up and over the force mount assembly. Secure in place with the flat washer and pan head screw. Torque to 100 in oz (1.2 Nm). 3. Connect force sensor cable to the plunger board at connector J1 and press excess cable flat against board. 4. Connect plunger cable to plunger board connector J2, and check to ensure cable remains in slot through force mount and plunger tube. 5. If you did not remove float plate seal skip to step 7; otherwise, use sharp tool or knife to clean slot for seal. Place the float plate into opening in plunger case left and start 2.5mm hex screw into this as93 Parts Replacement sembly. Slide a .002” shim between float plate and the wall of the plunger case. Tighten screw and torque to 100 in oz (1.2 Nm), then remove shim. 6. If seal was damaged, replace with a new seal. Place small drops of Loctite 454 (cyanoacrylate adhesive) at four points in the slot and then press the seal into place. 7. Install timing plates and reassemble plunger case per above. Left plunger case Note: Ensure plunger head is fully extended away from pump housing before starting. Additional tools needed For this disassembly procedure you will also need: • .002” (.051mm) shim Removal 1. Disassemble plunger case and remove timing plates per above. 2. Remove plunger flippers and gears per above. 3. Gently pull on the plunger cable unplugging it from connector J2. Unplug force sensor cable from J1 on plunger board. 4. Using a Phillips screwdriver, remove pan head screw with washer from the force mount assembly. 5. On newer assemblies it is not necessary to remove float plate seal. Gently try to pull plunger case left towards the pump. If it comes apart skip to step 8 below, otherwise remove float plate seal. 6. Grab float plate seal with pliers or hemostats and pull off from plunger case left. (Float plate seal is glued in place and may be damaged in removal.) 7. Using a metric 2.5mm hex wrench , remove the screw holding the float plate. 8. Slide plunger case left toward pump until the two small flat head screws are accessible on the force mount. Unscrew two flat head screws on force mount. Pull plunger cable out of slot on force mount bracket and plunger tube. Slide off the force mount assembly from the plunger tube. 9. Slide plunger case left off of plunger tube. 94 Replacement 1. Install flippers and flipper gears per above into new plunger case left. 2. Transfer plunger board into new plunger case. 3. Slide new plunger case left onto plunger tube. (Ensure case is correctly oriented.) 4. Thread plunger cable through force mount assembly and slide assembly onto plunger tube align screw holes and cable slot. Apply (mild threadlocking adhesive) Loctite 242 to flat head screws and secure the force mount to the plunger tube. Torque to 100 in oz (1.2 Nm). [Be careful not to cross-thread screws.] 5. Slide the plunger case left up and over the force mount assembly. Secure in place with the flat washer and pan head screw. Torque to 100 in oz (1.2 Nm). 6. Connect force sensor cable to the plunger board at connector J1 and press excess cable flat against board. 7. Press plunger cable into slot though plunger tube, force mount, and plunger case left. Ensure exposed braid of cable touches metal on force mount or plunger tube. 8. Connect plunger cable to plunger board connector J2, and check to ensure cable remains in slot through force mount and plunger tube. 9. If you did not remove the float plate seal, skip to step 11. Place the float plate into opening in plunger case left and start 2.5mm hex screw into this assembly. Slide a .002” shim between float plate and the wall of the plunger case. Tighten screw and torque to 100 in oz (1.2 Nm), then remove shim. 10. Use a new seal. Place small drops of Loctite 454 (cyanoacrylate adhesive) at four points in the slot and then press the seal into place. 11. Install timing plates and reassemble plunger case per above. 40-5648-51B Calibration & Adjustment Using Biomed > Calibration This section explains the use of Biomed Calibration for the calibration of internal sensors of the Medfusion™ 3000 Series pumps. Biomed > Calibration In order to complete the calibration of the Medfusion™ 3000 Series infusion pumps, you need the Smiths Medical Medfusion™ 3000 Series Calibration Kit. This kit contains one (each) of the following: • • • Small Calibration Slug Large Calibration Slug Force Gauge Note: The equipment supplied in the Calibration Kit should be added to your annual calibration and maintenence schedule. To access Biomed > Calibration, from the Main menu use the number buttons to choose Biomed (you may need to press More to find it; if libraries are enabled you may need to press Main Menu, then More). Enter the Passcode (2580) then press Enter. PRESS THE NUMBER TO SELECT THE MODE CALIBRATION 5. SET LANGUAGE DIAGNOSTICS UTILITIES UPDATE FIRMWARE 1. 2. 3. 4. 1 2 3 4 PRESS THE NUMBER TO SELECT CALIBRATION DIAGNOSTICS UTILITIES SET LANGUAGE Use the number buttons to select Calibration. 1. 2. 3. 4. 1 2 3 4 PRESS THE NUMBER SIZE AND POSITION FORCE SENSOR PRESSURE SENSOR PLUNGER POSITION CAL CAL CAL CAL CAL CAL CAL CAL TO 5. 6. 7. 8. SELECT THE MODE CAL SYRINGE SIZE SENSOR ADJUST CONTRAST VIEW CALIBRATION DATA SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT SIZE AND POSITION 5 ADJUST CONTRAST FORCE SENSOR 6 VIEW CALIBRATION DATA PLUNGER POSITION 7 SAVE CHANGES AND EXIT SYRINGE SIZE SENSOR 40-5648-51B 95 Calibration & Adjustment Below is table which summarizes the options available for calibration. Calibration Option What it Controls Calibrate (Syringe) Size and Position Performs concurrent adjustment of syringe size & position sensors settings. This requires Smiths Medical “calibration slugs”. Performs adjustment of force sensor settings. Calibrate Force Sensor This is a future option of the Medfusion™ 3000 Series pumps. Calibrate Pressure Sensor Performs adjustment of plunger position sensor settings. Calibrate Plunger Position Sensor Performs adjustment of syringe size sensor setting. Calibrate Syringe Size Sensor Varies the onscreen contrast of the LCD. The pump is shipped with Adjust Contrast a “factory average” default. You may set it above or below for “comfortable” viewing. Displays the “current” calibration data settings. View Calibration Data Saves the new calibration settings and then returns to the main Save Changes and Exit Biomed menu. 96 40-5648-51B Calibration & Adjustment Calibrate (Syringe) size and position This procedure calibrates both the syringe size sensor and the syringe position sensor. The syringe size sensor is part of the barrel clamp assembly and measures the syringe barrel external diameter allowing the software to determine the syringe size loaded onto the pump. The syringe position sensor is part of the drive train assembly and measures the plunger head position allowing the software to determine the empty position and plunger head travel. Performing both size & position calibration 1. From the Calibration Menu, use the number buttons to choose Cal Size and Position. 1. 2. 3. 4. 1 2 3 4 CAL CAL CAL CAL CAL CAL CAL CAL PRESS THE NUMBER SIZE AND POSITION FORCE SENSOR PRESSURE SENSOR PLUNGER POSITION TO 5. 6. 7. 8. SELECT THE MODE CAL SYRINGE SIZE SENSOR ADJUST CONTRAST VIEW CALIBRATION DATA SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT SIZE AND POSITION 5 ADJUST CONTRAST FORCE SENSOR 6 VIEW CALIBRATION DATA PLUNGER POSITION 7 SAVE CHANGES AND EXIT SYRINGE SIZE SENSOR 2. Load the small calibration slug into the barrel clamp. Keeping the barrel clamp perpendicular to the slug, move the clamp slightly back and forth to find the lowest size reading, then press Continue to calibrate the small size. SETUP LOW STANDARD - PRESS CONTINUE WHEN READY MAX VALUE SYRINGE SIZE MIN VALUE DATA: 175 COUNTS DATA: 125 COUNTS DATA: 75 COUNTS CONTINUE SETUP LOW STANDARD - PRESS < CONTINUE > WHEN READY MAX VALUE SYRINGE SIZE MIN VALUE DATA: 175 COUNTS DATA: 902 COUNTS DATA: 75 COUNTS CONTINUE 40-5648-51B 97 Calibration & Adjustment 3. Squeeze the plunger lever to hold the flippers open, move the plunger head against the small slug, and press Continue to calibrate the low position. SETUP LOW STANDARD - PRESS CONTINUE WHEN READY MAX VALUE PLUNGER POS MIN VALUE DATA: 200 COUNTS DATA: 151 COUNTS DATA: 100 COUNTS CONTINUE SETUP LOW STANDARD - PRESS < CONTINUE > WHEN READY MAX VALUE PLUNGERR POS MIN VALUE DATA: 200 COUNTS DATA: 559 COUNTS DATA: 100 COUNTS CONTINUE 4. Load the large calibration slug into barrel clamp. Keeping the barrel clamp perpendicular to the slug, move the clamp slightly back and forth to find the lowest size reading, then press Continue to calibrate large size. SETUP HIGH STANDARD - PRESS CONTINUE WHEN READY MAX VALUE SYRINGE SIZE MIN VALUE DATA: 1024 COUNTS DATA: 975 COUNTS DATA: 925 COUNTS CONTINUE SETUP HIGH STANDARD - PRESS < CONTINUE > WHEN READY MAX VALUE SYRINGE SIZE MIN VALUE DATA: 1024 COUNTS DATA: 125 COUNTS DATA: 850 COUNTS CONTINUE 5. Load the large calibration slug into barrel clamp. Squeeze the plunger lever to hold the flippers open, move the plunger head against the large slug, and press Continue to calibrate high position. SETUP HIGH STANDARD - PRESS CONTINUE WHEN READY MAX VALUE PLUNGER POS MIN VALUE DATA: 175 COUNTS DATA: 125 COUNTS DATA: 75 COUNTS CONTINUE SETUP HIGH STANDARD - PRESS < CONTINUE > WHEN READY MAX VALUE PLUNGER POS MIN VALUE DATA: 950 COUNTS DATA: 901 COUNTS DATA: 850 COUNTS CONTINUE 98 40-5648-51B Calibration & Adjustment 6. You return to the Calibration menu. You may calibrate another mode, choose Save Changes and Exit to exit calibration, or press â to return to the Biomed menu. 40-5648-51B 99 Calibration & Adjustment Calibrate force sensor 1. From the Calibration menu, choose Cal Force Sensor. 1. 2. 3. 4. 1 2 3 4 CAL CAL CAL CAL CAL CAL CAL CAL PRESS THE NUMBER SIZE AND POSITION FORCE SENSOR PRESSURE SENSOR PLUNGER POSITION TO 5. 6. 7. 8. SELECT THE MODE CAL SYRINGE SIZE SENSOR ADJUST CONTRAST VIEW CALIBRATION DATA SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT SIZE AND POSITION 5 ADJUST CONTRAST FORCE SENSOR 6 VIEW CALIBRATION DATA PLUNGER POSITION 7 SAVE CHANGES AND EXIT SYRINGE SIZE SENSOR 2. Ensure nothing is loaded in the plunger head, press Continue and wait until force sensor zero is finished. SETUP LOW STANDARD - PRESS CONTINUE WHEN READY OFFSET DATA: 0 COUNTS MAX VALUE DATA: 50 COUNTS FORCE DATA: MIN VALUE DATA: 34 COUNTS CONTINUE SETUP LOW STANDARD - PRESS < CONTINUE > WHEN READY OFFSET DATA: 0 COUNTS MAX VALUE DATA: 50 COUNTS FORCE DATA: MIN VALUE DATA: 34 COUNTS CONTINUE 3. The pump then auto-zeroes the force sensor’s offset (this takes about 40 seconds). [Do not use arrow keys.] ADJUST THE FORCE OFFSET - PRESS ENTER TO CONTINUE OFFSET DATA: 138 COUNTS MAX VALUE DATA: 50 COUNTS FORCE DATA: 44 COUNTS MIN VALUE DATA: 34 COUNTS ↑ ↓ ENTER ADJUST THE FORCE OFFSET - PRESS < ENTER > TO CONTINUE OFFSET MAX VALUE FORCE MIN VALUE DATA: 138 COUNTS DATA: 50 COUNTS DATA: 44 COUNTS DATA: 34 COUNTS ↑ ↓ ENTER 4. Press Enter when zeroing is complete. 100 40-5648-51B Calibration & Adjustment 5. Press the zero button on the force gauge. Load the force gauge under the barrel clamp resting flush on the case top. Ensure the flippers are below (closed) the force gage head, and use the thumbscrew to adjust the gauge to 10 lbs. ±0.2, then press Continue. The force calibration is complete. 6. You return to the Calibration menu. You may calibrate another mode, choose Save Changes and Exit to exit calibration, or press â to return to the Biomed menu. 40-5648-51B 101 Calibration & Adjustment Calibrate pressure sensor (future option) Do not use, this is a “future option” of the Medfusion™ 3000 Series. Calibrate plunger position 1. From the Calibration menu, choose Cal Plunger Position. 1. 2. 3. 4. 1 2 3 4 CAL CAL CAL CAL CAL CAL CAL CAL PRESS THE NUMBER SIZE AND POSITION FORCE SENSOR PRESSURE SENSOR PLUNGER POSITION TO 5. 6. 7. 8. SELECT THE MODE CAL SYRINGE SIZE SENSOR ADJUST CONTRAST VIEW CALIBRATION DATA SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT SIZE AND POSITION 5 ADJUST CONTRAST FORCE SENSOR 6 VIEW CALIBRATION DATA PLUNGER POSITION 7 SAVE CHANGES AND EXIT SYRINGE SIZE SENSOR 2. Load the small calibration slug into the barrel clamp. Squeeze the plunger lever to hold the flippers open, move the plunger head against the small slug, and press Continue to calibrate the low position. SETUP LOW STANDARD - PRESS CONTINUE WHEN READY MAX VALUE PLUNGER POS MIN VALUE DATA: 200 COUNTS DATA: 151 COUNTS DATA: 100 COUNTS CONTINUE SETUP LOW STANDARD - PRESS < CONTINUE > WHEN READY MAX VALUE PLUNGERR POS MIN VALUE DATA: 200 COUNTS DATA: 559 COUNTS DATA: 100 COUNTS CONTINUE 3. Load the large calibration slug into barrel clamp. Squeeze the plunger lever to hold the flippers open, move the plunger head against the large slug, and press Continue to calibrate high position. SETUP HIGH STANDARD - PRESS CONTINUE WHEN READY MAX VALUE PLUNGER POS MIN VALUE DATA: 175 COUNTS DATA: 125 COUNTS DATA: 75 COUNTS CONTINUE SETUP HIGH STANDARD - PRESS < CONTINUE > WHEN READY MAX VALUE PLUNGER POS MIN VALUE DATA: 950 COUNTS DATA: 901 COUNTS DATA: 850 COUNTS CONTINUE 102 40-5648-51B Calibration & Adjustment 4. You return to the Calibration menu. You may calibrate another mode, choose Save Changes and Exit to exit calibration, or press â to return to the Biomed menu. 40-5648-51B 103 Calibration & Adjustment Calibrate syringe size sensor 1. From the Calibration menu, choose Cal Syringe Size Sensor. 1. 2. 3. 4. 1 2 3 4 CAL CAL CAL CAL CAL CAL CAL CAL PRESS THE NUMBER SIZE AND POSITION FORCE SENSOR PRESSURE SENSOR PLUNGER POSITION TO 5. 6. 7. 8. SELECT THE MODE CAL SYRINGE SIZE SENSOR ADJUST CONTRAST VIEW CALIBRATION DATA SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT SIZE AND POSITION 5 ADJUST CONTRAST FORCE SENSOR 6 VIEW CALIBRATION DATA PLUNGER POSITION 7 SAVE CHANGES AND EXIT SYRINGE SIZE SENSOR 2. Load the small calibration slug into the barrel clamp. Keeping the barrel clamp perpendicular to the slug, move the clamp slightly back and forth to find the lowest size reading, then press Continue. SETUP LOW STANDARD - PRESS CONTINUE WHEN READY MAX VALUE SYRINGE SIZE MIN VALUE DATA: 175 COUNTS DATA: 125 COUNTS DATA: 75 COUNTS CONTINUE SETUP LOW STANDARD - PRESS < CONTINUE > WHEN READY MAX VALUE SYRINGE SIZE MIN VALUE DATA: 175 COUNTS DATA: 902 COUNTS DATA: 75 COUNTS CONTINUE 3. Load the large calibration slug into barrel clamp. Keeping the barrel clamp perpendicular to the slug, move the clamp slightly back and forth to find the lowest size reading, then press Continue to calibrate large size. SETUP HIGH STANDARD - PRESS CONTINUE WHEN READY MAX VALUE SYRINGE SIZE MIN VALUE DATA: 1024 COUNTS DATA: 975 COUNTS DATA: 925 COUNTS CONTINUE SETUP HIGH STANDARD - PRESS < CONTINUE > WHEN READY MAX VALUE SYRINGE SIZE MIN VALUE DATA: 1024 COUNTS DATA: 125 COUNTS DATA: 850 COUNTS CONTINUE 4. You return to the Calibration menu. You may calibrate another mode, choose Save Changes and Exit to exit calibration, or press â to return to the Biomed menu. 104 40-5648-51B Calibration & Adjustment Adjust contrast (voltage) setting The factory default contrast voltage setting is 00BF (however this value may vary for different LCD display manufactures). This is the nominal setting for most lighting conditions and may be adjusted higher or lower. 1. From the Calibration menu, choose Adjust Contrast. 1. 2. 3. 4. 1 2 3 4 CAL CAL CAL CAL CAL CAL CAL CAL PRESS THE NUMBER SIZE AND POSITION FORCE SENSOR PRESSURE SENSOR PLUNGER POSITION TO 5. 6. 7. 8. SELECT THE MODE CAL SYRINGE SIZE SENSOR ADJUST CONTRAST VIEW CALIBRATION DATA SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT SIZE AND POSITION 5 ADJUST CONTRAST FORCE SENSOR 6 VIEW CALIBRATION DATA PLUNGER POSITION 7 SAVE CHANGES AND EXIT SYRINGE SIZE SENSOR 2. Use the “↑” and “↓” keys to setup the contrast voltage. “↑” increases contrast. ADJUST CONTRAST - PRESS ENTER TO CONTINUE CONTRAST VOLTAGE: ↑ 00B6 ↓ ENTER ADJUST CONTRAST - PRESS < ENTER > TO CONTINUE CONTRAST VOLTAGE: ↑ 00B6 ↓ ENTER 3. When ready, press Enter to accept the new contrast voltage setting and return to the Calibration menu. You may calibrate another mode, choose Save Changes and Exit to exit calibration, or press â to return to the Biomed menu. 40-5648-51B 105 Calibration & Adjustment View calibration data This feature allows you to display the pump’s calibration data onscreen. This screen is generally used in factory service or for troubleshooting. 1. From the Calibration menu, choose View Calibration Data. 1. 2. 3. 4. 1 2 3 4 CAL CAL CAL CAL CAL CAL CAL CAL PRESS THE NUMBER SIZE AND POSITION FORCE SENSOR PRESSURE SENSOR PLUNGER POSITION TO 5. 6. 7. 8. SELECT THE MODE CAL SYRINGE SIZE SENSOR ADJUST CONTRAST VIEW CALIBRATION DATA SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT SIZE AND POSITION 5 ADJUST CONTRAST FORCE SENSOR 6 VIEW CALIBRATION DATA PLUNGER POSITION 7 SAVE CHANGES AND EXIT SYRINGE SIZE SENSOR 2. When ready, press Continue to return to the Calibration menu. You may calibrate another mode, choose Save Changes and Exit to exit calibration, or press â to return to the Biomed menu. PRESS CONTINUE WHEN READY FORCE 42 COUNTS 475 COUNTS 0 PLUNGER POS 151 COUNTS 901 COUNTS PRESSURE 0 COUNTS 0 COUNTS SYRINGE SIZE 125 COUNTS 975 COUNTS CONTINUE PRESS < CONTINUE > WHEN READY FORCE PLUNGER POS SYRINGE SIZE 42 COUNTS 151 COUNTS 125 COUNTS 475 901 975 COUNTS COUNTS COUNTS 138 CONTINUE 106 40-5648-51B Calibration & Adjustment Save changes and exit This feature is the normal path to save the new calibration values when exiting Biomed > Calibration. If a mistake occurred in the calibration process press â to exit Biomed > Calibration without saving any new calibration values. 1. From the Calibration menu, choose Save Changes and Exit. 1. 2. 3. 4. 1 2 3 4 PRESS THE NUMBER SIZE AND POSITION FORCE SENSOR PRESSURE SENSOR PLUNGER POSITION CAL CAL CAL CAL CAL CAL CAL CAL TO 5. 6. 7. 8. SELECT THE MODE CAL SYRINGE SIZE SENSOR ADJUST CONTRAST VIEW CALIBRATION DATA SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT SIZE AND POSITION 5 ADJUST CONTRAST FORCE SENSOR 6 VIEW CALIBRATION DATA PLUNGER POSITION 7 SAVE CHANGES AND EXIT SYRINGE SIZE SENSOR 2. Press â to exit Biomed and return to the main menu. Exit calibration without saving changes You may exit the Calibration menu at any time − without saving your changes − by pressing Back. 1. To exit without saving changes, press â to exit and the following screen appears. SAVE CHANGES? YES NO 2. Press No to exit without saving new calibration values. 40-5648-51B 107 Calibration & Adjustment Retest guidelines The following are minimum guidelines for re-calibration and re-testing after repair. Repair Type From Biomed > Calibration, perform: From Periodic Maintenance, perform: Pump Opened Repair drive-train None Quick Check-out Replace motor None Complete Mandatory Annual Maintenance Testing Complete Mandatory Annual Maintenance Testing Replace clutches, square rod, leadscrew, or plunger cable Repair sensors Replace ear clip or ear clip sensor Replace barrel clamp assy or size pot. Replace force sensor Recalibrate position & size Replace position pot Recalibrate position & size Repair electronics Replace speaker Replace interconnect cable Replace AC supply Replace battery Replace interconnect board Replace keypad, display or backlight Replace main board/ component Replace plunger board/ component Software Updates Reprogramming Repair case or case parts Replace case bottom 108 Recalibrate size Recalibrate size Recalibrate force Quick Check-out & Calibration Verification Quick Check-out & Calibration Verification Quick Check-out & Calibration Verification Quick Check-out & Calibration Verification & Plunger Travel Test None None Quick Check-out Quick Check-out None None Quick Check-out Quick Check-out & after AC charging run Power-up Tests Quick Check-out None None Recalibrate all sensors Recalibrate force Quick Check-out & Calibration Verification Complete Mandatory Annual Maintenance Testing Quick Check-out & Calibration Verification See update instructions See update instructions None Quick Check-out 40-5648-51B Calibration & Adjustment Replace case top Recalibrate all sensors Replace case handle Recalibrate position & size Replace plunger head, or flippers Replace IR lens Replace plunger lever Replace pump labels Replace feet Replace tubing holders Recalibrate force 40-5648-51B None None None None Recalibrate size Complete Mandatory Annual Maintenance Testing Quick Check-out & Calibration Verification Quick Check-out & Calibration Verification Quick Check-out Quick Check-out Quick Check-out Quick Check-out Quick Check-out & Calibration Verification 109 Calibration & Adjustment 110 40-5648-51B KEYPAD INTERFACE PLUNGER KEY_MATRIX_TAIL LED_TAIL 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 3 4 3 2 1 4 J2 J12 J11 J10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 LOGIC_SPLY (FILTERED) 11 12 FORCE_EXC FORCE_PREAMP_OUT PLUNGER_SNSR1_OUT PLUNGER_SNSR2_OUT PLUNGER_SNSRS_ENBL FORCE_SYS_TEST VNEG_SPLY FORCE_PREAMP_OSADJ KEYPAD_PWRSWX KEYPAD_COL2 KEYPAD_COL1 KEYPAD_COL0 KEYPAD_LOCKOUT_LED KEYPAD_COL5 KEYPAD_COL4 KEYPAD_COL3 KEYPAD_ROW3 KEYPAD_ROW2 KEYPAD_ROW1 KEYPAD_ROW0 KEYPAD_BATTERY_LED KEYPAD_AC_LED KEYPAD_PCELL_LED KEYPAD_INFUSION_LEDL KEYPAD_INFUSION_LEDM KEYPAD_INFUSION_LEDR KEYPAD_CAUTION_LED KEYPAD_WARNING_LED LOGIC_SPLY (FILTERED) SYRINGE_EAR_DETECT SYRINGE_EAR_SNSR_ENBL SYRINGE EAR DETECTOR SYRINGE_SIZE BACK-UP BUZZER BACK-UP POWER SOURCE MAIN_PCB LOGIC_SPLY (FILTERED) LCD_CONTRAST EVALID_WRITE BFRD_EVALID_READ LCD_CS LCD_COMMAND (NOT USED) LCD_RESET B_DATE0 B_DATE1 B_DATE2 B_DATE3 B_DATE4 B_DATE5 B_DATE6 B_DATE7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 (NOT USED) 1 2 3 4 5 6 7 8 PRESSURE_SNSR_OUTL PRESSURE_SNSR_OUTH PRESSURE_SNSR_EXH SET_IN_SNSR_DRV SET_IN_DETECT SPEAKER_DRIVE SPEAKER_RET POWER_FNRI AC_PWR_DETECT CHARGE_DETECT BACKUP_CHARGE_SRC EXTERNL_PWR_DETECT VLOW_BATTERY BATTERY_DATA UNSWX_CD_POWER FILT_5V IR_RCV_DATA IR_XMT_DATA TRAVEL_SNSR_OUT TRAVEL_SNSR_EXC POWER TRANSDUCER SET_IN_SENSOR POSITION SENSOR STEP MOTOR CLASS II AC INPUT 6ND DISPLAY J8 J9 4 3 2 1 1 MTR_DRV_PHA 2 MTR_DRV_PHA 3 MTR_DRV_PHB 4 MTR_DRV_PHB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 J7 J3 12V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2 J4 2 1 J3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Pack Battery RCVR XMTR OPTICAL COMMUNICATION INTERFACE EXTERNAL DC SUPPLY 2 3 1 INTERCONNECT PCB CHARGE_DETECT 1 J1 SIZE_SNSR_EX CHARGE BATTERY_POS_LEAD BATTERY_DATA 1 2 3 4 5 6 7 8 9 10 40-5648-51B VLOW_BATTERY SYRINGE SIZE DETECTORJ4 J2 1 2 SPEAKER Schematics & PCB Assemblies System layout 111 12V INTERNAL POWER SUPPLY {4} BFRD_XTAL LINK GROUND LINK GL1 GROUND LGND 2 R11 4.99KOHM 1% 1/10 W 0805 TP29 {5, 14..18} ATOD_REF_BFRD 1% 0805 1.10 W R12 15.0KOHM TP278 MOTOR_SPLY RGND TP430 C34 + 10UF 20% TANT 10 V SMT_B RGND R21 4.99KOHM 1% 1/10 W 0805 R25 4.99KOHM 1% 1/10 W 0805 RGND R8 1.0KOHM 1% 1/10 W 0805 RGND R7 4.99KOHM 1% 1/10 W 0805 RGND R29 4.99KOHM 1% 1/10 W 0805 R43 15.0KOHM 1% 1/10 W 0805 VPOS_SPLY SN74AHC1G14DBVR SOT23-5 ANALOG_SPLY 4 U45 LOGIC_SPLY_5V LGND FB1 LGND J5 1 2 TP33 X2 TP222 TP207 TP8 TP213 TP224 TP12 TP429 TP137 TP7 C18 + 10UF 20% TANT 10 V SMT_B LGND DATA7 DATA6 DATA5 DATA4 DATA3 DATA2 DATA1 DATA0 TP178 TP177 TP251 TP261 TP397 TP252 TP198 TP199 TP185 TP57 TP142 ATOD_REF_MEAS C5 0.01UF 10% X7R 50 V 0805 62 61 60 59 58 57 56 55 76 75 74 37 38 39 40 41 42 35 78 71 70 25 22 20 1 84 83 69 21 54 68 67 45 34 44 43 C20 0.01UF 10% X7R 50 V 0805 ANALOG_SPLY_MEAS MOTOR_SPLY_MEAS PROCESSOR DECOUPLING TP5 2N841 2N842 2N885 2N887 2N890 TP111 2N1112 TP149 2N861 TP130 2N805 2N417 2N419 VPOS_SPLY_MEAS MTR_TIMER TP112 TP179 TP167 TP148 TP62 5% 0805 1/10 W LOGIC_SPLY_5V {3,5} SPI_CLOCK {3, 5} SPI_MOSI {3, 5} SPI_MISO {3, 13} DATA [0:7] {6} PWR_STRB_O {6} SUPERCAP_DETECT RGND 5% 0805 1/10 W R64 1KOHM 5% 0805 1/10 W {19} SPEAKER_DETECT {5, 17} FORCE_OSV_ADJ TP9 2N742 U16 LM4040DIM3-4.1 4.096V 1% TO236AB R17 2.0KOHM 1% 1/10W 0805 R70 1KOHM R71 1KOHM TP15 {9} RESET # TP138 R1 10MOHM 5% 1/8 W 1206 {3} TOD_INTRPT# {7} BUZZER_DETECT {16} MOTION_DETECT {6} PRGM1 # 1% 0805 1/10 W R44 10.0 KOHM 5% 0805 1/10 W R86 1KOHM EC2SM 16.000NHZ SMT HTSW-102-06-T-2 THRUHOLE LGND R102 1KOHM 5% 1/10 W 0805 LOGIC_SPLY_5V C21 18PF 5% NPO 50 V 0805 C12 27PF 5% NPO 50 V 0805 5_VDC_FILT C107 0.01UF 10% X7R 50 V 0805 LGND C40 0.01 UF 10% X7R 50 V 0805 1 2 BLM21A102SPT 0805-100 mA 5 3 1 U19 LGND C126 0.01UF 10% X7R 50 V 0805 ADDR 15 ADDR 14 ADDR 13 ADDR 12 ADDR 11 ADDR 10 ADDR 9 ADDR 8 ADDR 7 ADDR 6 ADDR 5 ADDR 4 ADDR 3 ADDR 2 ADDR 1 ADDR 0 P G 5/XADDR 18 P G 4/XADDR 17 P G 3/XADDR 17 P G 2/XADDR 15 AHC1G14 DECOUPLING C22 0.01UF 10% X7R 50 V 0805 DATA 7 DATA 6 DATA 5 DATA 4 DATA 3 DATA 2 DATA 1 DATA 0 P D4/S C K P D3/MO S I P D2/MIS O P E 7/AN7 P E 6/AN6 P E 5/AN5 P E 4/AN4 P E 3/AN3 P E 2/AN2 P E 1/AN1 P E 0/AN0 X OUT E P H4/C S IO P H5/CS G P1 P H6/CS GP 2 P H7/CS P R OG R/W * P A6/OC 2 P A5/OC 3 P A4/OC 4 P A3/IC 4/OC 5 84PLCC_SKT P D5/SS * P D1/TXT P D0/RXD P H0/PW1 P H1/PW2 P H2/PW3 P H3/PW4 P G6 P G 1/XADDR 14 P G 0/XADDR 13 68HC11K1 P A7/OC 1/P AI MODA MODB T E S T14 T E S T15 T E S T16 P A0/IC 3 P A1/IC 2 P A2/IC 1 RESET XIR Q IR Q XTAL EXAL AVSS AVDD VRH VRL LOGIC_SPLY_5V 2 23 64 VDD VDD VDD VSS VSS VSS 112 3 24 63 LOGIC_SPLY_5V 4 5 6 7 8 9 10 11 46 47 48 49 50 51 52 53 28 29 30 31 66 65 16 17 18 19 26 79 80 81 82 77 73 72 12 13 14 15 27 32 33 TP63 TP97 TP64 TP98 TP65 TP129 TP66 TP67 TP211 TP221 TP210 TP220 TP209 TP219 TP208 TP218 TP192 TP193 TP200 TP201 TP147 TP146 TP131 TP132 TP93 TP140 TP55 TP42 TP95 TP68 TP73 TP6 TP11 TP13 2N952 ADDR 14 ADDR 13 ADDR 12 ADDR 11 ADDR 10 ADDR 9 ADDR 8 ADDR 7 ADDR 6 ADDR 5 ADDR 4 ADDR 3 ADDR 2 ADDR 1 ADDR 0 XADDR 18 XADDR 17 XADDR 16 XADDR 15 2N1043 2N1332 XADDR [15:18] {3} E_CLOCK {3} IO_CS# {4, 13} RAM_CS# {3} EEPROM1_CS# {3} FLASH_CS# {3} WRITE# {3} ADDR_BUS ASYNC_BATTERY_DATA {9} PLUNGER_DETECT1 {17} PLUNGER_DETECT2 {17} POWER_STROBE {6} IR_XMT_DATA {8} IR_RCV_DATA {8} SPEAKER_FREQUENCY {19} SPEAKER_VOLUME {19} MTR_PHA_IREF {14} MTR_PHB_IREF {14} ADC_CS# {5} DAC_CS# {5} RESET_PIO {4, 5} ADDR [0:14] {3, 4} XADDR_BUS R27 10KOHM 5% 1/10 W 0805 LOGIC_SPLY_5V R103 10KOHM 5% 1/10 W 0805 ACU_PWR_STRB_ON {6} Schematics & PCB Assemblies Main board schematics The following are the main board schematics if the Medfusion™ 3000 Series pump. Main board / logic kernel 40-5648-51B TP232 R45 1KOHM 5% 1/10W 0805 LOGIC_SPLY_5V {2} E_CLOCK {2} WRITE # SN74AHC00PWR LGND C10 0.01UF 10% X7R 50 V 0805 LOGIC_SPLY_5V {4}TOD_WR_ENBL # {4} TOD_CS {4} EEPROM2_CS # {2, 5} SPI_MIS 0 {2} EEPROM1_CS# {2, 5} SPI_CLOCK {2, 5} SPI_MIS 1 TP81 {2} FLASH_CS # 3N990 U5C 7400 10 TSSOP14 9 {2, 4} ADDR [0:14] {2} XADDR [15:18] TSSOP14 TSSOP14 SERIAL EEPROM 16K X 8 VCC 8 SERIAL EEPROM 16K X 8 VCC 8 AT25256AN-10SI-2.7 C8 0.01UF 10% X7R 50 V 0805 C27 0.01UF 10% X7R 50 V 0805 3 TP60 EEPROM + 10UF C13 20% TANT 10 V SMT_B U11A SN74AHC125PWR TSS0P14 LGND C72 0.01UF 10% X7R 50 V 0805 2 1 LGND R46 4.99KOHM 1% 1/10 W 0805 LOGIC_SPLY_5V 1 CS S08 2 6 CLK DATAOUT 5 DATAIN GND 4 3 WP 7 HOLD U2 AT25256AN-10SI-2.7 6 11 LOGIC_SPLY_5V SN74AHC00PWR 5 SN74AHC00PWR U5B 4 7400 13 S08 2 1 CS DATAOUT 6 CLK 5 DATA IN GND 4 3 WP 7 HOLD U4 3N1168 TP56 IC DECOUPLING 8 U5D 12 7400 14 7 RS5C316B U8 C30 20% TANT 10 V SMT_B FLASH LGND INTRPT RS5C316B SSOP8 TIME OF DAY OSOUT 3 SDATA 5 6 VCC 8 OSC IN 7 VCC GND TP80 3N1043 TP89 DATA7 DATA6 DATA5 DATA4 DATA3 DATA2 DATA1 DATA0 3 2 LGND C14 0.01UF 10% X7R 50 V 0805 5V_AO TIME OF DAY DECOUPLING LGND 1 ADDR14 ADDR13 ADDR12 ADDR11 ADDR10 ADDR9 ADDR8 ADDR7 ADDR6 ADDR5 ADDR4 ADDR3 ADDR2 ADDR1 ADDR0 3N1193 2 TP91 R63 1KOHM 5% 1/10 W 0805 LOGIC_SPLY_5V C7 10PF 5% NPO 50 V 0805 {2} RAM_CS# LOGIC_SPLY_5V MC306-32.768KA-E3 SMT X1 LGND 8 24 29 28 27 26 25 23 22 21 3N1041 I/O7 I/O6 I/O5 I/O4 I/O3 I/O2 I/O1 I/O0 5V_AO W29C040T-90B A18 A17 A16 A15 512KBTE A14 A13 FLASH A12 A11 MEMORY A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 A0 WE 32TSOP OE CE 4 GND +10UF TP94 6 10 11 5 4 12 1 31 2 3 13 14 15 16 17 18 19 20 7 32 30 U22 9 TIME OF DAY 1 ENBL 2 SCLK TP110 TP413 XADDR18 XADDR17 XADDR16 XADDR15 ADDR14 ADDR13 ADDR12 ADDR11 ADDR10 ADDR9 ADDR8 ADDR7 ADDR6 ADDR5 ADDR4 ADDR3 ADDR2 ADDR1 ADDR0 1 4 TC55257DFL70L LGND 3 U5A R9 4.7KOHM 5% 1/10 W 0805 TP92 DATA1 DATA0 DATA3 DATA2 DATA7 DATA6 DATA5 DATA4 LGND LOGIC_SPLY_5V SN74AHCOOPWR 7400 TSSOP14 19 18 17 16 15 13 12 11 14 28 LOGIC_SPLY_5V A14 A13 VCC A12 A11 GND A10 A9 32K SRAM A8 I/O7 A7 I/O6 A6 I/O5 A5 I/O4 A4 I/O3 A3 I/O2 A2 I/O1 A1 I/O0 A0 WE OE SOP28 CE U17 LOGIC_SPLY_5V 1 26 2 23 21 24 25 3 4 5 6 7 8 9 10 27 22 20 14 40-5648-51B 7 {2, 13} DATA [0:7] EVALID_WRITE # {4, 5, 13} TOD_INTRPT # {2} EVALID_WRITE {13} EVALID_READ # {4, 5} Schematics & PCB Assemblies Main Board / Logic Kernel -- Continued 113 Schematics & PCB Assemblies Main Board / Logic Kernel -- Continued ADDR8 ADDR9 1 2 3 6 4 5 8 I/O PORT DECODER U24 15 A Y0 14 B Y1 13 C Y2 Y3 12 Y4 11 G1 Y5 10 G2A Y6 9 Y7 7 G2B TSSOP16 GND VCC 16 SN74AHC138PWR TP27 TP28 TP23 LOGIC_SPLY_5V ADDR [0:14] {2, 3} {3, 5, 13 EVALID_WRITE# {2} BFRD_XTAL {3, 5} EVALID_READ# {2, 5} RESET_PIO {3, 5, 13} EVALID_WRITE# PORT1_CS# PORT2_CS# ADDR1 ADDR0 3 4 6 11 13 14 9 1 16 U46 D1 D2 D3 D4 D5 D6 CLK CLR VCC AHC138 C42 0.01UF 10% X7R 50 V 0805 AHC125 Q1 Q2 Q3 Q4 Q5 Q6 GND {14} MTR_CURRENT_DETECT# {12} PWR_SW_MCU {12} KEYPAD_IN_COL5 {12}KEYPAD_IN_COL4 {12} KEYPAD_IN_COL3 {12} KEYPAD_IN_COL2 {12} KEYPAD_IN_COL1 {12} KEYPAD_IN_COL0 {5, 13} BFRD_DATA [0:7] LGND 2 BPORT1_CS# 5 BPORT2_CS# {5} 7 BADDR1 10 BADDR0 12 DELAYED_WRITE# {13} 15 8 C152 0.01UF 10% X7R 50 V 0805 HC174 SN74HC174D S016 74HC174 LOGIC_SPLY_5V 82C55 C6 0.01UF 10% X7R 50 V 0805 LOGIC_SPLY_5V C66 0.01UF 10% X7R 50 V 0805 LGND TP365 TP104 TP287 TP288 TP302 TP289 TP314 TP329 TP237 BFRD_DATA7 BFRD_DATA6 BFRD_DATA5 BFRD_DATA4 BFRD_DATA3 BFRD_DATA2 BFRD_DATA1 BFRD_DATA0 TP253 TP300 5 4 9 10 U33 PB7 PB6 PB5 PB4 PB3 PB2 PB1 PB0 PC7 PC6 PC5 PC4 PC3 PC2 PC1 PC0 28 27 26 25 24 22 21 20 11 13 14 15 19 18 17 16 6 TP96 U11B SN74AHC125PWR TSSOP14 8 TP412 U11C SN74AHC125PWR TSSOP14 TP260 TP275 TP274 TP334 TP285 TP244 TP254 TP312 TP327 TP326 TP325 TP324 TP368 TP322 TP350 TP323 82C55 CS LOGIC_SPLY_5V READ WRITE VCC 29 A1 A0 GND 8 RESET CS82C55A LGND 44PLCC DATA7 DATA6 DATA5 DATA4 DATA3 DATA2 DATA1 DATA0 PA7 PA6 PA5 PA4 PA3 PA2 PA1 PA0 I/O PORT EXPANDER #1 41 42 43 44 2 3 4 5 30 31 32 33 35 36 37 38 7 6 40 9 10 39 LGND LGND LCD_CS# {13} EEPROM2_CS# {3} PET_WATCHDOG {6, 20} SUPERCAP_TEST {6} TOD_CS {3} TOD_WR_ENBLE# {3} SPEAKER_ENVELOPE3 {19} SPEAKER_ENVELOPE2 {19} SPEAKER_ENVELOPE1 {19} WARNING_LED_ON# {11} INFUSING_LEDL_ON# {10} INFUSING_LEDM_ON# {10} INFUSING_LEDR_ON# {10} PCELL_LED_ON# {10} BATTERY_LED_ON {11} CAUTION_LED_ON# {10} LOCKOUT_LED_ON# {11} LCD_COMMAND {13} BADDR1 {15} BADDR0 {5} BFRD_EVALID_READ# {13} 40-5648-51B 114 LOGIC_SPLY_5V {2, 13} IO_CS # LGND AHC138 {2, 3} SPI_MOSI {2} ADC_CS# {16} TRAVEL_SENSE {15} SYRINGE_SIZE {17} FORCE AMPOUT {18} PRESSURE_AMPOUT {2} DAC_CS# {2, 3} SPI_CLOCK 5% 0805 1/10 W 5% 0805 1/10 W R80 1KOHM 5% 0805 1/10 W R79 1KOHM 5% 0805 1/10 W R67 1KOHM R68 1KOHM TP214 {7} BUZZER_ARMED {6, 8, 11} EXTRNL_POWER_DETECT {7, 11, 14} WATCHDOG_ALARM 8BIT D/A 5N821 5N832 5N828 SCLK DIN REF OUT B OUT A U20 6 5 7 LGND TP186 TP134 TP159 TP141 TP119 LGND 16 3 2 6 7 8 9 MAX522CSA SO8 TP239 10 BIT A/D 5N661 5N666 5N673 5N680 LGND TP301 TP61 TP310 TP309 ANALOG_SPLY MAX 522 D/A C24 0.1UF 10% X7R 50 V 1206 1 CS 2 8 LGND 5% 0805 1/10 W R62 10KOHM 5% 0805 1/10 W R41 10KOHM 5% 0805 1/10 W R42 10KOHM TEST_IN 1 VDD 3 GND 4 AHC541 CONV_START FS INV_CLK U13 20% TANT 10 V SMT_B 10 13 12 LGND TP103 TLV1544CD C71 0.22UF 10% X7R 25 V 1206 TP184 TP335 U44 LM4040BIM3-4.1 4.096 V 0.2% TO236AB TP161 R81 825.0OHM 1% 1/10 W 0805 LGND TP22 TP35 TP26 TP41 TP53 TP54 TP78 TP79 TP90 7 6 40 9 10 39 30 31 32 33 35 36 37 38 41 42 43 44 2 3 4 5 U3 PC7 PC6 PC5 PC4 PC3 PC2 PC1 PC0 PB7 PB6 PB5 PB4 PB3 PB2 PB1 PB0 8 29 11 13 14 15 19 18 17 16 28 27 26 25 24 22 21 20 10% X7R 50 V 1206 C84 0.1UF LGND SPI_MIS 0 {2, 3} LGND TP133 5N730 C2 0.047UF 10% X7R 50 V 0805 TP102 5% 0805 1/10 W R49 220OHM LGND C123 0.01UF 10% X7R 50 V 0805 TP115 R47 120KOHM 5% 1/10 W 0805 4.096 V ATOD_REF_BFRD {2, 14, 18} MTR_PHB_DIR {14} MTR_PHB_ENBL# {14} MTR_PHA_DIR {14} MTR_PHA_ENBL# {14} KEYPAD_SEL_ROW3# {12} KEYPAD_SEL_ROW2# {12} KEYPAD_SEL_ROW1# {12} KEYPAD_SEL_ROW0# {12} SET_IN_SNSR_ENBL# {18} SYRINGE_EAR_SNSR_ENBL {15} PLUNGER_SNSRS_ENBL {15} MOTION_SNSR_ENBL {16} FORCE_SNSR_TEST# {17} PRESSURE_SNSR_TEST# {18} LCD_RESET# {13} FORCE_OCV_ADJ {2, 17} LCD_CONTRAST_ADJ {9} TEST_OUT1 LOGIC_SPLY_5V TP87 TP86 TP128 TP85 TP77 TP76 TP126 TP127 TP21 TP14 TP24 TP25 TP40 TP43 TP52 TP75 3 + U10 5N574 LMC7111 1 4 – LMC7111BIM5 SOT23-5 + ANALOG_SPLY C116 0.01UF 10% X7R 50 V 0805 82C55 CS READ WRITE VCC A1 A2 GND RESET CS82C55A 44PLCC DATA7 DATA6 DATA5 DATA4 DATA3 DATA2 DATA1 DATA0 PA7 PA6 PA5 PA4 PA3 PA2 PA1 PA0 I/O PORT EXPANDER #2 LGND ANALOG_REF C89 0.1UF 10% X7R 50 V 1206 LGND C112 0.01UF 10% X7R 50 V 0805 BFRD_DATA7 BFRD_DATA6 BFRD_DATA5 BFRD_DATA4 BFRD_DATA3 BFRD_DATA2 BFRD_DATA1 BFRD_DATA0 TP340 ANALOG_SPLY {4} BPORT2_CS# {3, 4} EVALID_READ# {3, 4, 13} EVALID_WRITE# {4} BADDR1 {4} BADDR0 {2, 4} RESET_PI0 LGND LGND REF + 15 TLV1544 CS EOC 4 SCLK DATA_OUT 114 DATA_IN REF – S016 CH0 CH1 CH2 CH3 10% X7R 50 V 1206 C16 0.1UF LOGIC_SPLY_5V 5N464 5N469 5N471 5N387 5N396 5N399 5N391 5N393 {4, 13} BFRD_DATA [0:7] C153 0.01UF 10% X7R 50 V 0805 LGND C25 10UF ANALOG_SPLY LGND C68 0.22UF 10% X7R 25 V 1206 LGND U41 D7 11 I7 D6 12 I6 D5 13 I5 D4 14 I4 D3 15 I3 D2 16 I2 D1 17 I1 D0 18 I0 VCC 20 OE1 10 GND OE2 SN74AHC541PWR TSSOP20 + 9 8 7 6 5 4 3 2 1 19 VCC 5 11 GND 1 2 2 40-5648-51B 5 {8} VLOW_BATTERY {18} SET_IN_DETECT {15} SYRINGE_EAR_DETECT {6, 8, 11} AC_POWER_DETECT Schematics & PCB Assemblies Main Board / Logic Kernel -- Continued 115 D13 D8 3 MMBD914LT1 200 mA SOT23 1 2 {20 ARM_STRB {12, 20} POWER_SWITCH# {20} ACU_OSC2 {20} ACU_OSC1 {4, 20} PET_WATCHDOG {2} POWER_STROBE {4} SUPERCAP_TEST {2} PRGM1# {8} VLOW_BATTERY# {5, 8, 11} AC_PWR_DETECT 2 1 1 2 D2 3 MMBD914LT1 200 mA SOT23 LGND C91 100PF 5% NPO 50 V 0805 LGND 6N262 6N498 TP120 6N423 TP118 R58 200KOHM 5% 1/10 W 0805 1 LGND 2 PIC 12C 508 4 GP3/MCLR/VPP TP2 PIC 12C 50804 SO8 3 R22 200KOHM 5% 1/10 W 2 0805 LGND ACU_SPLY {12, 20} GP2/TOCKI 5 LGND GP0 7 GP1 6 C94 0.01UF 10% X7R 50 V 0805 LGND C82 0.22UF 10% X7R 25 V 1206 TP162 R54 200KOHM 5% 1/10 W 2 0805 LGND R23 1MOHM 5% 1/10 W 0805 LGND TP4 C88 6N322 1 2 D12 MMBD914LT1 1 200 mA SOT23 20% TANT 16 V SMT_A + 1UF TP212 LGND R40 64.9KOHM 1% 1/10 W 0805 20% TANT 16 V SMT_A C32 2 TP163 D16 MMBD914LT1 200 mA SOT23 TP343 1 R174 100OHM 5% 1/10 W 0805 TP223 R34 100OHM 5% 1/10 W 0805 ACU_PWR_STRB_ON {2} WATCHDOG_STRB {7, 20} POWER_ENBL {7, 8} LGND TP282 R167 100OHM 5% 1/10 W 0805 TP276 6N250 Q17 TP0610T SOT23 TP107 5V_AO TP48 R33 100OHM 5% 1/10 W 0805 LGND TP122 PWR_STRB_ON {2} TP47 C11 + 1F 20% ELECT 5.5 V RADIAL TP39 ALWAYS ON SUPPLY R32 200KOHM 5% 1/10 W 0805 5V_AO TP404 + 1UF Q20 TP0610T SOT23 3 MMBD914LT1 200 mA SOT23 5V_AO D10 MAIN UP POWER CONTROL Q7 TP0610T SOT23 LOGIC_SPLY_5V Q14 2N7002-T1 SOT23 TP108 C15 + 10UF 20% TANT 10 V SMT_B LM2936M-5.0 SO8 8 V IN V OUT 1 4 NC1 NC2 5 LM2936 5 VDC TP51 C78 0.1UF 10% X7R 50 V 1206 3 6N379 Q15 TP0610T SOT23 TP50 LGND D9 MMBD914LT1 200 mA SOT23 6N305 1 TP20 6N266 Q13 2N7002-T1 SOT23 6N260 1 TP49 R30 10KOHM 5% 1/10 W 0805 2 R51 2.2MOHM 5% 1/10 W 0805 6N331 AUXILIARY CONTROLLER U39 2 GP5/OSC1/CLKIN 3 GP4/OSC2 MAX6326UR31-T SOT23 RESET MAX 6326 U38 10% 25V X7R 1206 C3 0.22UF Q12 2N7002-T1 SOT23 5V_AO TP58 LGND X3 CSBF455KJ58-R1 455 kHz C92 100PF 5% NPO 50 V 0805 R52 1KOHM 5% 1/10 W 0805 1 TP328 3 MMBD914LT1 200 mA SOT23 3 MMBD914LT1 200 mA SOT23 1 2 3 2 TP1 3 1 1 3 2 {5, 8, 11} EXTRNL_PWR_DETECT VCC 3 1 GND 2 D3 3 1 3 GND GND GND GND 2 3 6 7 {8} BACKUP_CHARGE_SRC 2 3 2 VDD 1 8 VSS 3 1 2 116 3 U7 SUPERCAP_DETECT {2} Schematics & PCB Assemblies Main Board / Power Control Logic Core 40-5648-51B {2} BUZZER_DETECT {6, 20} WATCHDOG_STRB 2 3 D11 MMBD914LT1 200 mA SOT23 C74 0.22UF 10% X7R 25 V 1206 TP176 TP38 TP135 1 LGND LGND C19 0.1UF 10% X7R 50 V 1206 R39 200KOHM 5% 1/10 W 0805 7N48 3 1 LGND 7N31 TP88 Q18 TP0610T SOT23 C33 0.22UF 10% X7R 25 V 1206 LGND TP74 C23 0.01UF 10% X7R 50 V 0805 R84 200KOHM 5% 1/10 W 0805 LGND Q16 MMBT2222ALT1 SOT23 TP164 R56 47KOHM 5% 1/10 W 0805 BUZZER ARMING LOGIC_SPLY_5V 7N34 1 TP105 R55 120KOHM 5% 1/10 W 0805 WATCHDOG DETECT TP174 R3 2.0KOHM 1% 0.100 W 0805 LGND 7N75 7N82 1 TP136 Q11 2N7002-T1 SOT23 7N40 R82 200KOHM 5% 1/10 W 0805 5V_AO TP106 LMC7211AIM5 SOT23-5 + 3 LMC7211 4 – U18 LOGIC_SPLY_5V 7N58 1 Q19 MMBT2222ALT1 SOT23 LGND 2 R83 200KOHM 5% 1/10 W 0805 BUZZER SENSE 1 3 2 2 3 R69 47KOHM 5% 1/10 W 0805 3 2 {6, 8} POWER_ENBL 2 5 LGND R2 2.7OHM 5% 1/8 W 1206 1 PRGM2# TP143 7N55 1 BUZZER_ARMED {5} DISABLE JUMPER FOR FLASH PROGRAMMING LGND R65 47KOHM 5% 1/10 W 0805 Q22 TP0610T SOT23 LOGIC_SPLY_5V HTSW-102-06-T-S THRUHOLE J13 BACKUP BUZZER LGND 1 2 R57 200KOHM 5% 1/10 W 0805 LGND Q21 2N7002-T1 SOT23 TP125 HMB-06 THRUHOLE TP165 XD1 5V_AO 1 2 3 2 2 40-5648-51B 3 5V_AO WATCHDOG_ALARM {5, 11, 14} Schematics & PCB Assemblies Main Board / Power Control Logic Core -- Continued 117 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 LGND 1306-26-S-02 THRUHOLE J9 FILT_5V BLM21A102SPT 0805 100 mA FB4 LOGIC_SPLY_5V IR_XMT_DATA {2} IR_RCV_DATA {2} UNSWX_DC_POWER BACKUP_CHARGE_SRC {6} CHARGE_DETECT {11} AC_PWR_DETECT {5, 6, 11} BATTERY_DATA {9} SPEAKER_RET {19} SPEAKER_DRIVE {19} TP175 LGND C154 1000PF 5% NPO 50 V 0805 1 LGND TP307 8N165 TP311 Q1 2N7002-T1 SOT23 R148 47KOHM 5% 1/10 W 0805 4 VLOW_BATTERY {5} Q41 MMBT2222ALT1 SOT23 LGND R66 120KOHM 5% 1/10 W 0805 VLOW_BATTERY# {6} EXTRNL_PWR_DETECT {5, 6, 11} R31 10KOHM 5% 1/10 W 0805 8N935 1 LOGIC_SPLY_5V R36 200KOHM 5% 1/10 W 0805 8N263 TP10 3 2 123 TP196 C98 0.1UF 10% X7R 50 V 1206 20% ELECT 35 V SMT-10X10 C102 TP248 + 330UF LGND TP342 Q2 MMSF3P02HD SO8 5678 N/C {6, 7} POWER_ENBL 3 2 C97 0.1UF 10% X7R 50 V 1206 TP256 LGND 2.0A SMT U34 TP338 8N537 R92 10KOHM 5% 1/10 W 0805 8N589 TP59 C55 0.047UF 10% X7R 50 V 0805 LGND L3 33UH TP37 C28 0.0047UF 10% X7R 50 V 0805 LT1372CS8 SO8 TP19 U21 TP298 TP279 ANALOG SUPPLY LT1121CST-5 SOT223 TP44 + C26 10UF 20% TANT 10 V SMT_B LGND ANALOG_SUPPLY LGND LT1372CS8 SO8 8N116 TP280 R132 C50 27KOHM 0.0047UF 5% 10% X7R 1/10 W 50 V 0805 0805 8N120 TP271 C46 0.047UF 10% X7R 50 V 0805 LGND C4 10% TANT 10 V SMT_D + 100UF TP272 LGND C49 + 220UF 20% ELECT 35 V SMT-8X10 MOTOR_SPLY C59 LGND R13 4.99KOHM 1% 1/10 W 0805 TP247 TP101 R26 4.99KOHM 1% 1/10 W 0805 R93 15.0KOHM 1% 1/10 W 0805 LGND 10% TANT 10 V SMT_D + 100UF LOGIC_SPLY_5V TP240 C45 + 220UF 20% ELECT 35 V SMT-8X10 R10 64.9KOHM 1% 1/10 W 0805 17V MOTOR SUPPLY L2 47UH 1.6 A SMT 30BQ060 3.0 A SMC C70 1UF 10% X7R 100 V CAP_200MIL D1 TP241 8N579 1 2 5V LOGIC SUPPLY D23 1 8 8N134 2 LGND 8N154 4 SHDWN VSWX 30BQ060 3 TP339 3.0 A LT1372 NFB SMC FB 2 8N118 OUT 3 LT1121-5.0V LGND U12 1.6A SMT 8 8N296 4 SHDWN VSWX 3 NFB LT1372 FB 2 8N602 TP297 C118 0.1UF 10% X7R 50 V 1206 LGND 8N82 TP255 4 TAB 6 GND1 SWDC_SPLY V IN 1 2 GND1 V IN 5 7 GND2 1 VC V IN 5 7 GND2 1 VC 118 6 GND1 L1 47UH Schematics & PCB Assemblies Main Board / DC-DC Converter 40-5648-51B C90 0.01UF 10% X7R 50 V 0805 VCC 3 MAX809LEURT SOT23 2 TP139 LGND C52 0.01UF 10% X7R 50 V 0805 R143 15.0KOHM 1% 1/10 W 0805 LOGIC_SPLY_5V {5} LCD_CONTRAST_ADJ LGND 1 GND RESET MAX809 U43 LGND 9N3 R16 2.0KOHM 1% 1/10 W 0805 C121 0.01UF 10% X7R 50 V 0805 RESET# {2} LGND TP295 R144 4.99KOHM 1% 1/10 W 0805 9N83 9N82 R140 20.0KOHM 1% 1/10 W 0805 C57 0.1UF 10% X7R 50 V 1206 C111 0.22UF 10% X7R 25 V 1206 TP121 TP361 C117 0.1UF 10% X7R 50 V 1206 LGND – TP354 9N43 1 R131 49.9KOHM 1% 1/10 W 0805 LGND R90 18KOHM 5% 1/10 W 0805 R89 4.7KOHM 5% 1/10 W 0805 LOGIC_SPLY_5V LGND U1A 3 + 9N44 1 OP296 2 – TP362 OP296HRU TSSOP8 VNEG_SPLY + TP426 LOGIC_SPLY_5V U1B 6 – 7 5 OP296 + OP296HRU TP315 TSSOP8 TP336 {2} ASYNC_BATTERY_DATA 8 4 LGND TP353 R18 24OHM 5% 1/8 W 1206 Q38 2N7002-T1 SOT23 R88 130OHM 5% 1/10 W 0805 TP375 LCD BACKLIGHT DRIVER LCD CONTRAST SUPPLY TP294 BATTERY_DATA {8} BATTERY DATA DETERMINATION 3 2 8 TP379 TP380 TP70 LGND TP45 1 LCD_BACKLIGHT_DRV# {13} LCD_CONTRAST {13} 9N107 10% TANT 25 V SMT_D C44 + 22UF 9N109 9N157 C37 22UF 10% TANT 25 V SMT_D 9N162 C2– C2+ C1+ C1– C56 0.1UF 10% X7R 50 V 1206 6 V+ 7 U36 LGND MAX865EUA SO8 V– 4 MAX865EUA V IN GND POWER ON RESET 3 2 LOGIC_SPLY_5V TP308 TP345 TP84 C38 22UF 10% TANT 25 V SMT_D C60 22UF 10% TANT 25 V SMT_D VPOS_SPLY VNEG_SPLY + + 40-5648-51B 5 + LOGIC_SPLY_5V NEGATIVE SUPPLY POSITIVE SUPPLY Schematics & PCB Assemblies Main Board / DC-DC Converter -- Continued 119 {4} CAUTION_LED_ON# {4} INFUSING_LEDR_ON# {4} INFUSING_LEDM_ON# {4} INFUSING_LEDL_ON# {4} PCELL_LED_ON# TP331 2 2 2 2 2 10N124 R154 3 TP360 160OHM Q33 5% 1/10 W TP0610T 0805 SOT23 10N311 R160 3 TP372 475.0OHM Q37 1% 1/10 W TP0610T 0805 SOT23 10N125 R157 3 TP370 160OHM Q34 5% 1/10 W TP0610T 0805 SOT23 10N127 R158 3 TP371 160OHM Q35 5% 1/10 W TP0610T 0805 SOT23 LGND C128 0.01UF 10% X7R 50 V 0805 10N129 R159 3 TP395 160OHM Q36 5% 1/10 W TP0610T 0805 SOT23 FB2 BLM21A102SPT 0805 100 mA 1 1 1 1 120 1 LOGIC_SPLY_5V C146 1000PF 5% NPO 50 V 0805 C147 1000PF 5% NPO 50 V 0805 C148 1000PF 5% NPO 50 V 0805 C149 1000PF 5% NPO 50 V 0805 C150 1000PF 5% NPO 50 V 0805 LGND TP389 LGND TP369 LGND TP386 LGND TP387 LGND TP388 10 V SMT_D C53 + 100UF 20% TANT KEYPAD_PCELL_LED KEYPAD_INFUSION_LEDL KEYPAD_INFUSION_LEDM KEYPAD_INFUSION_LEDR KEYPAD_CAUTION_LED {11} KEYPAD_WARNNG_LED {11} KEYPAD_BATTERY_LED {11} KEYPAD_AC_LED {11} KEYPAD_LOCKOUT_LED TP304 C131 1000PF 5% NPO 50 V 0805 LED_SPLY {11} C132 1000PF 5% NPO 50 V 0805 C133 1000PF 5% NPO 50 V 0805 C134 1000PF 5% NPO 50 V 0805 J10 13 14 15 16 17 18 19 20 21 22 23 24 LGND 1-104069-2 THRUHOLE 1 2 3 4 5 6 7 8 9 10 11 12 LGND C143 1000PF 5% NPO 50 V 0805 C137 1000PF 5% NPO 50 V 0805 C142 1000PF 5% NPO 50 V 0805 C136 1000PF 5% NPO 50 V 0805 C138 1000PF 5% NPO 50 V 0805 C144 1000PF 5% NPO 50 V 0805 C135 1000PF 5% NPO 50 V 0805 C145 1000PF 5% NPO 50 V 0805 C139 1000PF 5% NPO 50 V 0805 C140 1000PF 5% NPO 50 V 0805 C141 1000PF 5% NPO 50 V 0805 KEYPAD_COL5 {12} KEYPAD_COL4 {12} KEYPAD_COL3 {12} KEYPAD_ROW3 {12} KEYPAD_ROW2 {12} KEYPAD_ROW1 {12} KEYPAD_ROW0 {12} KEYPAD_PWRSWX {12} KEYPAD_COL2 {12} KEYPAD_COL1 {12} KEYPAD_COL0 {12} Schematics & PCB Assemblies Main Board / Keypad Interface 40-5648-51B {4} LOCKOUT_LED_ON# {10} KEYPAD_AC_LED {5, 6, 8} AC_PWR_DETECT {5, 6, 8} EXTRNL_PWR_DETECT {5, 7, 14} WATCHDOG_ALARM {4} WARNING_LED_ON# LGND R153 120KOHM 5% 1/10 W 0805 TP318 TP319 LED_SPLY TP385 2 R152 120KOHM 5% 1/10 W 0805 LGND 1 TP124 R166 220KOHM 5% 1/10 W 0805 LED_SPLY 1 2 1 2 1 2 3 11N415 3 3 MMBD914LT1 200 mA SOT23 D5 MMBD914LT1 200 mA SOT23 D4 MMBD914LT1 200 mA SOT23 D20 TP151 TP424 Q26 TP0610T SOT23 3 1 2 1 2 3 3 160OHM 5% 1/10 W 0805 R138 R94 200KOHM 5% 1/10 W 0805 TP123 1 MMBD914LT1 200 mA SOT23 D7 MMBD914LT1 200 mA SOT23 D6 C119 0.01UF 10% X7R 50 V 0805 LGND 11N332 TP291 {8} CHARGE_DETECT Q27 TP0610T SOT23 3 1 2 3 11N136 TP383 Q42 2N7002-T1 SOT23 11N274 TP292 R173 200KOHM 5% 1/10 W 0805 LGND 2 R139 TP415 TP150 11N264 160OHM 5% 1/10 W 0805 2 3 1 Q40 TP0610T SOT23 LGND Q30 2N7002-T1 SOT23 TP382 1 3 40-5648-51B 2 {10} LED_SPLY CHARGE_LED_ON TP290 R53 160OHM 5% 1/10 W 0805 TP117 KEYPAD_LOCKOUT_LED {10} BATTERY_LED_ON {4} KEYPAD_BATTERY_LED {10} KEYPAD_WARNING_LED {10} Schematics & PCB Assemblies Main Board / Keypad Interface -- Continued 121 {4} KEYPAD_IN_COL1 {5} KEYPAD_SEL_ROW3 # {5} KEYPAD_SEL_ROW2 # {5} KEYPAD_SEL_ROW1 # {5} KEYPAD_SEL_ROW0 # {4} KEYPAD_IN_COL5 {4} KEYPAD_IN_COL4 {4} KEYPAD_IN_COL3 {4} KEYPAD_IN_COL2 R59 1KOHM 5% 1/10W 0805 {6, 20} POWER_SWITCH # {4} PWR_SW_MCU R60 1KOHM 5% 1/10W 0805 R73 1KOHM 5% 1/10W 0805 R124 10KOHM 5% 1/10 W 0805 TP156 R72 1KOHM 5% 1/10W 0805 R128 1KOHM 5% 1/10W 0805 LGND 1 Q28 2N7002-T1 SOT23 R61 10KOHM 5% 1/10 W 0805 LOGIC_SPLY_5V R122 1KOHM 5% 1/10W 0805 3 122 2 {4} KEYPAD_IN_COL0 TP423 R127 1KOHM 5% 1/10W 0805 TP421 12N585 R129 1KOHM 5% 1/10 W 0805 R187 10KOHM 5% 1/10 W 0805 R135 1KOHM 5% 1/10 W 0805 R134 1KOHM 5% 1/10 W 0805 R123 10KOHM 5% 1/10 W 0805 TP155 TP262 12N525 FB10 3 3 D22 D19 2 1 LGND MMBD914LT1 200 mA SOT23 2 1 MMBD914LT1 200 mA SOT23 TP418 TP109 TP144 TP145 TP286 TP408 TP313 TP303 TP330 TP409 BLM21A102SPT 0805 100 mA LOGIC_SPLY_5V R177 10KOHM 5% 1/10 W 0805 12N455 R170 10KOHM 5% 1/10 W 0805 ACU_SPLY {6, 20} LOGIC_SPLY_5V C122 0.1UF 10% X7R 50 V 1206 TP394 R178 10KOHM 5% 1/10 W 0805 R171 10KOHM 5% 1/10 W 0805 R179 10KOHM 5% 1/10 W 0805 KEYPAD_ROW3 {10} KEYPAD_ROW2 {10} KEYPAD_ROW1 {10} KEYPAD_ROW0 {10} KEYPAD_COL5 {10} KEYPAD_COL4 {10} KEYPAD_COL3 {10} KEYPAD_COL2 {10} KEYPAD_COL1 {10} KEYPAD_COL0 {10} KEYPAD_PWRSWX {10} R172 10KOHM 5% 1/10 W 0805 Schematics & PCB Assemblies Main Board / Keypad Interface - Continued 40-5648-51B {5} LCD_RESET # {4} BFRD_EVALID_READ # {4} LCD_COMMAND {4} LCD_CS # {3, 5} EVALID_WRITE # {3} EVALID_WRITE {4} DELAYED_WRITE # {2, 4} IO_CS # {2, 3} DATA [0:7] {9} LCD_CONTRAST {9} LCD_BACKLIGHT_DRV # 12 13 11 U11D SN74AHC125PWR TSSOP14 C151 0.01UF 10% X7R 50 V 0805 R175 1KOHM 5% 1/10 W 0805 LGND R96 10KOHM 5% 1/10 W 0805 LOGIC_SPLY_5V TP283 TP293 11 12 13 14 15 16 17 18 20 10 LGND LGND 13N211 C124 0.01UF 10% X7R 50 V 0805 LOGIC_SPLY_5V DATA7 DATA6 DATA5 DATA4 DATA3 DATA2 DATA1 DATA0 12 13 14 15 16 17 18 19 VCC 20 Q7 Q6 Q5 Q4 Q3 Q2 Q1 Q0 SN74AHC573PWR TSSOP20 U32 D7 D6 D5 D4 D3 D2 D1 D0 ENBL ENBL_OUT GND 13N33 LCD DATA WRITE LATCH 9 8 7 6 5 4 3 2 11 1 10 U6 I7 98 D7 D6 I6 7 D5 I5 6 D4 I4 5 D3 I3 4 D2 I2 3 D1 I1 2 D0 I0 OE1 119 VCC OE2 GND SN74AHC541PWR TSSOP20 LCD DATA READ BUFFER AHC541 40-5648-51B AHC573 TP373 TP351 TP332 TP410 TP374 TP352 TP333 TP411 {4, 5} BFRD_DATA [0:7] LGND C125 0.01UF 10% X7R 50 V 0805 LOGIC_SPLY_5V TP396 LGND BFRD_DATA7 BFRD_DATA6 BFRD_DATA5 BFRD_DATA4 BFRD_DATA3 BFRD_DATA2 BFRD_DATA1 BFRD_DATA0 LGND 2 4 6 8 10 12 14 16 18 20 J12 2 1 4 3 6 5 8 7 10 9 12 11 14 13 16 15 18 17 20 19 1437045-2 THRUHOLE 8X8 FONT 930-T-DS-02 THRUHOLE J7 C108 0.1UF 10% X7R 50 V 1206 1 2 TO LCD BACKLIGHT (LED) 1 3 5 7 9 11 13 15 17 19 LGND TP414 20% TANT 10 V SMT_B + 10UF C69 FB11 BLM21A102SPT 100 mA 0805 TP398 LOGIC_SPLY_5V LGND 13N63 C120 0.1UF 10% X7R 50 V 1206 Schematics & PCB Assemblies Main Board / Graphic Display Interface 123 {2} MTR_PHB_IREF {5} MTR_PHB_DIR {5} MTR_PHB_ENBLE # {5, 7, 11} WATCHDOG_ALARM {2} MTR_PHA_IREF {5} MTR_PHA_DIR TP114 1 TP113 LGND MODE PHASE ENBL BRAKE LGC_SPLY R15 PHASE B MOTOR DRIVER 0.5OHM 1% 1/2 W 2010 TP267 A3953SLB SO16 C29 0.047UF 10% X7R 50 V 0805 TP206 TP246 0.5OHM 1% 1/2 W 2010 R6 LGND TP205 A3953SLB SO16 U26 6 LGC_SPLY MTR_SPLY 1 BRAKE 8 OUTA ENBL 7 PHASE A3953 OUTB 14 MODE 2 TP195 VREF OFF_DELAY LOGIC_SPLY_5V TP306 LGND OUTB OUTA MTR_SPLY OFF_DELAY A3953 U35 PHASE A MOTOR DRIVER 2 VREF TP317 R5 1.0KOHM 1% 1/10 W 0805 14N106 7 8 1 6 14 C31 0.047UF 10% X7R 50 V 0805 C47 0.01UF 10% X7R 50 V 0805 LGND TP152 TP268 LGND 40.2KOHM 1% 0805 1/10 W R116 Q3 2N7002-T1 SOT23 STOP_MOTOR # 14N41 LGND R14 1.0KOHM 1% 1/10 W 0805 LGND 40.2KOHM 1% 0805 1/10 W R142 R97 10KOHM 5% 1/10 W 0805 C61 0.01UF 10% X7R 50 V 0805 LOGIC_SPLY_5V GND GND GND GND 4 5 12 13 {5} MTR_PHA_ENBLE # 3 2 SENSE 11 4 GND 5 GND 12 GND 13 GND 11 SENSE 3 15 10 16 LGND 14N99 TP269 C105 1000PF 5% NPO 50 V 0805 TP402 TP400 MTR_DRV_PHA# MTR_DRV_PHA TP277 TP215 R115 15.0KOHM 1% 1/10 W 0805 MTR_DRV_PHB # MTR_DRV_PHB R141 15.0KOHM 1% 1/10 W 0805 C106 0.1UF 10% X7R 50 V 1206 LGND LGND C110 0.1UF 10% X7R 50 V 1206 14N52 LGND TP356 C113 1000PF 5% NPO 50 V 0805 TP401 TP403 MOTOR_SPLY 3 15 10 16 MOTOR_SPLY 14N94 R104 20.0KOHM 1% 1/10 W 0805 TP377 LGND C65 0.01UF 10% X7R 50 V 0805 14N15 R126 20.0KOHM 1% 1/10 W 0805 {2, 5, 15, 18} ATOD_REF_BFRD 14N39 LGND B4B-PH-SM3-TB SMT STEP MOTOR J3 8 LGND C64 0.01UF 10% X7R 50 V 0805 14N32 MTR_CURRENT_DETECT # {4} MOTOR CURRENT DETECTOR 5 + U40B 7 6 –LM393 LM393M SO8 C63 0.01UF 10% X7R 50 V 0805 14N7 R156 10KOHM 5% 1/10 W 0805 LOGIC_SPLY_5V C114 0.1UF 10% X7R R155 50 V 150.0KOHM 0805 1% 1/10 W 0805 LGND + U40A 3 + 1 TP357 2 –LM393 LM393M TP305 _SO8 R19 1.0KOHM 1% 1/10 W LGND 0805 1 2 3 4 LGND 6 5 124 4 LOGIC_SPLY_5V Schematics & PCB Assemblies Main Board / Motor Drive 40-5648-51B 1 2 3 4 104071-7 THRUHOLE J4 LGND LGND 1 2 3 4 C162 1000PF 5% NPO 50 V 0805 TP225 TP99 LGND B4B-ZR-SM3-TF SMT J2 LGND SIZE_SNSR_EX 5 TP166 TP320 TP158 15N303 R85 120KOHM 5% 1/10 W 0805 15N223 R98 220OHM 5% 1/10 W 0805 15N130 TP157 LGND 1 R78 10KOHM 5% 1/10 W 0805 LGND C87 0.1UF 10% X7R 50 V 1206 FB3 BLM21A102SPT 100 mA 0805 TP160 TP284 C35 0.047UF 10% X7R 50 V 0805 LOGIC_SPLY_5V 15N312 220OHM 5% 1/10 W 0805 R77 SYRINGE SIZE DETECTOR LGND _ 15N198 LMC7111BIM 5 SOT23-5 4 1 Q4 MMBT2222ALT1 SOT23 – SYRINGE EAR DETECTOR LGND U30 + 3 LMC7111 + 2 5 3 2 40-5648-51B 6 ANALOG_SUPPLY TP169 15N315 R105 4.99KOHM 1% 1/10 W 0805 LGND C17 0.01UF 10% X7R 50 V 0805 SYRINGE_EAR_DETECT {5} SYRINGE_EAR_SNSR_ENBL {5} SYRINGE_SIZE {5} ATOD_REF_BFRD {2, 5, 14, 16, 18} Schematics & PCB Assemblies Main Board / Syringe Sensing 125 MOTOR ENCODER SENSOR LGND LGND 16N217 1 Q6 MMBT2222ALT1 SOT23 TP171 TP170 TP183 LGND R121 1.37KOHM 1% 1/10 W 0805 TP204 TP189 C100 0.22UF 10% X7R 25 V 1206 16N50 R99 120KOHM 5% 1/10 W 0805 MOTION_SNSR_ENBL {5} C129 0.01UF 10% X7R 50 V 0805 R136 40.2KOHM 1% 1/10 W 0805 LOGIC_SPLY_5V LGND LGND R91 10.0KOHM 1% 1/10 W 0805 TP187 R106 4.99KOHM 1% 1/10 W 0805 TRAVEL_SNSR_OUT TRAVEL_SNSR_EXC U29 SFH9201 SO6 LOGIC_SPLY_5V TP194 16N222 R107 160OHM 5% 1/10 W 0805 16N219 3 2 C95 0.1UF 10% X7R 50 V 1206 LGND 1 2 3 4 B4B-ZR-SM3-TF SMT 2 5 LOGIC_SPLY_5V 1 6 LGND J6 5 6 3 4 LGND R164 4.99KOHM 1% 1/10 W 0805 TP257 16N280 16N239 16N56 TP190 LGND + C96 0.1UF 10% X7R TP216 50 V 1206 ANALOG_SPLY 16N49 6 Hz LOW PASS FILTER 4.096V LOGIC_SPLY_5V TP425 LGND – 3 + U23A 1 2 OP296 – OP296HRU TSSOP8 LGND R169 20.0KOHM 1% 1/10 W 0805 R101 120KOHM 5% 1/10 W 0805 C101 0.22UF 10% X7R 25 V 1206 MOTION DETECTOR LGND 3 + 1 4 LMC7211 TP431 – U37 LMC7211AIM5 SOT23-5 C130 0.1UF 10% X7R 50 V 1206 TP299 POSITION SENSOR EXCITATION 8 4 2 126 5 C163 1000PF 5% NPO 50 V 0805 TP191 MOTION_DETECT {2} R137 120KOHM 5% 1/10 W 0805 220OHM 5% 1/10 W 0805 R95 16N138 C36 0.047UF 10% X7R 50 V 0805 7 TP427 16N142 LGND C48 0.01UF 10% X7R 50 V 0805 TRAVEL_SENSE {5} TP384 OP296HRU TSSOP8 – U23B + 5 OP296 6 ATOD_REF_BFRD {2, 5, 14, 15, 17, 18} Schematics & PCB Assemblies Main Board / Position Sensing 40-5648-51B LGND J11 1 2 3 4 5 6 7 8 9 10 11 12 12 1 2 3 4 5 6 7 8 9 10 11 LGND TP258 LGND TP273 EXF_SPLY FB13 BLM21A102SPT 100 mA 0805 LOGIC_SPLY_5V LGND C86 1000PF 5% NPO 50 V 0805 VNEG_SPLY LGND TP316 C155 1000PF 5% NPO 50 V 0805 TP341 C58 1000PF 5% NPO 50 V 0805 LGND 4.096V FB14 BLM21A102SPT 100 mA 0805 17N10 EXF_SPLY 3 Q8 MMBT2222ALT1 SOT23 C76 0.01UF 10% X7R 50 V 0805 OP727ARU 17N541 LGND C67 0.01UF 10% X7R 50 V 0805 TP234 TP116 LGND ATOD_REF_BFRD C75 0.01UF 10% X7R 50 V 0805 TP168 TP217 TP172 FB6 BLM21A102SPT 100 mA 0805 FB5 BLM21A102SPT 100 mA 0805 C93 0.22UF 10% X7R 25 V 1206 TP153 _ LGND FORCE_OSV_ADJ {2, 5} R151 10.0KOHM 1% 1/10 W 0805 LGND + 3 + U27 1 17N785 4 LMC7111 – LMC7111BIM5 SOT23-5 17N779 LGND C160 0.1UF 10% X7R 50 V 1206 ANALOG_SPLY ATOD_REF_BFRD {2, 5, 14, 16, 18} PLUNGER_DETECT2 {2} PLUNGER_DETECT1 {2} PLUNGER_SNSRS_ENBL {5} R75 15.0KOHM 1% 1/10 W 0805 TP154 R76 40.2KOHM 1% 1/10 W 0805 C85 0.22UF 10% X7R 25 V 1206 FORCE_AMPOUT {5} 6 Hz LOW PASS FILTER GAIN = 3.7 PLUNGER FLIPPERS SENSOR INTERFACE TP181 R146 200KOHM 5% 1/10 W 0805 LGND R74 120KOHM 5% FORCE_SNSR_TEST # {5} 1/10 W 0805 R149 15.0KOHM 1% 1/10 W 0805 LGND LGND R133 200KOHM 5% 1/10 W 0805 C54 0.01UF 10% X7R 50 V 0805 LGND 17N432 FB7 BLM21A102SPT 100 mA 0805 LGND R48 10.0KOHM 1% 1/10 W 0805 C99 0.1UF 10% X7R 50 V 1206 VNEG_SPLY SENSOR EXCITATION R150 24.9KOHM 1% 1/10 W 0805 LGND C156 1000PF 5% NPO 50 V 0805 LGND TP188 TP197 C157 1000PF 5% NPO 50 V 0805 17N1 TP30 C9 0.1UF 10% X7R 50 V 1206 TP69 – TSSOP8 OP727 2 – LGND U15A 3 + + VPOS_SPLY VNEG_SPLY 1 17N543 OP727ARU TSSOP8 OP727 6 – + 5 C80 0.1UF 10% X7R 50 V 1206 TP31 R35 220OHM 5% 1/10 W 0805 17N3 TP82 17N6 U15B 1 17N537 7 R147 10.0KOHM 1% 1/10 W 0805 TP182 R113 51OHM 5% 1/10 W 0805 R28 1.0KOHM 1% 1/10 W 0805 TP32 2 8 4 PLUNGER_SNSR2_OUT OFFSET AUTO ADJUST -2.6 TO +2.5 VDC C62 1000PF 5% NPO 50 V 0805 FORCE_SYS_TEST # FORCE_PREAMP_ASADJ FORCE_EXC FORCE_PREAMP_OUT B11B-ZR-SM3-TF SMT 13 13 2 40-5648-51B 5 PLUNGER_SNSR1_OUT Schematics & PCB Assemblies Main Board / Force Sensing 127 1 12 2 3 3 4 4 5 5 6 6 7 7 8 8 53048-0810 THRUHOLE J8 {5} PRESSURE_SNSR_TEST # LGND 4.096VDC PRESSURE_SNSR_OUTL PRESSURE_SNSR_OUTH PRESSURE_SNSR_EXH SET_IN_SNSR_DRV 3 LGND TP242 2 18N110 Q5 TP0610T SOT23 TP100 R100 825.0OHM 1% 1/10 W 0805 TVS15 VC080505A150 5.6 V 18V CLAMP 0805 C158 1000PF 5% NPO 50 V 0805 TP420 TP422 LGND LGND TVS16 VC080505A150 5.6 V 18V CLAMP 0805 1 TP18 R24 150.0KOHM 1% 1/10 W 0805 LGND R112 1KOHM 5% 1/10 W 0805 R185 ANALOG_SPLY R37 1.0KOHM 1% 1/10 W 0805 18N17 7 TP226 18N15 C73 0.1UF 10% X7R 50 V 1206 TP17 R38 220OHM 5% 1/10 W 0805 TP36 + U14B TP72 – OP296 C41 0.1UF 10% X7R 50 V 1206 18N247 18N13 OP296HRU TSSOP8 6 5 5 6 AD623AR SO8 OUT U9 C79 0.01UF 10% X7R 50 V 0805 ATOD_REF_BFRD C81 0.1UF 10% X7R 50 V 1206 PREAMP GAIN: = 122 LGND LGND TP235 0.373 VDC OFFSET INSTR. AMP. AD623 3 IN+ VS+ 1 RG1 2 IN – VS – 8 RG2 REF LGND ANALOG_SPLY TP83 R50 649.0OHM 1% 1/10 W 0805 18N148 TP46 18N192 18N186 18N147 LGND TP71 TP3 TP227 C127 27PF 5% NPO 50 V 0805 Q45 TP0610T SOT23 2 3 Q10 MMBT2222ALT1 SOT23 1 18N19 1.0KOHM 1% 1/10 W 0805 R186 1.0KOHM 1% 1/10 W 0805 FB15 BLM21A102SPT 100 mA 0805 2 TP321 TP16 3 FB12 BLM21A102SPT 100 mA 0805 4 7 SET_IN_SNSR_DRV 1 TP34 1 + FIXED OFFSET ~0.373V LGND – 2 C77 0.1UF 10% X7R 50 V 1206 18N275 18N285 LGND OP296HRU TSSOP8 – OP296 + 3 U14A VPOS_SPLY PRESSURE CELL DETECTION 8 128 4 LOGIC_SPLY_5V TP233 SET_IN_SNSR_ENBL # {5} ATOD_REF_BFRD {2, 5, 14, 17} LGND TP259 PRESSURE_AMPOUT {5} R120 4.99KOHM 1% 1/10 W 0805 R165 49.9KOHM 1% 1/10 W 0805 SET_IN_DETECT {5} Schematics & PCB Assemblies Main Board / Pressure Sensing 40-5648-51B {2} SPEAKER_DETECT {2} SPEAKER_FREQUENCY {2} SPEAKER_VOLUME 19N279 8 TP229 R109 R145 20.0KOHM 1% 1/10 W 0805 2.2MOHM 5% 1/10 W 0805 TP245 U25A LGND C1 0.1UF 10% X7R 50 V 1206 19N184 TP391 3 U25B SN74HC4066PW SO14 9 U25C SN74HC4066PW SO14 10 U25D SN74HC4066PW SO14 1 2 7 GND VCC 14 SN74HC4066PW SO14 LOGIC_SPLY_5V LGND TP364 C43 10UF + 20% TANT 10 V SMT_B 19N239 TP238 R111 19N289 4 TP230 392.0KOHM 1% 1/10 W 0805 {4} SPEAKER_ENVELOPE3 120KOHM 5% 1/10 W 0805 {4} SPEAKER_ENVELOPE2 R108 19N282 11 TP202 27KOHM 5% 1/10 W 0805 {4} SPEAKER_ENVELOPE1 12 6 5 R110 19N458 R162 1.0KOHM 1% 1/10 W 0805 LGND TP406 R125 2.0KOHM 1% 1/10 W 0805 TP203 + C109 0.1UF 10% X7R 50 V 1206 TP228 G1G2 TP263 LGND – 6 OP296 5 + LGND 2 1 R161 LGND R87 1.0KOHM 1% 1/10 W 0805 40.2KOHM 1% 1/10 W 0805 LGND C39 0.1UF 10% X7R 50 V 1206 + LOGIC_SPLY_5V LGND SPEAKER CURRENT SENSE TP390 LGND C83 0.047UF 10% X7R 50 V 0805 R4 24OHM 5% 1/8 W 1206 19N413 TP180 TP250 R168 1.0KOHM 1% 1/10 W 0805 TP399 TP337 LGND TP265 LGND R20 0.5OHM 1% 1/2 W 2010 TP363 PRE-AMPLIFIED AUDIO SIGNAL TP266 SPEAKER R119 49.9KOHM 1% 1/10 W 0805 SPEAKER_DRIVE {8} SPEAKER_RET {8} U28A 19N245 3 + 1 TP243 2 OP296 – OP296HRU C103 19N236 TSSOP8 1000PF 5% NPO – 50 V 0805 TP270 SPEAKER DRIVE Q24 2N7002-T1 SOT23 MMBD914LT1 200 mA SOT23 19N197 19N496 TP344 3 LGND C159 R117 AUTO SHUTDOWN 47KOHM 5 % 1/10 W 0805 1000PF 5% NPO 50 V 0805 D14 20% TANT 10 V SMT_D C51 1 Q29 2N7002-T1 SOT23 19N248 + 100UF TP264 U42B 19N481 7 TP376 OP296HRU TSSOP8 SPEAKER TEST CIRCUIT MMBD914LT1 200 mA SOT23 MMBD914LT1 200 mA SOT23 D15 2 1 3 LGND TP296 LGND C161 0.1UF 10% X7R 50 V 1206 1 TP249 19N392 U31 19N226 3 + 5 TP428 2 LM386 – LM386M-1 SO8 _ TP231 10KOHM 5% 1/10 W 0805 R118 VNEG_SPLY FB8 19N225 BLM31P500SPT 0805 3000 mA + 5 + U28B 7 6 OP296 – OP296HRU TSSOP8 LGND 19N228 LOGIC_SPLY_5V LGND C104 0.1UF 10% X7R 50 V 1206 C115 0.1UF 10% X7R 50 V 1206 LGND 19N366 3 + U42A 1 TP281 2 OP296 R182 – OP296HRU 1.0KOHM 19N250 TSSOP8 1% 1/10 W – 0805 R181 40.2KOHM 1% 1/10 W 0805 LOGIC_SPLY_5V 6 3 2 ENVELOPE SELECTION 7 13 8 4 8 1 4 3 2 8 40-5648-51B 4 LOGIC_SPLY_5V Schematics & PCB Assemblies Main Board / Speaker Drive 129 130 {6, 12} ACU_SPLY {6} ACU_OSC1 {6} ACU_OSC2 {6, 12} POWER_SWITCH # {6} ARM_STRB {6, 7} WATCHDOG_STRB {4, 6} PET_WATCHDOG LGND 1 2 3 4 5 6 7 8 ACU_EMULATOR_SOCKET THRUHOLE J1 ACU EMULATOR SOCKET MH1 LGND MH2 MOUNTING HOLES MH3 Schematics & PCB Assemblies Main Board / ACU-ICE Socket 40-5648-51B C95 1 J7 U40 1 J3 1 J6 C96 U23 C106 C79 U35 U26 C77 R137 J10 C111 R50 R186 C127 U1 C45 R143 C23 R3 R84 R158 C128 R144 C146 C148 C150 C134 R131 C131 R153 C132 R166 R140 R159 U9 Q38 C48 R185 C36 R95 C121 U34 L3 C19 R2 J13 C112 FB2 U20 C49 U18 C24 C71 C68 Q45 L1 U12 D1 Q22 Q16 Q21 R55 FB12 C25 C116 R68 R80 R67 U15 U36 R148 Q2 J11 Q41 L2 C44 U42 FB7 FB5 R133 C58 C38 C99 FB6 R146 R20 C89 U13 XD1 C53 C16 R152 C41 R56 R76 R181 R182 R113 C9 C102 U28 C98 U21 U33 C26 U25 C86 C66 U8 X1 U7 C15 U31 C78 1 D8 U3 U4 FB8 U4 R103 C91 C125 C124 U39 U2 X3 U32 C123 Q18 U38 C94 C92 C152 C10 C42 C21 U6 R1 U44 R83 C12 C81 C13 R45 R46 R88 R90 U14 C110 R16 J8 C114 R104 C57 R18 C117 D23 C59 C4 C97 C37 C70 C60 J9 C14 C51 C8 C7 + J5 U11 X2 U5 1 2 C11 J12 U46 R89 R63 R96 20 19 131 + + C118 + + + R36 1 + + + + R9 40-5648-51B Date Code/Serial # Assembly Rev. 8 + + + + + + C68 + U22 1 U19 U17 J2 C30 C17 C35 J4 C72 U30 + C27 1 U24 C6 R85 R77 Main Board Assembly Drawing – Top Side Schematics & PCB Assemblies Schematics & PCB Assemblies Main Board Assembly Drawing – Bottom Side C5 R86 R43 R174 D10 C22 R12 R25 R167 R8 R21 R33 C107 R17 R23 C3 D7 FB3 C87 R7 C40 R98 + FB1 C18 C108 C120 C90 FB11 C126 U45 R44 C82 R175 C151 R69 Q19 R71 R57 R64 C74 Q11 + R82 R125 Q15 Q14 Q13 D16 C109 R51 R30 R58 R119 D3 D2 D13 Q29 R52 FB4 C154 R31 C33 R66 Q1 C23 R39 Q20 R40 D11 D12 R54 C103 C83 R117 R4 R118 R60 R65 R59 R41 R72 R42 R73 R62 C153 Q24 FB13 C104 Q12 Q17 C39 R108 R111 R32 R110 C161 R141 C31 C105 R160 R6 C29 R5 C101 R28 R151 C76 R91 R101 C129 C84 C143 C135 C140 C138 C139 C73 R124 R37 R187 R123 C158 FB15 TVS15 TVS16 R38 R165 R120 R100 R24 R112 Q5 R164 U10 C133 Q10 R136 C136 R61 C163 C2 R47 R49 R81 C141 C142 Q28 D19 C100 D6 U37 R121 C75 R150 R53 R138 C149 C145 R99 Q3 U29 132 R107 R149 C67 R139 C144 D22 R97 R106 R76 FB14 C54 Q26 R14 R156 C147 C119 Q40 C47 C113 C65 R170 R173 C137 R116 R115 R126 R179 D20 Q34 Q33 C52 R155 R135 D4 D6 D4 Q36 R154 R142 C64 R134 R128 D5 Q35 Q42 Q30 Q27 Q37 R94 R157 R19 R178 C156 R75 R147 C50 R132 C46 C63 R48 C80 R93 R15 C155 C85 R177 R35 R26 C61 R127 R129 C62 C157 R74 Q8 R87 C55 R92 C28 C122 D15 D14 C56 C93 R171 R168 R161 C159 C160 R172 U27 C115 R122 FB10 C1 R162 R109 R13 R10 R105 C34 + U43 R27 R78 R11 C20 R102 R70 C162 C43 Q4 D9 R22 + U16 + C88 R145 R29 R34 C130 R169 40-5648-51B Schematics & PCB Assemblies Main Board Assembly – Parts list # QTY 1 36 2 Package Value C1, C9, C16, C19, C24, C39, C41, C56, C57, C73, C77, C78, C80, C81, C84, C87, C89, C95, C96, C97, C98, C99, C104, C106, C108, C109, C110, C114, C115, C117, C118, C120, C122, C130, C160, C161 1206W 0.1UF CAPACITOR, 50V, X7R, 10%, 1206; GMC31X7R104K50NT, CAL-CHIP 12065C104KAT2A AVX 8 C2, C29, C31, C35, C36, C46, C55, C83 0805W .047UF CAPACITOR, 50V, X7R, 10%, 0805; GMC21X7R473K50NT, CAL-CHIP 3 11 C3, C33, C68, C71, C74, C82, C85, C93, C100, C101, C111 1206W 0.22UF CAPACITOR, 25V, X7R, 10%, 1206; GMC31X7R224K25NE, CAL-CHIP 12063C224KAT2A AVX 4 2 C4, C59 TANT_D 100UF CAPACITOR, 10V, TANT, 10%, SMT_D; TPSD107K010R0100, AVX; T495D107K010AS, KEMET 5 42 C5, C6, C8, C10, C14, C17, C20, C22, C23, C27, C40, C42, C47, C48, C52, C54, C61, C63, C64, C65, C66, C67, C72, C75, C76, C79, C90, C94, C107, C112, C116, C119, C121, C123, C124, C125, C126, C128, C129, C151, C152, C153 0805W .01UF CAPACITOR, 50V, X7R, 10%, 0805; GMC21X7R103K50NT, CAL-CHIP 6 1 C7 0805W 10PF CAPACITOR, 50V, NPO, 5%, 0805; GMC21CG100J50NT, CAL-CHIP 7 1 C11 SUPERCAP 1F 8 2 C12, C127 0805W 27PF CAPACITOR, 50V, NPO, 5%, 0805; GMC21CG270J50NT, CAL-CHIP 9 9 C13, C15, C18, C25, C26, C30, C34, C43, C69 TANT_B 10UF CAPACITOR, 10V, TANT, 20%, SMT_B; TCMIA106BT, CALCHIP; TAJB106M010R, AVX; T491B106M010AS, KEMET 10 1 C21 0805W 18PF CAPACITOR, 50V, NPO, 5%, 0805; GMC21CG180J50NT, CAL-CHIP 11 2 C28, C50 0805W .0047UF 12 2 C32, C88 TANT_A 1UF CAPACITOR, 16V, TANT, 20%, SMT_A; TCMIC105AT, CALCHIP; TAJA105M016R, AVX 13 4 C37, C38, C44, C60 TANT_D 22UF CAPACITOR, 25V, TANT, 10%, SMT_D; TPSD226M025R0200, AVX; T495D226M025AS, KEMET 14 2 C45, C49 SMT_8X10_8 220UF CAPACITOR, 35V, ELECT, 20%, RADIAL; NACZ221M35V8X10.8TR13, NIC; 35VCV220GX, SURGE COMPONENTS 40-5648-51B REF. Designator Part Spec CAPACITOR, 5.5V, ELECT, 20%, RADIAL; FYD0H105Z; TOKIN CAPACITOR, 50V, X7R, 10%, 0805; GMC21X7R472K50NT, CAL-CHIP 133 Schematics & PCB Assemblies # QTY 15 2 C51, C53 REF. Designator Package Value TANT_D 100UF CAPACITOR, 10V, TANT, 20%, SMT_D; TCMIA107DT, CALCHIP; TAJD107M010R, AVX; T491D107M010AS, KEMET 16 13 C58, C62, C86, C103, C105, C113, C155, C156, C157, C158, C159, C162, C163 0805W 1000PF CAPACITOR, 50V, NPO, 5%, 0805; GMC21CG102J50NT, CAL-CHIP 17 1 C70 CAP_200MIL 1UF CERAMIC, 100V, X7R, 10%, LEADED; SR401C105KAA, AVX; RPE114X7R105K100V, MURATA ERIE 18 2 C91, C92 0805W 100PF CAPACITOR, 50V, NPO, 5%, 0805; GMC21CG101J50NT, CALCHIP 19 1 C102 SMT_10X10_8 330UF CAPACITOR, 35V, ELECT, 20%, RADIAL; NACZ331M35V10X10.8TRHIL, NIC 20 21 C131, C132, C133, C134, C135, C136, C137, C138, C139, C140, C141, C142, C143, C144, C145, C146, C147, C148, C149, C150, C154 0805W 1000PF CAPACITOR, 50V, NPO, 5%, 0805;GMC21CG102J50NT, CALCHIP 21 2 D1,D23 22 18 D2,D3,D4,D5,D6, D7,D8,D9,D10,D11, D12,D13,D14,D15, D16,D19,D20,D22 SOT23 MMBD914LT1, MOTOROLA 23 13 FB1,FB2,FB3,FB4, FB5,FB6,FB7, FB10,FB11,FB12, FB13,FB14,FB15 0805W BLM21A102SPT, MURATA ERIE 24 1 FB8 1206W BLM31P500SPT, MURATA ERIE 25 1 GL1 GNDLNK 26 2 J2,J6 4P_059SMTHDR B4B-ZR-SM3-TF, JST 27 1 J3 4P_079SMTHDR B4B-PH-SM3-TB, JST 28 1 J4 4P_050THHDR 104071-7, AMP 29 2 J5,J13 30 1 31 SMC Part Spec CMSH3-60, CENTRAL SEMI; 30BQ060, INTERN. RECTIFIER N/A 2P_THJMPR HTSW-102-06-T-S, SAMTEC J7 2PINTH_ TERMBLK 30.870.002 OR 930-T-DS-02, WECO 1 J8 8P_050RATHHDR 53048-0810 molex 32 1 J9 26P_ 079THDRHDR 1306-26-S-02, SINGATRON 33 1 J10 24P_050RATHDRHDR 1-104069-2, AMP 34 1 J11 11P_059SMTHDR B11B-ZR-SM3-TF, JST 35 1 J12 20P_100THHDR 609-2027, THOMAS & BETTS 36 2 L1, L2 SMT_POTCORE DT3316P-473, COILCRAFT 37 1 L3 SMT_POTCORE DT3316P-333, COILCRAFT 134 40-5648-51B Schematics & PCB Assemblies # QTY 38 13 Q1,Q3,Q11,Q12, Q13,Q14,Q21,Q24, Q28,Q29,Q30,Q38, Q42 39 1 Q2 40 7 Q4,Q6,Q8,Q10,Q16, Q19,Q41 SOT23 MMBT2222ALT1, MOTOROLA 41 16 Q5,Q7,Q15,Q17, Q18,Q20,Q22,Q26, Q27,Q33,Q34,Q35, Q36,Q37,Q40,Q45 SOT23 TP0610T, Supertex; TP0610T, Vishay SILICONIX (TEMIC) [obsolete] 42 1 R1 1206W 43 1 R2 1206W 44 4 R3, R16, R17, R125 0805W 2.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F2001CT, CALCHIP 45 2 R4, R18 1206W 24OHM RESISTOR, 1/8W, TCR=400PPM, 5%, 1206; RM12J240CT, CALCHIP; ERJ-8GEYJ240V, PANASONIC 46 12 R5, R8, R14, R19, R28, R37, R87, R162, R168, R182, R185, R186 0805W 1.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F1001CT, CALCHIP 47 3 R6, R15, R20 2010 0.5OHM RESISTOR, 1/2W, TCR=100PPM, 1%, 2010; WSL2010R500F, DALE; LR201001R500F, IRC 48 13 R7, R11, R13, R21, R25, R26, R29, R46, R105, R106, R120, R144,R164 0805W 4.99KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F4991CT, CALCHIP 49 24 R27, R30, R31, R41, R42, R61, R62, R78, R92, R96, R97, R103, R118, R123, R124, R156, R170, R171, R172, R177, R178, R179, R187 0805W 10KOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J103CT, CALCHIP 50 2 R10, R40 0805W 64.9KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F6492CT, CALCHIP 51 8 R12, R43, R75, R93, R115, R141, R143, R149 0805W 15.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F1502CT, CALCHIP 52 14 R22, R32, R36, R39, R54, R57, R58, R82, R83, R84, R94, R133, R146, R173 0805W 200KOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J204CT, CALCHIP 53 1 R23 0805W 1MOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J105CT, CALCHIP 54 2 R24, R155 0805W 150.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F1503CT, CALCHIP 55 4 R33, R34, R167, R174 0805W 100OHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J101CT, CALCHIP 40-5648-51B REF. Designator Package Value SOT23 Part Spec 2N7002T1, SILICONIX (TEMIC); CENTRAL SEMICONDUCTOR SO8 MMSF3P02HDR2G, On Semi 10MOHM 2.70OHM RESISTOR, 1/8W, TCR=400PPM, 5%, 1206; RM12J106CT, CALCHIP RESISTOR, 1/8W, TCR=400PPM, 5%, 1206; RM12J2R7CT, CALCHIP; IRC WCR1206 135 Schematics & PCB Assemblies # QTY Package Value Part Spec 56 7 R35, R38, R49, R77, R95, R98, R166 0805W 220OHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J221CT, CALCHIP 57 7 R44, R104, R126, R140, R145,R169 0805W 20.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F2002CT, CALCHIP 58 26 R45, R52, R59, R60, R63, R64, R67, R68, R70, R71, R72, R73, R79, R80, R86, R102, R112, R122, R127, R128, R129, R134, R135, R175 0805W 1KOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J102CT, CALCHIP 59 12 R47, R55, R66, R74, R85, R99, R101, R108, R137, R152, R153 0805W 120KOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J124CT, CALCHIP 60 4 R48, R91, R147, R151 0805W 10.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F1002CT, CALCHIP 61 1 R50 0805W 649.0OHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F6490CT, CALCHIP 62 2 R51, R109 0805W 2.2MOHM RESISTOR, 1/10W, TCR=400PPM, 5%, 0805; RM10J225CT, CALCHIP 63 8 R53, R107, R138, R139, R154, R157, R158, R159 0805W 160OHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J161CT, CALCHIP 64 5 R56, R65, R69, R117, R148 0805W 47KOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J473CT, CALCHIP 65 6 R76, R116, R142, R161, R181, R136 0805W 40.2KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F4022CT, CALCHIP 66 2 R81, R100 0805W 825.0OHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F8250CT, CALCHIP 67 2 R110, R132 0805W 27KOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J273CT, CALCHIP 68 1 R111 0805W 392.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F3923CT, CALCHIP 69 1 R113 0805W 51OHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J510CT, CALCHIP 70 3 R119, R131, R165 0805W 49.9KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F4992CT, CALCHIP 71 1 R150 0805W 24.9KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F2492CT, CALCHIP 72 1 R160 0805W 475.0OHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F4750CT, CALCHIP 136 REF. Designator 40-5648-51B Schematics & PCB Assemblies # QTY 73 412 74 2 TVS15, TVS16 0805W VC080505A150, AVX 75 5 U1,U14,U23, U28, U42 TSSOP8 OP296HRU, ANALOG DEVICES 76 2 U2, U4 SO8 AT25256AN-10SU-2.7, Atmel; M95256-WMN6TP ST Microelectronics; M95256-WMN6-TGST Microelectronics 77 2 U3, U33 44PLCC CS82C55A, HARRIS/INTERSIL; MSM82C55A-2VJS, OKI 78 1 U5 TSSOP14 SN74AHC00PWR, TEXAS INSTR 79 2 U6, U41 TSSOP20 SN74AHC541PWR, TEXAS INSTR 80 1 U7 SO8 81 1 U8 SSOP8 82 1 U9 SO8 83 3 U10, U27, U30 SOT23-5 LMC7111BIM5, NATIONAL SEMICONDUCTOR; MIC7111BM5, MICREL 84 1 U11 TSSOP14 SN74ACH125PWR, TEXAS INSTR 85 2 U12, U34 SO8 LT1372CS8, LINEAR TECH 86 1 U13 SO16 TLV1544CD, TEXAS INSTR 87 1 U16 TO236AB LM4040DIM3-4.1, NATIONAL SEMICONDUCTOR, MICREL SEMICONDUCTOR 88 1 U17 SOP28 TC55257DFL85L, TOSHIBA; TC55257DFL70L, TOSHIBA; M5M5256DFP-70LL, Mitsubishi; LH52256CN-70LL, Sharp 89 2 U18, U37 90 1 U19 84PLCC_SKT 91 1 U20 SO8 92 1 U21 SOT223 LT1121CST-5, LINEAR TECH 93 1 U22 32TSOP AT29C040A-12TU Atmel 94 1 U24 TSSOP16 SN74AHC138PWR, TEXAS INSTR 95 1 U25 SO14 96 2 U26, U35 97 1 U29 SO6 SFH9201-2/3, Osram (Smiths Medical catalog number G6000157) 98 1 U31 SO8 LM386M-1, NATIONAL SEMICONDUCTOR; NJM386BM, NEW JAPAN RADIO 99 1 U32 TSSOP20 40-5648-51B REF. Designator TP1, TP2, TP3, TP4, TP5 Package TESTPOINT SOT23-5 SO16W Value Part Spec N/A LM2936M-5.0; NATIONAL SEMI RS5C316B, RICOH AD623AR, ANALOG DEVICES LMC7211AIM5, NATIONAL SEMICONDUCTOR; MIC7211BM5, MICREL 68HC11K1CFN4 OR 68HC11K0CFN4, MOTOROLA MAX522CSA, MAXIM MC74HC4066AD, OnSemi; SN74HC4066PW, TEXAS INSTR A3953SLB, ALLEGRO SN74AHC573PWR, TEXAS INSTR 137 Schematics & PCB Assemblies # QTY 100 1 U36 SSO8 101 1 U38 SOT23 MAX6326UR31-T, MAXIM 102 1 U39 SO8W PIC12C50804/SM, MICROCHIP (programmed) 103 1 U40 SO8 104 1 U43 SOT23 105 1 U44 TO236AB LM4040BIM3-4.1, NATIONAL SEMI 106 1 U45 SOT23-5 SN74AHC1G14DBVR, TEXAS INSTR 107 1 U46 SO16 MC74HC174AD, MOTOROLA; SN74HC174D, TEXAS INSTR.; 74HC174D, PHILIPS; M74HC174M1R, SGS 108 1 X1 SMT_32KHZXTAL 32KHZ MC306-32.768KA-E3, EPSON; ECPSM29T-32.768KTR, ECLIPTEK; SX1555-32.768KT/R, MTRON 109 1 X2 SMT_16MHZXTAL 16MHZ EC2SM 16.000MHZ T&R, ECLIPTEK 110 1 X3 SMT_455KHZXTAL 455KHZ CSBFB455KJ58-R1, MURATA ERIE 111 1 XD1 TH_BUZZER 112 1 PCB N/A RAW, PRINTED CIRCUIT BOARD 113 1 PRESS_IN NUT N/A PRESS-IN NUT , 2-56 THREAD, 0.219” DIA., STAINLESS STEEL; P/N 4860, KEYSTONE; KFS2-256, PEM 114 1 U15 TSSOP8 115 1 R121 0805W 1.37KOHM CRCW08051371F50 Vishay, RK73GC2ATTD1371F KOA 116 2 R9, R89 0805W 4.7KOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; CRCW0805472J, Vishay Dale; RK73B2ATTD472J KOA Speer 117 1 R88 0805W 130OHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; CRCW0805131JRT6, Vishay Dale; RK73B2ATTD131J KOA Speer 118 1 R90 0805W 18KOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; CRCW0805183J, Vishay Dale; RK73B2ATTD183J KOA Speer 138 REF. Designator Package Value Part Spec MAX865EUA, MAXIM LM393M, NATIONAL SEMI; LM393D, TEXAS INSTR MAX809LEURT, MAXIM; ADM809LART, ANALOG DEVICES HMB-06, STAR MICRONIX (Smiths Medical catalog number 6940000100) OP727ARU Analog Devices 40-5648-51B FORCE SENSOR 1 2 3 4 LGND 90814-0004 SMT J1 1 1 2 3 4 5 6 7 8 9 10 11 2N97 LGND LOGIC_SPLY_5V R5 2.0KOHM 1% 1/16 W 0603 R4 2.0KOHM 1% 1/16 W 0603 LGND LGND C7 + 1UF 20% TANT 16 V SMT_A FB1 BLM11A102SGPT 0603 LGND FB2 BLM11A102SGPT 0603 2N108 2N111 PLUNGER_SNSR2_OUT PLUNGER_SNSR1_OUT PLUNGER_SNSRS_ENBL 2N114 2N158 2N118 B11B-ZR-SM3-TF SMT 1 2 3 4 5 6 7 8 9 10 11 2 3 LGND J2 C4 470PF 2% NPO 50 V 0603 LGND R2 2.7MOHM 5% 1/10 W 0805 FORCE_SNSR_O+ FORCE_SNSR_EX FORCE_SNSR_O- 1N102 Q2 TP0610T SOT23 VNEG_SPLY FB6 BLM11A102SGPT 0603 1N38 C14 470PF 2% NPO 50 V 0603 FORCE_PREAMP_OSADJ LGND C13 470PF 2% NPO 50 V 0603 LGND C5 470PF 2% NPO 50 V 0603 R9 2.0KOHM 1% 1/16 W 0603 LGND C12 470PF 2% NPO 50 V 0603 R10 267.0OHM 1% 1/16 W 0603 FORCE_PREAMP_OUT FORCE_PREAMP_OSADJ FORCE_SNSR_TEST# FB4 BLM11A102SGPT 0603 LGND C10 470PF 2% NPO 50 V 0603 VNEG_SPLY – 1N23 6 AD620AR SO8 U1 LGND INSTR. AMP REF 3 IN+ 8 RG1 VS+ AD620 + 1 RG2 VS2 IN- 1N21 1N353 C11 470PF 2% NPO 50 V 0603 LOGIC_SPLY_5V R1 267.0OHM 1% 1/16 W 0603 FB5 BLM11A102SGPT 0603 LGND C1 470PF 2% NPO 50 V 0603 C2 470PF 2% NPO 50 V 0603 C3 470PF 2% NPO 50 V 0603 7 4 FORCE_SNSR_TEST # 5 R3 24.9KOHM 1% 1/16 W 0603 2N13 C6 470PF 2% NPO 50 V 0603 LGND R6 24.9KOHM 1% 1/16 W 0603 LOGIC_SPLY_5V LGND R8 24.9KOHM 1% 1/16 W 0603 LOGIC_SPLY_5V 3 4 1 C9 470PF 2% NPO 50 V 0603 US RPI-352 THRUHOLE U2 RPI-352 THRUHOLE R7 100OHM 5% 1/10 W 0805 LGND Q1 MMBT2222ALT1 SOT23 2N11 3 4 12 12 13 13 2 1 2 1 3 40-5648-51B 2 LOGIC_SPLY_5V LGND C8 0.1UF 10% X7R 50 V 1206 Schematics & PCB Assemblies Plunger Board Schematic Plunger Board / Force Preamplifier 139 140 LGND J2 12 11 10 9 8 7 FB6 LGND FB1 FB5 470PF 2% C14 FORCE_PREAMP_OSADJ FORCE_SNSR_TEST PLUNGER_SNSRS_ENBL 5 FB4 PLUNGER_SNSR1_OUT 6 PLUNGER_SNSR2_OUT FORCE_PREAMP_OUT FORCE_SNSR_EX 4 FB3 FB2 LGND C12 470PF 2% 3 2 1 C10 470PF 2% VNEG_SPLY LGND C6 470PF 2% LGND LGND C13 470PF 2% C9 C5 470PF 2% LGND LGND C7 470PF 2% C11 1U 16V + 5_VDC LOGIC_SPLY 470PF 2% LGND R9 2.0KOHM 100OHM R7 2N2222A Q1 LGND LGND C8 0.1UF 5_VDC LOGIC_SPLY 4 1 4 1 U3 U2 3 2 3 2 LGND 24.9KOHM R6 LGND 24.9KOHM R8 Schematics & PCB Assemblies Plunger Board / Flipper Sensor 40-5648-51B Schematics & PCB Assemblies Plunger Board Assembly Drawing Top Side: PH2 FB1 C7 + J2 C10 U1 PH1 U2 R2 U3 C1 R5 C3 Q2 R4 R3 J1 Q1 R9 Bottom Side: FB5 FB6 FB4 C13 C12 C2 C4 R1 FB2 C11 C5 R10 C14 R7 C9 R6 C6 C8 R8 SERIAL LABEL 40-5648-51B 141 Schematics & PCB Assemblies Plunger Board Assembly – Parts list # QTY Package Value Part Spec 1 12 C1, C2, C3, C4, C5, C6, C9, C10, C11, C12, C13, C14 0603 470PF CERAMIC, 50V, NP0, 2%, 0603; GMC10CG471G50NT, CAL-CHIP 2 1 C7 TANT_A 1U CAPACITOR, 16V, TANT, 20%, SMT_A; TCMIC105AT, CALCHIP; TAJA105M016R, AVX 3 1 C8 1206 0.1UF CAPACITOR, 50V, X7R, 10%, 1206; GMC31X7R104K50NT, CAL-CHIP 12065C104KAT2A; AVX 4 5 FB1, FB2, FB4, FB5, FB6 0603 5 1 J1 4PINSMTHDR_ WBOSS 90814-0004, MOLEX 6 1 J2 11PIN_1_ 5MMSMTHDR B11B-ZR-SM3-TF, JST 7 1 Q1 SOT23 MMBT2222ALT1, ON SEMICONDUCTOR; CMPT 2222ATR or TR13 CENTRAL SEMICONDUCTOR 8 1 Q2 SOT23 TP0610T, Supertex, Vishay Silconix (TEMIC) - (obsolete) 9 2 R1, R10 0603 267.0OHM RESISTOR, 1/16W, TCR=100PPM, 1%, 0603; RM06F2670CT, CALCHIP 10 1 R2 0805 2.7MOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J275CT, CALCHIP 11 3 R3, R6, R8 0603 24.9KOHM RESISTOR, 1/16W, TCR=100PPM, 1%, 0603; RM06F2492CT, CALCHIP 12 3 R4, R5, R9 0603 2.0KOHM RESISTOR, 1/16W, TCR=100PPM, 1%, 0603; RM06F2001CT, CALCHIP 13 1 R7 0805 100OHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J101CT, CALCHIP 14 1 U1 SO8 LT1167CS8, LINEAR TECHNOLOGY; AD620AR, ANALOG DEVICES 15 2 U2, U3 RPI_LEADEDOPTO RPI-352, ROHM 16 1 PCB N/A PCB RAW 142 REF. Designator BLM11A102SGPT, MURATA ERIE 40-5648-51B CON1 J2 CON1 BATTERY_NEG_LEAD R7 100.0K 0.5% 1/8 W 1206 R6 499.0K 0.5% 1/8 W 1206 BATTERY_POS_LEAD J3 C6 0.1U 10% X7R 50 V 1206 POWER_GND 10 9 8 7 6 5 4 3 2 1 HEADER 5X2 2mm-DIP-2X5 – VSR + R4 0.2 1% 1W 2512 R5 100K 5% 1/10 W 0805 C5 0.1U 10% X7R 50 V 1206 BATTERY_DATA CHARGE* VLOW_BATTERY* R8 1M 5% 1/10 W 0805 U3 R2 1.69M 1% 1/10 W 0805 Vth Clr BQ2012 SO-16 1 2 3 4 5 6 7 16 10 C1 0.1U 10% X7R 50 V 1206 4 1 VCC 12 EMPTY DISP 13 DATA 14 CHRG LCOM 15 REF PRG1 PRG2 11 PRG3 SB PRG4 SR 9 PRG5 SEG6 8 GND C2 1000P 5% NPO 50 V 0805 CHARGE_DETECT R1 5.90M 1% 1/10 w 0805 C3 0.1U 10% X7R 50 V 1206 3 Vs Gnd 2 40-5648-51B C7 1000P 5% NPO 50 V 0805 NC1 VIN R9 10K 5% 1/10 W 0805 C8 + 10U 20% TANT 10 V SMT_A 4 2 NC2 S812 SOT23-5 VO U2 R14 See Chart 5% 1/10 W 0805 R15 See Chart 5% 1/10 W 0805 R12 See Chart 5% 1/10 W 0805 R13 See Chart 5% 1/10 W 0805 R10 See Chart 5% 1/10 W 0805 R11 See Chart 5% 1/10 w 0805 5 3 R17 See Chart 5% 1/10 W 0805 R16 See Chart 5% 1/10 W 0805 BATTERY CAPACITY SELECTION PRG1 PRG2 PRG3 PRG4 5 Out MAX835 SOT23-5 U1 3 1 2 1N4148 200 mAS OT23 D1 GND 1 J1 20% TANT 10 V SMT_A C4 + 10U 3.3V Schematics & PCB Assemblies Battery Gauge Schematic 143 3 2 1 EXTDC_IN EXTERNAL DC JACK DC-001B-CRSN THRUHOLE J5 LGND R28 20.0KOHM 1% 1/10 W 0805 TP44 4 1 321 LGND D1 20UH 50 V/3 A THRUHOLE L3 4 TP8 3 2 RESET MAX809 U3 1 2 LGND 1N270 1 1N338 TP7 LGND 1% 1/10 W 0805 LGND R29 1.0KOHM C1 0.1UF 10% X7R 50 V 1206 LGND 1 R10 200KOHM 5% 1/10 W 0805 POWER_ENBL EXTERNAL DC DETECTOR TVS1 SA13CA 14.0 V 21.5V clamp D0204-AC LGND D12 30BQ060 3 .0 A SMC J3 1 12 2 22-03-5025 THRUHOLE Q1 2N7002-T1 1 SOT23 Q5 MMBT2222ALT1 SOT23 2 MAX809LEURT SOT23 2 R5 200KOHM 5% 1/10 W 0805 1N202 TP1 C4 0.01UF 10% X7R 50 V 0805 MMBD914LT1 SOT23 200 mA 3 1N215 BATTERY SWITCH EXTERNAL +12V DC SUPPLY 8765 Q7 MMSF3P02HD SO8 1N123 C5 0.01UF 10% X7R 50 V 0805 1N621 1N516 2 D17 MMBD914LT1 200 mA SOT23 20% 35 V ELECT S MT-8X10 C2 0.1UF 10% X7R 50 V 1206 RUE 185 1.85 A THRUHOLE PS1 {3} BATTERY_POS_LEAD B2B-PH-K THRUHOLE TP9 3 1 1 2 N/C C9 220UF 3 2 3 1N375 1N522 R8 1.0KOHM 1% 1/10 W 0805 2 1 3OBQ060 3.0 A SMC D11 TP3 1 2 R9 10.0KOHM 1% 1/10 W 0805 {3} BATTERY_SWX_ON# TP6 3 1 2 3 1N629 3 1N519 D16 MMSZ5232BT1 5.6 V SOD-123 EXTRNL_PWR_DETECT AC DETECTOR TP11 Q2 MMBT2907ALT1 SOT23 TP2 D15 MMSZ234BT1 6.2 V SOD-123 1N245 2 TP4 Q4 MMBT2222ALT1 SOT23 1 2 MMBD914LT1 SOT23 200mA 3 D2 MMBD914LT1 SOT23 200 mA D3 R7 1.0 KOHM 1% 1/10 W 0805 TP12 1N52 1 R11 2.0KOHM 1% 1/10 W 0805 LGND MMBD914LT1 200 mAS0T23 D5 TVS2 VC120614D300D 14.0 V 32 V clamp 1206 {3} UNSWX_DC_POWER C19 0.1UF 10% X7R 50 V 1206 REG_DC_INTRNL LGND 1 2 1 2 2 3 1 2 J2 3 VCC 1 GND 1 2 1 TP5 1N492 R6 10.0KOHM 1% 1/10 W 0805 1N278 2 D9 MURS120T3 1 A SMB LGND 3 3 Q11 TP0610T SOT23 LGND LGND TVS4 VC080505A150 5.6 V 18V clamp 0805 FB1 5V BLM21A102SPT 100 mA 0805 {4} IR_XMT_DATA {4} IR_RCV_DATA UNSWX_DC_POWER {3} BATTERY_DATA {3} VLOW_BATTERY# AC_PWR_DETECT BACKUP_CHARGE_SRC TVS3 VC120614D300D 14.0 V 32V clamp 1206 TP10 C3 0.01UF 10% X7R 50 V 0805 LGND SPEAKER_RET SPEAKER_DRIVE POWER_ENBL TP43 LGND LOGIC_SPLY_5V C21 100PF 5% NPO 50 V 0805 MMBD914LT1 200 mAS0T23 D4 Q10 2N7002-T1 SOT23 TP42 {3} CHARGE_DETECT TP13 1 3 144 + 2 SPEAKER LGND 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 DNS THRUHOLE (1306-26-S-02) J4 Schematics & PCB Assemblies Interconnect Board Schematic Interconnect Board / Power Control 40-5648-51B 10 9 8 7 6 5 4 3 2 1 1306-10-R-02 THRUHOLE J1 BATTERY PACK LGND {2} BATTERY_POS_LEAD BATTERY_DATA {2} CHARGE # VLOW_BATTERY # {2} L2 3.3UH 400 mA SMT CHARGE CURRENT TP45 LGND C20 1000PF 5% NPO 50 V 0805 1 R27 10.0KOHM 1% 1/10 W 0805 LGND S /S 5 LT1512 TP30 2N70 TP27 LGND Q23 2N7002-T1 SOT23 R14 200KOHM 5% 1/10 W 0805 BATTERY CHARGER 4 C15 0.1UF 10% X7R 50 V 1206 LGND BATTERY_SWX_ON# 2N561 R19 200KOHM 5% 1/10 W 0805 TP40 C10 + 220UF 20% ELECT 35 V SMT-8X10 6 GNDS V IN GND 7 U5 3 4 LGND 8765 1 2 3 TP28 Q6 IR F 7201 S08 TP29 2N88 TP31 2N121 TP20 2N14 TP21 IC HRG_SENSE TP22 LT1512CS8 S08 TP32 2N113 C12 0.22UF 10% X7R 25 V R4 1206 0.50 HM 1% 1/2 W 2010 IF B VSW 8 FB 2 VC 1 C18 1UF 10UH SMT 3 4 LGND TP41 R3 1.50 HM 1% 1/8 W 1206 R2 240 HM 5% 1/8 W 1206 10% X7R 50 V 1825 2 1 L1 TP17 2N119 2N76 2N61 2N73 TP23 R12 392.0KOHM 1% 1/10 W 0805 LGND R15 10.0KOHM 1% 1.10 W 0805 C13 0.22UF 10% X7R 25 V 1206 LGND TP16 R16 10.0KOHM 1% 1/10 W 0805 TP18 TP39 MURS120T3 1A SMB D10 C11 0.22UF 10% X7R 25 V 1206 TP24 LGND _ LGND + R17 1.0KOHM 1% 1/10 W 0805 2N25 TP26 C14 0.1UF 10% X7R 50 V 1206 LGND 2N27 1 Q9 TP0610T SOT23 R18 6.49KOHM 1% 1/10 W 0805 TP15 2N498 TP33 LGND 3 + U2 1 4 LMC7111 LMC7111BIM5 – SOT23-5 10% TANT 25 V SMT_D C8 + 22UF TP19 2 3 2N279 3 2 2 5 Q8 2N7002-T1 SOT23 1 CHARGE DETECTOR LGND TP14 R26 200KOHM 5% 1/10 W 0805 BATTERY_SWX_ON# {2} CHARGE_DETECT {2} FB2 BLM21A102SPT 100 mA 0805 R13 100OHM 5% 1/10 W 0805 2N520 3 2 40-5648-51B UNSWX_DC_POWER {2} Schematics & PCB Assemblies Interconnect Board / Battery Management 145 {2} IR_XMT_DATA LGND 3N46 TP34 R25 475.0OHM 1% 1/10 W 0805 20% TANT 10 V SMT_B C7 + 10UF 1 TP35 R23 100.0OHM 1% 1/8 W 1206 TP37 LGND R1 100.0OHM 1% 1/8 W 1206 C16 0.1UF 10% X7R 50 V 1206 LGND R21 220OHM 5% 1/10 W 0805 U1 PS5042 THRUHOLE LOGIC_SPLY LGND EXTERNAL INFRARED COMM PORT D14 DN504 THRUHOLE 3N52 Q3 MMBT2907ALT1 SOT23 3N49 2 3 TP36 LGND C6 0.01UF 10% X7R 50 V 0805 R20 220OHM 5% 1/10 W 0805 R22 6.49KOHM 1% 1/10 W 0805 LOGIC_SPLY 3N15 3N5 TP25 TP38 R24 200KOHM 5% 1/10 W 0805 4 3 – LGND C17 0.1UF 10% X7R 50 V 1206 LGND U4 LMC7211AIM5 SOT23-5 LMC7211 + LOGIC_SPLY 2 146 5 LOGIC_SPLY IR_RCV_DATA {2} Schematics & PCB Assemblies Interconnect Board / Infrared Serial Communications 40-5648-51B Schematics & PCB Assemblies Interconnect Board Assembly Drawing Top Side: FB1 C7 R4 C8 C18 R2 D10 C12 L1 C10 L3 C5 C17 U5 R25 Q3 D11 TVS1 U4 R3 C13 R1 D5 Q8 D12 D1 R21 R20 R5 Q11 Q10 R6 R24 Q4 R8 C6 Q2 D2 Q7 R26 R18 R17 R22 C2 U3 TSV4 TVS3 R11 R7 D16 D3 C4 Q6 Q9 C20 R27 C1 D15 Q5 D4 D17 Q1 R19 C15 C3 C9 R28 R29 R10 R9 U2 J2 C21 C11 R15 PS1 C14 J4 Q23 FB2 L2 1 C19 R13 R12 R16 2 J3 R14 J1 TVS2 C16 R23 Bottom Side: J5 D1 4 40-5648-51B U 1 147 Schematics & PCB Assemblies Interconnect board assembly – parts list # QTY 1 7 2 Package Value C1,C2,C14,C15,C16, C17,C19 1206W 0.1UF CAPACITOR, 50V, X7R, 10%, 1206; GMC31X7R104K50NT, CAL-CHIP 4 C3, C4, C5, C6 0805W .01UF CAPACITOR, 50V, X7R, 10%, 0805; GMC21X7R103K50NT, CAL-CHIP 3 1 C7 TANT_B 10UF TCMIA106BT, CAL-CHIP; TAJB106M010R, AVX; T491B106M010AS, KEMET 4 1 C8 TANT_D 22UF CAPACITOR, 25V, TANT, 10%, SMT_D; TPSD226M025R0200, AVX; T495D226M025AS, KEMET 5 2 C9, C10 SMT_8X10_8 220UF CAPACITOR, 35V, ELECT, 20%, RADIAL; NACZ221M35V8X10.8TR13, NIC; 35VCV220GX, SURGE COMPONENTS 6 3 C11, C12, C13 1206W 0.22UF CAPACITOR, 25V, X7R, 10%, 1206; GMC31X7R224K25NE, CAL-CHIP 7 1 C18 1825 1UF 8 1 C20 0805W 1000PF CAPACITOR, 50V, NPO, 5%, 0805; GMC21CG102J50NT, CAL-CHIP 9 1 C21 0805W 100PF CAPACITOR, 50V, NPO, 5%, 0805; GMC21CG101J50NT, CALCHIP 10 6 D1, D2, D3, D4, D5, D17 SOT23 MMBD914LT1, MOTOROLA 11 2 D9, D10 SMB_X MURS120T3, MOTOROLA; CMR1U-02, CENTRAL SEMICONDUCTOR 12 2 D11,D12 SMC 13 1 D14 LEADED_IR 14 1 D15 SOD-123 6.2V MMSZ5234BT1, MOTOROLA 15 1 D16 SOD-123 5.6V MMSZ5232BT1, MOTOROLA 16 2 FB1,FB2 17 1 J1 10P_079RATHHDR 1306-10-R-02, SINGATRON 18 1 J2 2P_079THHDR B2B-PH-K, JST 19 1 J3 2P_100THHDR 22-03-5025, MOLEX 20 1 J4 Cable 26 pin 21 1 J5 DC_JACK 22 1 L1 SMT_TOROID 148 REF. Designator Part Spec CERAMIC, 1UF, 50V, X7R, 10%, 1825; GMC45X7R105K50NT, CAL-CHIP CMSH3-60, CENTRAL SEMI; 30BQ060, INTERN. RECTIFIER DN504, STANLEY 0805W BLM21A102SPT, MURATA ERIE 12121-09-A, Singatron DC-001-B-CRSN, POWER DYNAMICS 10U 10UH, +/-20%, SMT TOROID; CTX10-1, COILTRONIX; 618-100M-01, C&K MAGNETICS 40-5648-51B Schematics & PCB Assemblies # QTY Package Value 23 1 L2 SMT_INDUCTOR1 3.3UH 24 1 L3 TH_10MMX7_ 5MM PLT2003C, MURATA ERIE 25 1 PS1 POLYSWX_RADIAL RUE185, RAYCHEM 26 4 Q1, Q8, Q10, Q23 SOT23 2N7002-T1, TEMIC; CENTRAL SEMICONDUCTOR 27 2 Q2, Q3 SOT23 MMBT2907ALT1, MOTOROLA 28 2 Q4, Q5 SOT23 MMBT2222ALT1, MOTOROLA 29 1 Q6 SO8 IRF7201, INTERN. RECTIFR; SI9410DY, TEMIC 30 1 Q7 SO8 MMSF3P02HD,MOTOROLA; SI9430DY,SILICONIX (TEMIC) 31 2 Q9, Q11 SOT23 TP0610T, Supertex, Vishay SILICONIX (TEMIC) (Obsolete) 32 2 R1, R23 1206W 100.0OHM RESISTOR, 1/8W, TCR=100PPM, 1%, 1206; RM10F1000CT, CALCHIP 33 1 R2 1206W 24OHM RESISTOR, 1/8W, TCR=400PPM, 5%, 1206; RM12J240CT, CALCHIP; ERJ-8GEYJ240V, PANASONIC 34 1 R3 1206W 1.5OHM RESISTOR, 1/8W, TCR=400PPM, 1%, 1206; ERJ8RQF1R5V, PANASONIC; RM12F1R5CT, CALCHIP; WCR12062R49F, IRC 35 1 R4 2010 0.5OHM RESISTOR, 1/2W, TCR=100PPM, 1%, 2010; WSL2010R500F, DALE; LR2010001R500F, IRC 36 6 R5, R10, R14, R19, R24, R26 0805W 200KOHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J204CT, CALCHIP 37 5 R6, R9, R15, R16, R27 0805W 10.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F1002CT, CALCHIP 38 4 R7, R8, R17, R29 0805W 1.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F1001CT, CALCHIP 39 1 R11 0805W 2.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F2001CT, CALCHIP 40 1 R12 0805W 392.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F3923CT, CALCHIP 41 1 R13 0805W 100OHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J101CT, CALCHIP 42 2 R18, R22 0805W 6.49KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F6491CT, CALCHIP 40-5648-51B REF. Designator Part Spec NL453232-3R3K, CAL-CHIP; IMC-1812 3.3UH 10%, DALE 149 Schematics & PCB Assemblies # QTY Package Value Part Spec 43 2 R20, R21 0805W 220OHM RESISTOR, 1/10W, TCR=200PPM, 5%, 0805; RM10J221CT, CALCHIP 44 1 R25 0805W 475.0OHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F4750CT, CALCHIP 45 1 R28 0805W 20.0KOHM RESISTOR, 1/10W, TCR=100PPM, 1%, 0805; RM10F2002CT, CALCHIP 46 1 TVS1 47 2 TVS2, TVS3 1206W VC120614D300D, AVX 48 1 TVS4 0805W VC080505A150, AVX 49 1 U1 LEADED_IR 50 1 U2 SOT23-5 51 1 U3 SOT23 52 1 U4 SOT23-5 LMC7211AIM5, NATIONAL SEMICONDUCTOR; MIC7211BM5, MICREL 53 1 U5 SO8 LT1512CS8, LINEAR TECH 54 1 PCB N/A INTERCONNECT PCB RAW, Medfusion™ 3000 Series 150 REF. Designator DO_204AC SA13CA, On Semiconductor SA13CA Vishay Semiconductor PS5042, STANLEY LMC7111BIM5, NATIONAL SEMICONDUCTOR; MIC7111BM5, MICREL MAX809LEURT, MAXIM; ADM809LART, ANALOG DEVICES 40-5648-51B Assembly Drawings & Parts Lists Assembly drawings The following section provides assembly drawings – exploded views, and detailed parts lists including Smiths Medical part numbers. Always follow the procedures (including warnings/ cautions) in “Parts Replacement” section of this manual while disassembling, replacing parts, and reassembling any Medfusion™ 3000 Series pump. Note: Part numbers and pricing are subject to change without notice. See the website at www.smiths-medical.com. 40-5648-51B 151 Assembly Drawings & Parts Lists Medfusion™ 3000 series main pump assembly See Note 1 152 40-5648-51B Assembly Drawings & Parts Lists Medfusion™ 3000 series main pump assembly – parts list Ref. # 1 2 3 4 5 6 7 8 10 12 16 17 18 Part Number See following drawing G6000059 No longer required G6000775 G6000763 G6000354 G6000112 G6002083 G6000117 Description Assembly Case Bottom Screw, 4-40 × .62 PH Phillips Label, Device Tracking Label, Warning Label, Warning, CE Mark Label, Warning, German Door, Battery Bay Label, Serial Number (Blank) Screw 4-40 × .31 FH SS Quantity 1 ea. 2 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 2 ea. G6001392 See following drawing G6000979 See note 2 G6000418 G6000623 G6000631 G6000142 G6000541 G6000605 Battery Assy, 3000 Assembly Case Top w/Plunger Head Label, Battery Warning Label, Date of Manufacture Label, MRI Warning Label, MRI Warning, German Label, MRI Warning, Spanish Label, Protege Logo Label, Medfusion™ 3010A Logo Label, Medfusion™ 3500 Logo 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. Notes: 1. Older model pumps may have this connector cable. In current pumps this cable is connected to the interconnect PCB. 2. This label changes yearly. Please specify the manufacturing year shown on your pump when communicating with the Service Center. 40-5648-51B 153 Assembly Drawings & Parts Lists Case bottom assembly Medfusion™ 3500BC 154 40-5648-51B Assembly Drawings & Parts Lists Case bottom assembly – parts list See also case bottom service assembly, note 4 below. To obtain replacement labels with the CE mark and national language, international customers must order the International Case Bottom Assy. See note 4 below. Ref. # 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part Number G6000094 G6000754 G6000014 G6000312 G6000773 G6000016 G6000017 G6000276 G6000102 G6000695 G6000693 G6000220 G6000192 G6000410 G6000118 G6000012 G6000387 0340IF1400 G6000706 G6000694 Description Case Bottom - No Feet (See note 4) Case Bottom - With Feet (See note 4) Speaker Assembly PCB Assembly, Interconnect (see note 6) Power Supply, Conformal Coated Shield, Power Supply Lens, IR Window Cable, AC Power Cable, AC Power, Medfusion™ 3500E Cable, AC Power, Medfusion™ 3500BC (See note 9) Screw, 4-40 × .31 PH Phillips Clamp, Cord Retainer Locknut, 6BA Nylock Washer, Shoulder, Nylon Pad, Battery Bay Cable, DC Power Cable Solder Feet, Rubber (glue type) (See note 5) (See note 7) Label, Functional Ground (See note 8) Notes: 1. In newer assemblies, the interconnect PCB assembly (item 4) P/N G6000312 has superseded the older assembly P/N G6000234. 2. In older assemblies, items 10 & 11 are Screw, 440 × .38 FH SS (G6000127) and Nut, 4-40 Nylock (G6000043). 3. In newer assemblies, the shoulder washer (item 12) has superseded the flat washer, Smiths Medical P/N G6000058. 4. Items 1, 17 (four pieces), 7, 13 and labels are available as a service subassembly part number: English: G6000438, Case Bottom Assembly – Service (USA) International: G6000622, Case Bottom Assy German – Service 5. Use with Loctite® 401, part number 036LT40100. 40-5648-51B Quantity 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 6 ea. 1 ea. 2 ea. 2 ea. 1 ea. 1 ea. 1 ea. 4 ea. 1 ea. Notes (continued): 6. Board comes with cable (#G6000387) attached. 7. Older models use Enlarged rubber foot (#G6000287). 8. Item 18 is adhered to the top of the AC power cable. 9. Item 8 ring terminal is secured at secondary-side mounting post of power supply. 155 Assembly Drawings & Parts Lists Case top assembly w/plunger 156 40-5648-51B Assembly Drawings & Parts Lists Case top assembly w/plunger – parts list See also plunger case left service assembly, note 1 below. Ref. # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 25 26 27 28 31 32 35 Part Number G6000067 G6000068 G6000069 G6000755 G6000071 G6000725 G6000074 G6000180 G6000925 G6000926 G6000085 G6000086 G6000669 G6000089 G6000087 G6000082 G6000927 G6000083 G6000103 G6000110 G6000105 G6000749 G6000090 G6000474 G6000693 See following drawing G6000544 G232100076 G6001656 Description Mount, Plunger Head Force Sensor Plate, Plunger Float Case Left, Plunger (See note 1) Cam Gear, Plunger Flipper, Plunger Case Right Plunger Assy PCB Plunger, Tested Service Timing Plate Left Push Block Screw, M4 × 12, Button Head Spring, .21 OD × 1.5 Lever, Plunger Gear, Plunger Flipper Gear, Plunger Lever Seal, Flipper Timing Plate Right Seal, Lever Screw 4-40 × ⅞ Pan Phil SS Pin, Dowel Screw, 4-40 × ⁷/₁₆ Pan Phil SS Screw, 4-40 × .18 FH SS Seal, Plunger Case Washer, Flat #4, SS Screw, Pan Phil, 4-40 1/4 SS Assy, Case Top w/o Plunger Screw, 6-19 × ½ (See note 3) Loctite Black Max O-ring (See note 2) Quantity 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 2 ea. 1 ea. 1 ea. 1 ea. 1 ea. 2 ea. 2 ea. 1 ea. 2 ea. 1 ea. 2 ea. 1 ea. 1 ea. 1 ea. 1 ea. 2 ea. 2 ea. 1 ea. 1 ea. 2 Ea. 1 ea. 2 ea. 1 ea. Notes: 1. Items 3, 4, 6 (two pieces), 14 (two pieces), and 17 (two pieces), and 31 (two pieces) are available as a service subassembly part number G6000439, Plunger Case Left Assembly - Service. 2. New style plunger case requires o-ring (older models do not require this part). 3. Use with Loctite® Black Max, part number G232100076 (Item 32). 40-5648-51B 157 Assembly Drawings & Parts Lists Case top assembly without plunger 158 40-5648-51B Assembly Drawings & Parts Lists Case top assembly without plunger – parts list See also case top service assembly, note 2 below. Ref. # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 19 21 22 23 27 28 32 33 35 36 37 38 39 40 41 Part Number See note 2. See note 4. G6000021 G6000022 G6001457L G6000023 See following drawing G6000034 See following drawing See note 3 G6000010 G6000692 G6001999 G6000101 G6000582 G6000064 G6000043 G6000122 G6000077 G6000474 G6000715 G6000802 G6000257 G6000903 0382000000 G6000339 G6000393 G6000397 G6000583 039TT10200 G6000585 G6000692 G6000238 Description Case Top, With Tubing Holders Keypad 3000 Stud Self Clench 4-40 × 625 Spacer, .25 OD × .31, Nylon Display, Liquid Crystal Ear Clip Assembly Barrel Clamp E-Ring Assembly Drive Train Assy 3000 Main PCB Optocoupler Assembly Screw 4-40 × .31 Phillips Case Handle Backlight Fiber Optic (Medfusion™ 3010A Series) Backlight Fiber Optic Dual LED (Medfusion™ 3500 Series) Standoff Hex 4-40 × .38 Nut 4-40 Nylock Seal, Barrel Clamp/Ear Clip Tube Seal Washer, #4 Flat Barrel Clamp Head Screw 4-40 × .25 BH Black Clamp, Stainless Steel Screw, Pan Phil 2-56 3/₁₆ SS Nylock Grease, Silicone 111 Lens, Keypad Support Sleeve, Ear Clip Spring, Ear Clip Spacer, LCD, Backlight (see note 5) Wire Tie (Medfusion™ 3500 Series) Cable, Backlight Dual LED (Medfusion™ 3500 Series) Nylok Screw Tube Holder Quantity 1 ea. 1 ea. 2 ea. 2 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 10 ea. 1 ea. 1 ea. 1 ea. 3 ea. 4 ea. 2 ea. 1 ea. 2 ea. 1 ea. 1 ea. 1 ea. 1 ea. 0.1 oz. 1 ea. 1 ea. 1 ea. 1-2 ea. 1 ea. 1 ea. 3 ea. 3 ea. - continued on next page - 40-5648-51B 159 Assembly Drawings & Parts Lists Notes: 1: Item 35 does not appear in older pumps. 2: Items 1, 2, 3 (two pieces), 13, 18, 19 and 33 are available as a service subassembly part number: For Medfusion™ 3010 and 3010a: G6000437, Case Top Protege Assembly - Service (old style barrel clap head and no keyway) G6000736, Case Top Protoge Assembly - Service (new style barrel clamp with keyway) For Medfusion™ 3500 (English): G6000610, Case Top 3500 – Service (old style barrel clamp head and no keyway) G6000737, Case Top 3500 - Service (new style barrel clamp with keyway) For Medfusion™ 3500 (International): G6000624, 3500 International Case Top - Service English: G6000438, Case Bottom Assembly – Service International: G6000622, Case Bottom Assy International – Service 3: Items 10 is available as service subassembly part numbers: G6000435, 3010 Main PCB Assembly – Software Version 2.0.6 - Service G6000361, 3500 Main PCB Assembly – Software Version 3.0.6 - Service G6001260, 3500 Main PCB Assembly – Software Version 4.0.2 - Service G6001560, 3500 Main PCB Assembly – Software Version 4.1.5 - Service G6001561, 3500 Main PCB Assembly – Software Version 3.0.9 - Service G6001562, 3500 Main PCB Assembly - Software Version 4.1.4 -Service Check with the Smiths Medical service department for other software versions. 4: Item 2, for Medfusion™ 3010 English Text Keypad use G6000005. For Medfusion™ 3500 English Text keypad use G6000607. For Medfusion™ 3500 International Keypad use G6000912. 5: Early Medfusion™ 3010 pumps have no spacer, later Medfusion™ 3010 pumps have 2 spacers. All Medfusion™ 3500 and later pumps have 1 spacer. 160 40-5648-51B Assembly Drawings & Parts Lists Barrel clamp assembly GREASE SILICONE III SOLDER NO CLEAN 40-5648-51B 161 Assembly Drawings & Parts Lists Barrel clamp assembly – parts list Ref. # 1 2 4 5 6 7 8 9 11 12 13 Part Number G6000716 G6000904 G6000031 G6000032 G6000024 G6000186 - See note 1 G6000096 - See note 1 G6000121 0340IF1400 - See note 1 0382000000 G6000906 Description Guide Barrel Clamp Rod Barrel Clamp Barrel Clamp Slide Spring, Barrel Clamp Spring .265 ID × .5 Pot Size Sensor, 10K Flex Cable Size Pot Screw #2 × .18 Plastite .030 DIA, Spool Solder Grease, Silicon 111 Screw, 6-32 ¼” Truss Nylock Quantity 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 0.01 oz. 0.1 oz. 1 ea. Notes: 1: These items 7, 8 and 9 are available as a service subassembly part number G6000436, Size Sensor Pot Assembly - Service. 162 40-5648-51B 40-5648-51B RED GREASE 111 GREASE LEFT SIDE VIEW SEE NOTE 2 RIGHT SIDE VIEW Assembly Drawings & Parts Lists Drive train assembly 163 Assembly Drawings & Parts Lists Drive train assembly – parts list Ref. # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part Number See following drawing G6000931 G6000717 G6000049 See note 2 G6001599 G6000053 G6000055 G6000056 G6000058 G6000059 G6000043 See note 1 G6001459 G6000051 G6000057 G6000075 G6000902 G6000072 See note 2 21 22 23 24 26 G6000063 See note 2 07020STP00 G6000791 036LT24200 27 28 30 See note 1 0391331800 G60001223 Description Assembly Clutch Extrusion Main Assy Right End Plate Plate Motor Mount Motor Stepper 7.5 Degree Pot Position 10K, 20% Bushing .19 ID × .25 Delron Rod, Guide, Precision Thrust Bearing Washer Steel .438 × .125 × .031 Screw 4-40 × .62 PH Phillips Nut 4-40 Nylock Worm Leadscrew Gear, Worm Bushing, Leadscrew, Right Screw 6-20 × .5 FH Thread Form Screw, 2-56 × .19 FH SS Washer Brass .340 × .117 × .050 Washer, Teflon®, .312 × .093 × .010 Screw, 4-40 × .31 PH Phillips Shaft Driver Grease, STP Washer, Wave Spring, .490 × .326 × .010 Loctite® 242 Coupling, Worm E-Clip Washer, Teflon® Quantity 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 2 ea. 1 ea. 1 ea. 1 ea. 1 ea. 4 ea. 1 ea. 1 ea. 1 ea. 1 ea. 7 ea. 1 ea. 1 ea. 1 ea. 2 ea. 1 ea. 0.1 oz. 1 ea. 0.01 oz. 1 ea. 1 ea. A/R Notes: 1: Items 13 and 27 are bonded together to form a worm assembly, in older pumps these may appear as a single machined part. These items are available as a service subassembly part number G6001480, Worm/ Coupling Assembly - Service. 2: Items 22, 20, and 5 are available as a service subassembly part number G6000431, Motor Service Assembly - Service. 164 40-5648-51B Assembly Drawings & Parts Lists Clutch assembly RED GREASE RED GREASE RED GREASE Clutch assembly – parts list Ref. # 1 2 3 4 5 6 7 8 9 10 11 12 13 15 Part Number G6000099 G6000928 G6000929 G6000924 G6000905 G6000044 G6000045 G6000738 0391331800 G6000378 G6000063 G6000310 G6000749 G6000159 07020STP00 Description Carriage Clutch, Left Clutch, Right Cam, Clutch Plate, Carriage Spring, Clutch Tube Plunger Insulated Tube E-Clip Square Shaft (See note below) Screw 4-40 × .31 PH Phillips Nut, Nylock, 4-40, SS, Small Screw 4-40 × .18 FH SS Assembly, Plunger Cable Grease, STP Quantity 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 3 ea. 3 ea. 2 ea. 1 ea. 0.1 oz. Notes: In newer pumps, square shaft (item 9) is being superseded by SS Square Shaft, P/N G6000378. 40-5648-51B 165 Assembly Drawings & Parts Lists Accessories – parts list Poleclamp assembly 166 40-5648-51B Assembly Drawings & Parts Lists Poleclamp parts (Catalog number 3000PC) Ref. # 3 11 13 16 18 Part Number G6000284 G6000286 G6000774 G6001456 G6000345 Description Poleclamp “C” Bracket Poleclamp “L” Bracket Screw, #8-32 × ⁵/₁₆”, Pan Head with Washer, Stainless Knob, ½-13 × 2”, Stainless Screw, #4-40 × ⁵/₁₆”, Flat Head, Stainless Quantity 1 ea. 1 ea. 4 ea. 1 ea. 4 ea. Rotating poleclamp parts (Catalog number 3000RPC) Ref. # 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 Part Number G6000496 0502003100 G6000284 G6000499 0482004400 0502002400 G6000497 046L050200 G6000505 G6000538 G6000286 G6000774 G6000551 G6000104 G6001456 G6000288 G6000345 Description Mount, Rotor Rotating Shoulder Bushing Poleclamp “C” Bracket Screw, #8-32 × ⁷/₁₆ Flat Index Cam Compression Spring Rotor Base ¼-20 × .5 Button Head Hex Indexing Plunger ⅜-24 Thread Assy, Plate Back Poleclamp “L” Bracket Screw, #8-32 × ⁵/₁₆ PAN Head Phillips w/Washer Nylock SS Bracket, Poleclamp Stop Screw 4-40 × .25 BH Black Knob, ½-13 × 2”, Stainless #4 External Conical Tooth Lockwasher Screw, #4-40 × ⁵/₁₆, FH, Locking, SS Quantity 1 ea. 1 ea. 1 ea. 4 ea. 2 ea. 4 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 4 ea. 2 ea. 4 ea. 1 ea. 2 ea. 2 ea. Miscellaneous parts Part Number G6000329 G6000193 G6000330 G6000331 40-5648-51B Description AC Line Cord, North American, Class II AC Line Cord, North American 3-Wire AC Line Cord, United Kingdom, Class II AC Line Cord, Continental European, Class II Quantity 1 ea. 1 ea. 1 ea. 1 ea. 167 Assembly Drawings & Parts Lists Calibration & repair – parts list Medfusion™ 3000 series calibration kit The Biomed Medfusion™ 3000 Series Calibration Kit contains the tools necessary for performing the periodic maintenance and calibration of the Medfusion™ 3000 Series pumps. Order kit number 3000CAL. This kit contains the following items : • • • 1 ea. − Small Calibration Slug, G6000216 1 ea. − Large Calibration Slug, G6000215 1 ea. − Analog Force Gauge, G6000294 Other tools & equipment required to service Medfusion™ 3000 series pumps The following tools are necessary for performing the maintenance, parts replacement, and diagnosis of the Medfusion™ 3000 Series pumps. • • • • • • • • • 168 1 ea. − 50 or 60cc syringe (see Operations Manual for list of acceptable types) 1 ea. − Medium bore tubing set, Smiths Medical 53-60-225 or equivalent 1 ea. − 3 Way Stopcock 1 ea. − Torque Screwdriver with #1 Phillips bit, #0 Flat bit, & 2.5mm Hex bit 1 ea. − ³/₁₆” nut driver 1 ea. − ¼” open end wrench or nut driver 1 ea. − .002” shim or feeler gauge 1 ea. − Pliers, standard & needle nose 1 ea. - Calipers 40-5648-51B Assembly Drawings & Parts Lists Notes _____________________________________________ _____________________________________________ _____________________________________________ 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_____________________________________________ _____________________________________________ _____________________________________________ _____________________________________________ _____________________________________________ _____________________________________________ _____________________________________________ _____________________________________________ _____________________________________________ _____________________________________________ 170 40-5648-51B Index Index A Accessories 67, 166 AC input assembly 79, 80 Removing 79 Replacing 79 Verifying 80 AC line leakage test 9, 12, 17, 22 AC Power 4, 16, 75 AC power detection description 49 AC power input & power supply board 30, 79 AC power supply 79 Removing 79 Replacing 79 Verifying 79 Adjust contrast (display) 105 Adjust contrast (voltage) setting 7, 65, 96, 105 Alarm history 72 Alarm message 9, 53 Alarms / alerts 10, 53, 60, 65 High priority 11, 53 Limit priority 11, 53 Low priority 11, 53 Medium priority 11, 53 System failure 12, 29, 59, 61 system fault 27 Always on supply 38 Analog supply 33, 40, 61, 71 Analog to digital converter 32, 33, 35, 63, 70, 71 Annual maintenance 19 Asembly, clutch 84, 165 Assembly, barrel clamp 82, 83, 84, 88, 90, 91, 108, 159, 160, 162 Assembly, case bottom 80, 108, 153, 154, 155 Assembly, case top without plunger 157, 158, 159 Assembly, case top with plunger 153, 155, 157 Assembly, drive train 82, 159, 163, 164 Assembly drawings 3, 151 Audio test 69 B Backlight 6, 11, 43, 82, 86, 87, 88, 108, 159 Removing 86 Replacing 87 Supply 41 40-5648-51B Backup audio buzzer 9, 38, 39 Backup super capacitor 9, 38 Barrel clamp 4, 19, 27, 54 Assembly 82, 83, 84, 88, 90, 91, 108, 159, 161, 162 Body 88 Head 88, 159 Barrel clamp body 88 Removal 88 Replacement 89 Barrel clamp head 88 Removal 88 Replacement 88 Verifying 88 Battery 6, 10, 11, 17, 30, 52, 54, 56, 62, 65, 77, 153 Calibration 24 Charger 51, 52 Compartment 76 gauge 9, 51, 52 Schematic 143 Maintenance 24 Management 51, 145 Monitoring status 70 Replacing 25, 75, 77, 108 Requirements 25 Verifying 77 Switchover 52 Battery board 52 Battery gauge 9, 30, 51, 52, 143 Biomed menu Accessing 68 Calibration 10, 68, 95 Calibrate (syringe) size and position 96, 97 Size sensor 20, 29 Calibrate force sensor 96, 100 Calibrate plunger position sensor 21, 96, 102 Calibrate pressure sensor 96, 102 Exit calibration without saving changes 107 Diagnostics 10, 68, 69, 70 Audio test 69 Display test 69 Drive train test 70 Indicator test 69 Keypad test 70 Monitor 6811 a2d group1 71 Monitor 6811 A2D group2 71 Monitor a2d selftest 71 Monitor analog sensors 70 Monitor digital sensors 70 171 Index Motor drive test 71 major options 7 Set language 69, 73 Understanding 7 Update firmware 69, 73 Utilities 69 Set/view last (or next) PM date 71 Set time & date 72 View alarm history 72 View infusion history 72 View service data 72 View software CRCs & view software versions 72 View EEPROM size 72 Bottom housing. See Case Bottom assembly C Calendar clock. See Clock, real time Calibrate (syringe) size and position 96, 97 Calibrate force sensor 96, 100 Calibrate plunger position sensor 96, 102 sensor check 21 Calibrate pressure sensor 96, 102 Calibrating the battery. See Battery Calibration and adjustment 95 Verification 20 Calibration kit 15, 95 Calibration menu 68, 95 Adjust contrast (display) 105 Calibrate (syringe) size and position 96, 97 Size sensor 20, 29 Calibrate force sensor 96, 100 Force sensor check 20 Calibrate plunger position sensor 96, 102 Check 21 Calibrate pressure sensor 96, 102 Exit calibration without saving changes 107 Case bottom assembly 80, 108, 153, 154, 155 Removing 80 Replacing 80 Case top without plunger assembly 157, 158, 159 Case top with plunger assembly 153, 155, 157 Charge detector (battery) 51, 52 Cleaning and care 18 Cleaning cautions 18 Clock, real time 10, 29, 33, 38, 60, 64, 72 Closing the pump 76 Closing the pump housing 76 Clutch assembly 84, 165 172 Controlling motor functions 27 CPI (Capacity Inaccurate), battery 10, 24 D Data input / output to LCD 43 DC power converter 29 DC power input jack 30 DC to DC converter 40 Depleted battery monitor 10, 52 Diagnostics menu 10, 69 Audio test 69 Display test 69 Drive train test 70 Indicator test 69 Keypad test 70 Monitor 6811 a2d group1 71 Monitor 6811 A2D group2 71 Monitor a2d selftest 71 Monitor analog sensors 70 Monitor battery status 70 Monitor digital sensors 70 Motor drive test 71 Digital to analog converter 32, 33, 35 Display. See LCD Display test 69 Drive train assembly 82, 159, 163, 164 Test 70 Drive train test 70 E Ear sensor. See Syringe flange sensor EEPROM. See Serial EEPROM ESD (Electrostatic Discharge) 1, 15, 75 ESD warning 8 Exit calibration without saving changes 107 Expansion port # 1 36 Expansion port # 2 37 External DC power conditioning / detection 50 F Flash memory 11, 34, 62 Reprogramming 34 Force preamplifier function 47 Force sensing interface 47 Force sensor check 20 Front panel interface 42 40-5648-51B Index G Glossary 9 Graphical display circuit board 29 Graphic display interface 43, 123 H High priority 11, 53 I I/O port expansion 36 Indicator test 69 Infrared receiver 50 Infrared serial data port 11, 50 Infrared transceiver 34 Infrared transmitter 50 Infusion Class 4 8, 11 Infusion Class 5 8, 11 Infusion history 72 Interconnect printed circuit board 11, 29, 78, 108, 155 Assembly drawing 147, 148 Removing 78 Replacing 78 Verifying 78 Schematic 49, 144 IPX3 11 K Keypad 4, 5, 19, 29, 42, 61, 65, 66, 108, 120, 159 Removing 87 Replacing 88 Keypad test 11, 70 L LCD 4, 86, 108, 123, 159 Adjust contrast 105 Backlight 6, 11, 43, 86 Supply 41 Removing 86 Replacing 86 Verifying 87 LED drive circuit 42 LMD (Last Measured Discharge), battery 10, 11 Logic core 28, 116 Logic kernel 31 Schematic 112 Logic supply 40, 63 40-5648-51B Low priority 11, 53 M Main microprocessor 28, 31 Main microprocessor interface 31 Main printed circuit board 28, 108, 159 Assembly drawing 131 Removing 81 Replacing 81 Schematic 31, 112 Maintenance, Annual 19 Maintenance, battery 24 Maintenance, periodic 17 maintenance tools 15 Medium priority 11, 53 Monitor 6811 a2d group1 71 Monitor 6811 A2D group2 71 Monitor a2d selftest 71 Monitor analog sensors 70 Monitor battery status 70 Monitor digital sensors 70 Motor current detector 36, 44 Motor current regulators 40, 44 Motor drive description 44 Motor drive test 21, 71 Motor rotation sensor 12, 27, 29 Motor speed detection 45 Motor supply 40, 71 N Negative supply 41 NiCad battery pack 30 NiMH battery pack 30 Nominal voltage 52 O Opening the pump housing 76 Overview of operation 27 P Parts replacement 75 Periodic maintenance 17 Plunger (driver) travel sensor 29, 35, 46 Plunger flipper sensor 48 Plunger force sensor 30, 62, 108, 157 Calibrate 96, 100 Removal 93 173 Index Replacement 93 Plunger loaded sensor 30 Plunger position sensor 46, 63 Calibrate 96, 97, 102 Test 21 Plunger printed circuit board 12, 30, 108, 157 Assembly drawing 141 Removal 92 Replacement 93 Schematic 47, 139 Power control 31, 34, 38, 116, 144 Always on 38 backup audio buzzer 9, 38 Backup super capacitor 9, 38 System reset 39 Power management 39 Power OFF state 32, 39 Power ON state 13, 32, 39 Power supply PCB 79, 155 Removing 79 Replacing 79 Verifying 79 Power switch interface 42 Problem solving 53. See also Troubleshooting Programming flash memory 34 Pump assembly 152 Closing the pump housing 76 Opening the pump housing 76 Pump cleaning. See Cleaning and care Pump design description 28 Pump returns. See Returning a pump for repair PWM current references 44 R Real time clock. See Clock, real time Rechargeable battery pack 30 Removing AC input module assembly 79 Replacing 79 Removing AC power supply 79 Replacing 79 Removing LCD and/or backlight assembly 86 Replacing 86 Removing the bottom housing 80 Replacing 80 Removing the keypad 87 Replacing 88 Removing the main board 81 Replacing 81 174 Requirements for battery pack replacement 25 Returning a pump for repair 67 S Safety Class II, Type CF equipment 9 Screen. See Display Serial EEPROM 12, 34, 45, 64 Service address. See Returning a pump for repair Set/view last (or next) PM date 71 Set language 69, 73 Set time & date 72 Severely depleted battery monitor 52 Shallow discharge (CPI) record 24 Speaker 12, 28, 30, 32, 33, 36, 78, 108, 155 Detect 71 Drive 129 Removal 78 Replacement 78 Verifying 78 Speaker control 46 Speaker detect 71 Speaker drive description 46 Speaker test 47, 65, 69 Standard cleaning. See Cleaning and care Static random access memory 34 Stepper motor 12, 27, 28, 29, 44, 63, 64 Symbol definitions 8 Syringe ear sensor. See Syringe flange sensor Syringe flange sensor 28, 29, 54, 58, 70 Syringe size sensor 20, 29 Syringe size sensing 35, 45 Description 45 System Failure 12, 29, 59 T Theory of operation 27 Time of day clock. See Clock, real time Troubleshooting 65, 68 U Update firmware 69, 73 Utilities Menu 69, 71 Set/view last (or next) PM date 71 Set time and date 72 View alarm history 72 View EEPROM size 72 View infusion history 72 40-5648-51B Index View service data 72 View software CRCs & view software versions 72 V Verify AC power supply function 79 Verifying AC input assembly module function 80 Verifying battery function after new battery replacement 77 Verify interconnect board function 78 Verify LCD & backlight assembly function 87 View alarm history 72 View calibration data 96, 106 View EEPROM size 72 View infusion history 72 View service data 72 View software CRCs & view software versions 72 W Watchdog 36, 39, 61 Alarm 9, 37, 39, 44 Circuit 13, 29 40-5648-51B 175 Index 176 40-5648-51B Smiths Medical MD, Inc. St. Paul, MN 55112 USA 1 800.848.1757 (USA), 1 651.633.2556 www.smiths-medical.com 2 Smiths Medical International Ltd. WD24 4LG, UK Tel. +44 (0)1923 246434 Australian Representative: Smiths Medical Australasia Pty. Ltd. 61 Brandl Street Eight Mile Plains, QLD 4113, Australia. Tel: +61 (0)7 3340 1300 Medfusion, PharmGuard and the Smiths Medical design mark are trademarks of the Smiths Medical family of companies. The symbol trademark is registered in the U.S. Patent and Trademark Office and certain other countries. ® indicates the All other names and marks are trademarks, tradenames, or service marks of their respective owners. U.S. and foreign patents pending. © 2008 Smiths Medical family of companies. All rights reserved. 2008-03 40-5648-51B s