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Medfusion-3500-Technical-Manual

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1. Top Side R14 R3 L2 5 2 C19 FB eel x ol 5 8 5 4 819 C20 dh Q6 R15 R10 db R27 R26 co J2 R26 R9 R18 Ler v dh Q C9 OF p4 R5 A R17 U5 dp 5 D12 C10 L1 JA 9 N R28 55 pli R29 811 Ils i 7 011 rg a 910 a R6 2 3 C6 4 820 C5 011 gt 51 z 5 e F57 N 17 zc Ros rin R23 Bottom Side 15 D1 U 4 1 x Lae CW 40 5648 51 147 Schematics amp PCB Assemblies Interconnect board assembly parts list 148 QTY REF Designator Package Value Part Spec 1 7 CLC2 CI4CI5 C16 C17 C19 1206W 0 1UF CAPACITOR 50V X7R 10 1206 GMC31X7R10
2. R86 e R145 ag R34 R29 8 8174 n2 R25 L 812 me 33 cer uH 2 R7 C40 R22 de Je R105 8102 C20 R70 Th C18 FBI R27 ge C108 C120 E 1 R175 z C151 R44 C82 R69 R71 864 R57 I e g R39 C74 R31 154 R40 des C33 cs R66 R82 13 185 de R125 R60 R65 e Im E ma 859 598 872 842 C153 R30 R58 C103 ES d ds R17 Gr EL mna din an FBIS C39 Rz C160 R108 m C 662 R32 FB10 m4 157 Bie C122 065 9155 R162 1109 8129 eus R178 8134 816 Rize LBZ C56 159 mzc dep ee R149 1179 tsa 667 95 Ciel C55 R35 mag 8150 8151 R92 cao 676 628 R147 R26 me 59 29 lt 8173 ee m Ln
3. 48027 HLJ ASL ni ON 12 DANS XldS 21901 wz YU 5 1 yerzenz V4 AYSO 2303 cad 01 LO WHO O Z 0 6 WHOX6 vz 68 0 8 94 34027 WW 4 S Dum 984 1531 USNS 35803 9 v MM 784 WPa JANI SYSNS YI NNId 4 INO LUSNS H35N TId c en INO CUSNS H3ON TId 6 1nO dWV3ud 32804 i N X3 USNS 32904 MAU Cf 284 9 015 2 i z T aD Y z cn 96 S yo 2 22 AldS 53NA 5 DANS en AldS 21901 c 2 Q 140 Schematics amp PCB Assemblies Plunger Board Assembly Drawing Top Side Bottom Side 40 5648 51 141 Schematics amp PCB Assemblies Plunger Board Assembly Parts list QTY REF Designator Package Value Part Spec 1 12 Cl C2 C3 C4 C5 C6 C9 C10 C11 0603 470PF CERAMIC 50V NPO 2 0603 C12 C13 C14 GMC10CG471G50NT CAL CHIP 2 1 C7 TANT_A 1U CAPACITOR 16V TANT 20 SMT 5 CAL CHIP TAJA105MOI6R AVX 3 1 C8 1206 0 1UF CAPACITOR 50V X7R 1096 1206 GMC31X7R104K50NT CAL CHIP 12065C104KAT2A AVX 4 5 1 FB2 FB4 FB5 FB6 0603 BLM11A102SGPT MURATA ERIE 5 1 JA A4PINSMTHDR 90814 0004 MOLEX WBOSS 6 1 J2 11PIN_1_ B11B ZR SM3 TE JST 5MMSMTHDR 7 1 Ql SOT23 MMBT2222ALT1 ON SEMICON DUCTO
4. 778 Seu amp SED 5 ZI I 75 S g a 5 p e 2 899 N 5 2 3 5 688 i8 22 a 015 m 06H est 765 ce 88H N ore xa g m 25 5 165 883 dg 75 9 gt 155 82 64 m 8 A 825 25 995 6r 2 S 5 e 9 o 9 gt in U e 5 984 oo 999 5 alls 5 elu priy 5 584 983 8 5 m 9 665 EIE 924 gt 798 085 L2 EL B 5 5 184 953 15 2h m SSH 5 Ta 682 j pity 915 8 399 52 15 8 749 a Z 8115 S 2 99 N 55 55 eu a 6519 ce l rem 3 9 5 sm perg 215 za lol IZID 5 919 8iH 115 755 a petu 68 s 058 psm 925 gt 5 965 9012 TRIS 8 1 t or er ER st 22 2 E219 S EA 2 Date Code Serial Assembly Rev m 40 5648 51C 131 Schematics amp PCB Assemblies Main Board Assembly Drawing Bottom Side
5. Ref Part Number Description Quantity 1 G6000716 Guide Barrel Clamp 1 ea 2 56000904 Rod Barrel Clamp 1 ea 4 G6000031 Barrel Clamp Slide 1 ea 5 G6000032 Spring Barrel Clamp 1 ea 6 G6000024 Spring 265 ID x 5 1 ea 7 G6000186 See note 1 Pot Size Sensor 10K 1 ea 8 G6000096 See note 1 Flex Cable Size Pot 1 ea 9 G6000121 Screw 2 x 18 Plastite 1 ea 11 0340IF1400 See note 1 030 DIA Spool Solder 0 01 oz 12 0382000000 Grease Silicon 111 0 1 07 13 G6000906 Screw 6 32 4 Truss Nylock 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 51C Assembly Drawings amp Parts Lists Drive train assembly a x mO 3SV3dD 034 10 LLL 163 40 5648 51C Assembly Drawings amp Parts Lists Drive train assembly parts list Ref Part Number Description Quantity 1 See following drawing Assembly Clutch 1 ea 2 G6000931 Extrusion Main 1 3 G6000717 Assy Right End Plate 1 ea 4 G6000049 Plate Motor Mount 1 ea 5 See note 2 Motor Stepper 7 5 Degree 1 ea 6 G6001599 Pot Position 10K 20 1 7 G6000053 Bushing 19 ID x 25 Delron 2 8 G6000055 Rod Guide Precision 1 ea 9 G6000056 Thrust Bearing 1 ea 10 G6000058 Washer Steel 438 x 125 x
6. 166 Poleclamip PANES E 167 Rotating poleelaenp 167 e aide rici goin Feld tet raa iria 167 Calibration amp repair parts DSL teneis 168 Medfusion 3000 series calibration kit 168 Other tools amp equipment required to service Medfusion 3000 series 168 Notes 169 40 5648 51C Important Information WARNING Read this entire manual before attempt ing and service or repair on a Medfusion 3000 Se ries 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 im portant safety information can be found in this sec tion 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 tech nician 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 e Attempts to repair or maintain a pump by person nel 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 procedur
7. pras tulerant 89 Renioval 89 TRG pCO 90 Pd E P 90 PREM 90 Replacements nnne 90 Tubing guide 90 90 PRG 91 Plunger case assembly 91 MISTS 5 91 Plgnper leef aote DUM DM iuda iE pe 91 i o c M 91 Replacement 91 Pl nger oeil 91 Disassembly ienesa 91 ssaa ER 91 Cam gear timing plate oae ptus 92 92 92 PHpper add Hipper g af 92 92 MET 92 Pl nger 92 Additional man 92 92 93 FOLGE rane 93 EEE eon tni rr 93 BReingval 93 00 CN 93 Left pl nger 94 Additional tools diee ddl emet 94 94 Replacement endo 94 Using Biomep gt CALIBRATION 95 BIOMED gt CALIBRATION 95 VI Calibration and Adjustment 95 Calibrate Syringe size and E 97 Performing both size amp position 97 Table of Contents Calibrat
8. 007 57105 7105 LUT Lean J Is AS AMdS 1901 i 981 1105 WX 01 LL ZOOLNZ A ING JO 9 gt gt UMOJ 2d XMSNn E LWX 3 A M ot 5 b 30D330DY wolf lt 9217504 Ave e WHON Of 40s VIVO Au3LlV8 6 1843 9909 QHZOdEJSWW Sus Y L IS ene 5080 dA Priva 60 0900908 sii 10 34001 5080 Tt ea anol 10 anol Ly T WHOYO HOLIMS z i gu LLvECZSWW Zig es P 007 TN AMO 1 4 20 AZL WNHDG E TNBIN 20 938 TIOHNYHL y Hd dc8 T3 0108 15 098 02 T INT UVAS 3345 40 5648 51 144 Schematics amp PCB Assemblies N51 ZN TIOHNYHL 70 8 01 9061 2 D4130 lt lt 5080 001 ldSzoLVLCWI8 81 SCNC LENT 5080 MOL L 6 0001 95 0105 lt L QN51 0153130 398 VH 9021 AOS 01 dno 0 10 XMS ABLLV8 X N51 L 22105 LI ZOOZNZ 80 loo 4 5080 MOL L re S dl WHOXO0Z 9t Interconnect Board Battery Management N51 INVL 0L ANC 8 041 080 t 00 anol A 5080
9. 21 Flow delivery accuracy test serere 22 AC line leakage test ioseph 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 25 40 5648 51C Table of Contents Overview of operation 27 Controlling motor Tanctiols u uiae ttr ior 27 Infusion control amp safety functions 27 lll Theory of Operation 27 Pump design description 28 Logic core of Medfusion 3000 Series pumps 28 AH MI 28 Microprocessor 28 Watchdog circi 29 DG powet carere eterne treni 29 Re al time a dM 29 Graphical display circuit board LCD 29 Keypad seneesa 29 Plunger driver travel sensor aue eerte 29 Motor rotation SENSOT ess 4 nre ttr ener 29 Stepper rer 29 Syringe flange loaded sensor 29 Syringe SEI oils aai usine nidi debetis 29 Interconnect printed circuit 29 AC power input amp power supply board 30 DG power iles pari vet mittit Usi ui 30 lil C m
10. _ CLEAR BRCKSPRCE 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 81 28 15 52 54 SYSTEM ADVISORY BATTERY NOT WORKING TUD PRESSURE 5 TRAVEL POS 375 CNTS SYRINGE DIA 652 CNTS FORCE CHTS ANALOG SUPPLY 68 CHTS a T PREU ALARM NEST ALARMI 2887 04 04 07 19 25 SYSTEM ADVISORY BATTERY WORKING PUD amp B BaML TRAVEL POS 957 E F RCE ac ANALOG SUPPLV CNTS SYRINGE DIA 982 CNTS PREU ALARM 72 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 ap proximately 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 STOP INFUSION 2887 83 28 12 11 45 pageh RATE H BBBB TRAVEL POS 3
11. 70 PRESS lt BACK gt STOP SYRINGE PLUNGER SENSOR TRUE SYRINGE EAR SENSOR TRUE MOTOR RATE SENSOR SAS 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 PRESS lt BACK gt TO STOP MA HOURS TMPGG BxBB FL6S1 ACITY 8 4 RENT 1588 8 MA HOURS FLGS2 Axa Drive TRAIN TEST This feature is for factory engineering use gt 5 screen 2 of 2 Within Biomed Diagnostics the following selections are available second of two screens Use the number buttons to select the test PRESS THE NUMBER TO SELECT THE MODE 1 MOTOR DRIVE TEST 2 MONITOR 820 SELT TEST 4 MONITOR 6811 A20 MONITOR 6811 A20 2 ss BEGINNING PRESS THE NUMBER TO SELECT Mi MOTOR DRIVE TEST MONITOR 20 SELT TEST MONITOR 6811 20 Gi MONITOR 6811 R2D 2 40 5648 51C Motor Drive Test The MOTOR DRIVE TEST allows running the motor without any alarms position rotation etc being ac tive Only use the SET MOTOR STEP PERIOD feature Enter a motor ste
12. 151 COUNTS MIN VALUE DATA 198 COUNTS 11 SETUP LOW STANDARD PRESS lt CONTINUE gt WHEN READY VALUE DATA 200 COUNTS PLUNGERR POS DATA 559 COUNTS MIN VALUE DATA 188 COUNTS 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 VALUE DATA 175 COUNTS PLUNGER POS 125 COUNTS MIN VALUE DATA 75 COUNTS CONTINUE SETUP HIGH STANDARD PRESS lt CONTINUE gt WHEN READY MAX VALUE DATA 950 COUNTS PLUNGER POS 981 COUNTS MIN VALUE DATA 850 COUNTS 102 40 5648 51 Calibration amp Adjustment 4 You return to the CALIBRATION menu You may calibrate another mode choose SAVE CHANGES AND EXIT to exit calibration or press to return to the BIOMED menu 40 5648 51C 103 Calibration amp Adjustment Calibrate syringe size sensor 1 104 From the CALIBRATION menu choose CAL Sy RINGE SIZE SENSOR PRESS THE NUMBER SELECT THE MODE 1 CAL SIZE AND POSITION 5 CAL SYRINGE SIZE SENSOR CAL FORCE SENSOR 6 ADJUST CONTRAST 4 CAL PRESSURE SENSOR 7 UIEU CALIBRATION DATA CAL PLUNGER POSITION 8 SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT FA CAL SIZE AND POSITION
13. 901 34 7 8r 919 105 Bu 5080 QN51 WX 01 MOL L L ide Tm WHOYO L usos aol gt 1D OBINGL 6080 6080 MOL L ASL 135340 20 80 6 WHOL OSLVSOSOBODA Ads SoA SISAL Main Board Pressure Sens 6 14 4 USNS NE 135 5 3130 135 23130 113 384055484 N51 90ZL 105 01 2105 1019041 70 10181 5080 001 AdSZOLVLZW18 181 AS KMS 20501 5080 ASL ASS OSLVSOSO80 A OLSAL USNS 135 40 5648 51 128 Schematics amp PCB Assemblies Main Board Speaker Drive 9941 5 ald dWY dad 3345 gt gt 10313433395 C N51 5080 Movi 115415 1931 45 ASNAS WHOMO L 57105 193307 8377345 198 840551 007 96240 0041 9661 Ua N51 9 54 02 22105 ane cii LLWLGOSWW yurooc 16 L MOL L L 0 WHONO LS 827 01 WHOXC Oy 8 1919 T d pA 1884 140001 5080 WX OL MOL L FTH 0 1 _ ut 692 F 80S WHON0 C 5
14. Calibrate Plunger Position Sensor Performs adjustment of plunger position sensor settings Calibrate Syringe Size Sensor Performs adjustment of syringe size sensor setting Adjust Contrast Varies the onscreen contrast of the LCD The pump is shipped with a factory average default You may set it above or below for com fortable viewing View Calibration Data Displays the current calibration data settings Save Changes and Exit Saves the new calibration settings and then returns to the main BIOMED menu 96 40 5648 51C Calibration amp 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 assem bly and measures the plunger head position allowing the software to determine the empty position and plunger head travel Performing both size amp position calibration 1 From the CALIBRATION Menu use the number buttons to choose CAL SIZE AND POSITION PRESS THE NUMBER TO SELECT THE MODE CAL SIZE AND POSITION 5 CAL SYRINGE SIZE SENSOR 2 CAL FORCE SENSOR 6 ADJUST CONTRAST 5 CAL PRESSURE SENSOR 7 VIEW CALIBRATION DATA 4 CAL PLUNGER POSITION 8
15. SET_IN_SNSR_ENBL PB6 Set to logic low to enable the set in detector to sense the pressure cell being installed SYRINGE EAR SNSR _ PB5 Set to logic high to enable the syringe detector to sense the syringe ENBL flange ears being installed PLUNGER SNSRS ENBL PB4 Set to logic high to enable the plunger detectors to sense the plunger flippers being properly engaged MOTION_SNSR_ENBL PB3 Set to logic high to enable the motion sensor monitoring the motor speed FORCE SNSR TEST PB2 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 operat ing properly PRESSURE SNSR TEST 1 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 LCD_RESET PBO Allows the main processor to reset the LCD display independently of other system devices The reset signal is active low MTR_PHB_DIR PC7 Controls the direction phase of motor current in coil B of the stepper motor PHB PUG Set to logic low to enable motor current in coil MTR_PHA_DIR PC5 Controls the direction phase of motor current in coil of the stepper motor MTR_PHA_ENBL PC4 Set to logic low to enable motor current in coil KEYPAD SEL Control signal to select row 4 of the four row keypad matrix To select the row requires a l
16. tod 0 9601 50 d3H no WODI i vivd 11 8 DDA 9021 M8 L 9660 30665 94 xAH311V8 MOTA 9021 AOS 9601 nuo d3Qv3H 4193130 358VHD ef 105 V IWS oer AOL AOS 1NYL 02 S Z10S INVL 02 WX KOI E 2185 r7 ALO EZLO SYW 002 2 c Ld QV31 504 LNOD 143 40 5648 51 Interconnect Board Schematic Interconnect Board Power Control Schematics amp PCB Assemblies ens ano1 lunn oswWW A a 2 5 5 0006 79 13539 m am conn 40103130 910 5080 MOL L L dL WHOMO L 628 iio aN NL 7105 7105 a TONE TIOHNMHL i 59 9100 20 t t t 5080 50 A05 qoum JNS 01 vor into 009 pA 090080 9 Ej 5080 7105 007 7105 Hd e 05119080809 Dun mw ma 0 1 gt gt 4NO XMS RBLLVG E id 5080 yu 001 anol es udo
17. 139 9379395 JAC 834 345 vc 02 6L e 245 3OuVHD 81 15313Q 9 r SI 4 Viva 11 8 AuiLlvd MOTA ANTI VIVO LWX Wl Wl AS 2X3 USNS I3AVUL a LINO USNS 14 1 4 30 3 NOILISOd VHd AUG L f AYG YLW YLW VHd AUG YLW c L f 437709 dnoi vg a 323105 YIMOd 82d NIVW 35304 145 DANA 1531 545 32304 18 3 585 5 YJDNN Id CHSNS YFONN Id 1107 185 5 YADNN Id 170 dWVvddd 35301 u35NfYld 144 0102 1105 102 QVdA3M XMSYMd QVdA33 QVdA30 QVdA33 VAGA XISIVW A33 QVdA3 102 QVdA3M 102 QVdA34 05 dVvdA33 1003201 GVdA33 Q31 QVdA33 GQVdA3X Q31 5NINHVM QVdA39 Q3T NOlLQVD QVdA33 NOISQ3NI QVdA3 NOISQ3NI 1031 NOISNANT QVdA33 031 QVdA3 231 1358 123130 3 35NIHAS 3 83114 145 21501 18 3 YSNS YVJ 5 YOLDILIG HV3 35NIHAS YSNS 3215 YOLDILIG 3215 J NIYAS 40 5648 51 Schematics amp PCB Assemblies Main board schematics The following are the main board schematics if the Medfusion 3000 Ser
18. 16 LLCNEL 080 ALUM 021 311100 SC 0440551 WMdEZS HVVZNS Oo AS 14 2901 aT ide 81 ST 0 ET 5080 106 OL 1070 0740551 9001 AOS _ WX OL 5 2901 3020 ay viva VIVA 33319 0734 1 D1 TIOHNYHL 20 S0 1 06 031 LHDIDDVS 21 01 7140551 UMdSZLIHVPZNS un Pr 5080 MOL L S WHO30L 964 AS 45 21901 lt 19539 0169 5 b QNVWWOD Quia p ILIYM 34 30 b ALIYM ANYAI 5 0690 gt LO viva 0166 8 02116 123 40 5648 51 Schematics amp PCB Assemblies 40103130 1438402 3010 WE6EW1 Daa 1N3uufD WW 5080 MOL L 6 WHONOL 9819 AS 5 21901 Main Board Motor Drive W 6 WI1 0102 N51 ML L ZS WHOS O 9 u 5080 106 OdN 5 140001 5012 106 WX 9601 31 7070 60 9155968 QN51 AVHG 440 56141 90 Lum 5080 5080 5080 T8Hd YW 3SVHd A 0S 106 MOL L 65657 YX YLX OL L v1no 30100 30100 WHOYO 0C YW 805 9 9 OLY YLW 4191 I ZNbL
19. 390815 YIMOd 2 0105 31009 lt 1S3 aiouadns tr 6 2405 11 000 cao 105 007 7105 LI ZOOLNZ 0909 62405 80 80 002 11191608 674 6080 WHOYOOC 2005 864 007 LIT L6OIWW 60105 005 el 11171608 tq lt MOTA 8 lt 109130 85 109130 LL 8 lt 245 39uVH 8 40 5648 51C Schematics amp PCB Assemblies UNIT 9021 AIO JIVI S080 5080 MOL L 10S 5 705 WX 9601 WHOLT WHOYO0Z 1100 aNd e me tO c eios 5090 gt gt 109130 37719 0 MOL L 966 WHOXT 598 DOGHIIWM KK 105 1019041 200 AS AMS 21501 0105 LL C00 NC 10 Stldl SSNZ TIOHNYHL 837708 91729 90 711 21901 xu ISNS 437708 406 WX 9601 danto 61 Board Power Control Logic Continued 41 ZN OV AS 67106 60141 ZN n mde TIOHNYHL 5 1 90 201 MS1H 080 9021 5080 S Pri gs c e WHOXOCL 3120 WHOOOC 965 F tB 288 WHOYOOC LENZ pA 5105 ZN l BSNL LL ZOOZNZ Ddo 10 5080 MOL L 5080 133130 500HD1VM wy OL 158 WHONLY OV AS z R lt euis 900 07 9 9 aawuv 837708 lt lt e 2105 DNI
20. 1 99 DILO Md OV LL D3HG N51 S080 5080 9 295 dova 406 MOL L OdN 965 140001 ysl 61 31149437945 KC 0105 4617 134 334345 LL C00 NC Ej LEAL AS 145 2901 WHOL 7106 n 591 v 6 WHOO00C 9 1883 YIMOd 29 40 5648 51 Schematics amp PCB Assemblies Main Board DC DC Converter Continued IWS AST INVI 9601 09 1445 3AILVD3N 9 145 DINA AdS SOdA 144 5 341504 EL 1 DT EL LSVYLNOY D1 N51 ZOLN6 vn3s9gxvW INVI 9601 A Vfi3S98XVW INV 9601 19 lov LSLN6 AS AMS 21501 57105 LL ZOOLNC S080 udi AdS DINA 840551 1100 09996740 83 40 1 9 021 7716 v gm 9021 96 wxMi 7 ANLO 15 AS KMS 21901 Alddfs 1510 01 ND1 080 MOL L WHOY6 67 LELY 1510 02149 1101 50105 LanF1608XVW gt viva 608XVW 5 uo NOLVNIWHJ3I3Q V1VQ Ad311V8 AS 185 20501 13538 NO 83 0 AS 45 21901 40 5648 51C Schematics amp PCB Assemblies N51 ro 7 p 440001 moves 101509 08D egea WHOOSEY 190 0919 LLENOL 7 Eid in E dE M 1019041 oed
21. Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality be fore returning it to use 40 5648 51C AC power supply This section defines the steps for removing and replac ing the AC Power Supply for the Medfusion 3000 Series infusion pump Tools needed For this disassembly procedure you will need e Torque screwdriver with a Phillips head amp small flat blade 5mm open end wrench nut driver Always work at an electrostatic controlled work sta tion 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 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 ter minals 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 thread ed bosses with J1 in line with the AC input cable 2 Secure the board with 2 pan head screws Medfu sion 3500 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 42 Nm 3 Connect the AC In
22. LED Task TIMEOUT Software timing failure A transient failure may have occurred in the soft ware if problem recurs replace the main board Loaic Supply BGND Test Background self test measured an invalid range on logic supply voltage Use BIOMED gt DIAGNOSTICS to check the voltage Replace the main board if invalid voltage found MCU Power FAILURE Failure in self test of power strobe output port signal from the main pro cessor Replace the main board if problem recurs Monitor TASK TIMEOUT Software timing failure A transient failure may have occurred in the soft ware if problem recurs replace the main board Motor FAILED To Stop ERROR 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 gt 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 chang ing Replace the main board if sensor has failed Motor Nor RuNNING ERROR 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 Rate ERROR Motor sensor did not measure the correct rotation rate for the stepper motor Sensor on main board may have failed or the force sensor m
23. e 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 51C Theory of Operation 35 Theory of Operation I O port expansion U3 033 There are two 82C55 input output port devices provid ing the additional input output requirements for the microprocessor They are accessed through the I O chip selects 1_ 5 and PORT2_CS Expansion port 1 1 cs Signal name Port location Description TECT 2 5 PB7 A logic low enables accessing the 224 serial EEPROM PET_WATCHDOG PB6 A logic signal used as a handshake for indicating valid operational status to the auxiliary controller SUPERCAP TEST PB5 A logic high enables testing the super capacitor i e backup power source TOD CS PB4 A logic high enables accessing the time of day IC TOD WR ENBL PB3 A logic low enables writing data to the time of day IC SPEAKER ENVELOPE3 PB2 A logic high selects the audio envelope time constant of 35 millisec onds Refer to the Main Speaker Drive description section SPEAKER ENVELOPE2 A logic high selects the audio envelope time constant of 11 millisec onds Refer to the Main Speaker Drive description section SPEAKER ENVELOPEI PBO A
24. e UPDATE FIRMWARE to reprogram the pumps 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 gt CALIBRATION Within BIOMED gt CALIBRATION the following selec tions are available See the Calibration section of this manual for further details PRESS THE NUMBER TO SELECT THE MODE 1 CAL SIZE AND POSITION 5 CAL SYRINGE SIZE SENSOR 2 CAL FORCE SENSOR 6 ADJUST CONTRAST 3 CAL PRESSURE SENSOR T VIEW CALIBRATION DATA 4 CAL PLUNGER POSTITION 8 SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT FACAL SIZE AND POSITION RDJUST CONTRAST FA CAL FORCE SENSOR E VIEW CALIBRATION DATA BY CAL PLUNGER POSITION SAVE CHANGES AND EXIT GA CAL SYRINGE SIZE SENSOR gt Diacnostics screen 1 of 2 Within BIOMED gt DiaGnostics the following selec tions are available one of two screens Use the num ber buttons to select the test PRESS THE NUMBER TO SELECT THE MODE 1 AUDIO TEST 5 MONITOR ANALOG SENSORS 2 DISPLAY TEST 6 MONITOR DIGITAL SENSORS 3 INDICATOR TEST MONITOR BATTERY STATUS 4 KEYPAD TEST PRESS THE NUMBER TO SELECT TEST EA MONITOR ANALOG SENSORS FI DISPLAY TEST MONITOR DIGITAL SENSORS BY INDICATOR TEST MONITOR BATTERY STATUS GA K
25. o HiS WN Ws 5s 35885 191 5080 5080 5 S I 7 mre MOL L 5080 5 MOL L 105 LAVIS ANOD WO 376 39NhIAS SL 3 mi inch 9001 9198201 MOL L 5080 6 m i A960 I Wo Yeu 20141 L i ENISOFOPWI MOL L 5080 965 68 34055384 81 i ij T MOL L 5080 965 m You BL vL O 438 1014 gt 19607 VISNS Ildio anol SINS AOL WHOOCC 017 DOW INVI 07 5080 EL qN51 9001 AOS MOL L anol SO WAX 960L 1 di anol KIAS 901VNY INLO v8 Klds 5OTWNY 9001 mo 185 90WNV 5080 ZTO 8 006 410 fito KDO Ids 2 90 15 DT 00 32404 A DIA WX 401 50850 20100 1349 8 67 E 1145 21901 8 7 r1 FIENI HLW S 9Hd 0 0938 evaa NS a GU aN HHL FNS UNS 1 4 LNO 1531 GE H3ONVdX3 1904 145 w a 1188 9001 son ASC YX OL SOTWNY 11720 Old 3538 b 2 85 oad n LOQY HALIYM EL v E ANYAI t 514049 ILO viva quia Lv soo am ano ALX 01 0240551 MOL L S080 5 31100 MMdLpSOHVPZNS mom aav 437719 10 PL LL I MOL L 5080 965 K D3I3O IND LL 8 9
26. 9021 5080 106 106 WX 01 YOLOW 9 3SVHd WX 01 3 10 31100 901 AOS o m l WX 9601 YOLOW AS AldS 2901 WHOXO L 1100 805 9 orn P 5080 MOL L Mort 5 5080 0 1 ssid MUL t mo WHOS O anro D Rn sly lt 334 Q01V 8L SL S Zh 1941 5080 5080 5080 MOL L 4 106 MOL L 1 cca WX OL L WHOYO SL SISES6EV 31200 WHOX0 L Wi viu AVI 440 8100 4 YLW ae IW F 491 1 85 4 879 5080 VA NI s VAI YOLOW V 3SVHd MOS YOLOW YX 01 LX OL 4415 1070 30100 tt 011 19 LN AdS 8010 45 21901 MOL L 9080 sl Olly gud LW s MLW S AN 67105 TX WI S00H01VA LL Z S 3010 4015 N51 MOL L S080 L WHONZ Ob lt saul VHd YLW 9 5080 MOL L 968 WHOWOL 168 7114 21901 40 5648 51C 124 Schematics amp PCB Assemblies QN51 S080 MOL L 968 WHOX0L 8 4 S D3130 YVI 39N045 lt lt 145 A 9001 30123134 uV3 5 A0S ino 19 4L ENS Z 878 c 18N3 USNS gt gt 6080 EIN EOENST 5080 MOL L WHON66 gt oy 2105 5501 YO SLENSL CL
27. 9021 J ZHNOO0 91 145223 290 avoszoL MS AS 145 21501 WHOWOL ex 5080 5080 5 AOS Le ewiaoror OdN S aNd WHOYOL u AS 4145 21901 AS AldS 21501 ANNONO 15 5080 87145 AOS AOL 01 1 02 3n 100 ov YED lt 080 145 0 1 183 AS 145 21901 40 5648 51C 0 LdU INT 001 Schematics amp PCB Assemblies ED ILIUM cv ava anva ELS DH HALIM Main Board Logic Kernel Continued unsi 0 91 DNAN II 145 21901 7140551 uMdSCDHVYZNS 7641 0017 94055 9915554 1 AVG 30 aNd 57 08433 805 O 8 0801 097 106 250 5 _ gt OdN 5 1641 _ 1401 DA TANI 64 s D pM MOL L 3 0SIW 145 S wn p o LSIW 145 S 7 A OY AS AWG 30 AWIL 20D 145150 AS 1145 21901 NO 5 110433 0 8X OL WOuds4 TIYIS 1841 0140 8906 10706 i dosize i ANUS 2145 31901 AS 4145 91901 0 _ asn 10 UNAOODHYELNS 0 10 110 6 5521 84002 77 15 0002 50 10 AMOWAW 09 E 6 8Y HSVHH 31815 DA ELY viv AS 145 21901 lt 81 51 udavx
28. Medfusion 3000 Series Technical Service Manual Smiths medtcal Table of Contents i 40 5648 51C Table of Contents I Introduction 1 Important Information 1 1 AE 2 Contents of this manual 3 Authorized use of thus martial retrace 3 About the pump 4 Features and 4 Keypad closeup sinnsir 5 Understanding Biomed mode 7 Whatis 7 Authorized 7 Biomed software program major options 7 8 Glossary OF Technical Tei MS issenensis 9 Preventive Maintenance Planning 15 Biomed maintenance tools 15 Using angsana 15 Electrostatic controlled workstation 15 Scheduled Maintenance 15 Service warnings tenente eerte 16 Periodic maintenance 17 Installation quick check out sess 17 Quick check out 17 Cleaning and CATS 18 Standard cleaning of Medfusion 3000 series pumps 18 Cleaning 18 Mandatory annual maintenance testing 19 General T 19 Powert u p test 19 Calibration verific tiO Nis bna lues 20 Force sensor Check teret ee 20 Syringe size sensor Checks vcnse nisiut uas 20 Plunger position sensor check 21 Motor drive amp occlusion operational test
29. tr 9 eL 2 40 5648 51C Schematics amp PCB Assemblies Main Board Logic Kernel Continued 1 0 PORT DECODER Sm gt gt LOD_CS 13 2 6 23 LOGIC_SPLY_5V TSSOP16 1 0 PORT EXPANDER 1 U33 14 MTR CURRENT DETECT EEPROMD_CS 3 12 PWR_SW_MCU on PET_WATCHDOG 6 20 2 e SUPERCAP_TEST 6 ENBLE 1003 FA SPEAKER ENVELOPES 19 SAPIEN e Onp379 Or SPEAKER_ENVELOPE1 19 5 13 BFRD_DATA 0 7 Ors WARNING_LED_ON 11 ee d pum TE 1 54 aw 01 INFUSING _LEDR_ON 10 DIRIGE ea D4 e CAUTION_LED_ON 10 3 5 13 EVALID_WRITE gt 05 ED WRITER 13 on LOCKOUT LED ONE 11 2 BERD_XTAL gt LOGIC SPLY 5V 7 ST 91538 31 LOND a 32 RESET LOGIC_SPLY_5V 582055A 7 4APLCC LGND 3 5 EVALID_READ gt 9 8 gt gt LCD COMMAND 13 3 5 13 EVALID_WRITE gt Og 5 2 5 RESET gt TSSOP 14 5 BADDR1 15 BADDRO 5 ghee gt m gt gt BFRD_EVALID_READ 13 SN74AHC125PWR 1550214 40 5648 51C Schematics amp PCB Assemblies Main Board Logic Kernel Continued 8 1801 87709107185 K 061 5 1 vava sogo s
30. 0 7 je 5080 5080 5080 5080 5080 5080 5080 106 NOS 106 106 106 16 106 5080 sm 1031 ONISNANI H OdN 966 OdN 966 OdN 6 OdN 966 OdN 965 OdN 966 OdN 966 OdN 96 OdN 96 OdN 965 OdN 96 C080 60105 140001 140001 340001 140001 390001 140001 140001 140001 140001 140001 140001 MOL L 5 1019041 ll 0710 6 Sel 10 PEL 80 LEL WHOO9L 21 0102 QVdA3 1009201 LL ZL L10 QVdA3 LIT 11 71 cL 09 Hie TAYAAN m qua H B 31 5NNIVMCQVaAD LL 71 CON QVI H EL TD 5080 ZL MONdVdAgY ee MOL L 5 21 S10 7 0 0 Vd ZL 10 QvdA3 t 11 NOISTHNI c GIT XYOMLIN QVdA3U CL 5102 QVdA3 0 S080 S080 5080 5080 AOS 105 105 A0S OdN 965 OdN 965 OdN 965 OdN 966 N51 340001 390001 390001 140001 Syl 9 L LEL 015 5080 AOL 105 er sogo 001 50 65 842 145001001840 1868 LATS NK zn 145 21901 Main Board Keypad Interface 40 5648 51C 120 Schematics amp PCB Assemblies 01031 1009207 lt lt 62106 5080 MOL L 5 MD WHOOSL 1624 CEENLL AMS 091 11090119 QND1 ZN 5 AIT ava 01 5080 ZN MOL L 0105 m
31. 031 1 ea 11 G6000059 Screw 4 40 x 62 PH Phillips 1 ea 12 G6000043 Nut 4 40 Nylock 4 ea 13 See note 1 Worm 1 ea 14 G6001459 Leadscrew 1 ea 15 G6000051 Gear Worm 1 ea 16 G6000057 Bushing Leadscrew Right 1 ea 17 G6000075 Screw 6 20 x 5 FH Thread Form 7 ea 18 G6000902 Screw 2 56 x 19 FH SS 1 ea 19 G6000072 Washer Brass 340 x 117 x 050 1 ea 20 See note 2 Washer Teflon 312 x 093 x 010 1 21 G6000063 Screw 4 40 x 31 PH Phillips 2 ea 22 See note 2 Shaft Driver 1 ea 23 070205 00 Grease STP 0 1 oz 24 G6000791 Washer Wave Spring 490 x 326 x 010 1 ea 26 036LT24200 Loctite 242 0 01 oz 27 See note 1 Coupling Worm 1 28 0391331800 E Clip 1 ea 30 G60001223 Washer Teflon AIR 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 subas sembly part number G6000431 Motor Service Assem bly Service 164 40 5648 51C Assembly Drawings amp Parts Lists Clutch assembly RED GREASE RED GREASE RED GREASE 9 Clutch assembly parts list Ref Part Number Description Quantity 1 G6000099 Carriage 1 2 G6000928 Clutch Left 1 ea 3 G6000929 Clutch Right 1 ea 4 G6000924 Cam Clutch 1 ea 5 G600
32. 82 R7 pun R132 29 ga ga R49 d R49 R81 Risa R160 Rss C84 8157 8139 52 c 1 3 8142 8116 cun C134 C61 mis R6 ca 6138 cma R4 ss 2 c136 3 139 Ra Gi cos R5 R61 mi C3 897 81 aa E R120 Ea 187 C63 5 pss 1 819 8155 R126 5164 R24 65 8158 Th C129 Jes R17 5 R121 E R169 132 40 5648 51C Main Board Assembly Parts list Schematics amp PCB Assemblies QTY REF Designator Package Value Part Spec 1 36 Cl C9 C16 C19 C24 C39 C41 C56 1206W 0 1UF CAPACITOR 50V X7R 10 C57 C73 C77 C78 C80 C81 C84 C87 1206 GMC31X7R104K50NT C89 C95 C96 C97 C98 C99 C104 CAL CHIP 12065C104KAT2A C106 C108 C109 C110 C114 C115 AVX C117 C118 C120 C122 C130 C160 C161 2 8 C2 C29 C31 C35 C36 C46 C55 C83 0805W 047UF CAPACITOR 50V X7R 1096 0805 GMC21X7R473K50NT CAL CHIP 3 11 C33 C68 C71 C74 C82
33. C85 C93 1206W 0 22UF CAPACITOR 25V X7R 1096 C100 C101 C111 1206 GMC31X7R224K25NE CAL CHIP 12063C224KAT2A AVX 4 2 C4 C59 TANT D 100UF CAPACITOR 10V TANT 1096 SMT D TPSD107K010R0100 AVX T495D107K010AS KEMET 5 42 C5 C8 C10 C14 C17 C20 C22 C23 0805W 01UF CAPACITOR 50V X7R 1096 C27 C40 C42 C47 C48 C52 C54 C61 0805 GMC21X7R103K50NT C63 C64 C65 C66 C67 C72 C75 C76 CAL CHIP C79 C90 C94 C107 C112 C116 C119 C121 C123 C124 C125 C126 C128 C129 C151 C152 C153 6 1 6 0805W 10PF CAPACITOR 50V NPO 596 0805 GMC21CG100J50NT CAL CHIP 7 pe SUPERCAP 1F CAPACITOR 5 5V ELECT 20 RADIAL FYD0H105Z TOKIN 8 27 C12 C127 0805W 27PF CAPACITOR 50V NPO 5 0805 GMC21CG270J50NT CAL CHIP 9 9 C15 C18 C25 C26 C30 C34 C43 TANT_B 10UF CAPACITOR 10V TANT 20 C69 SMT_B TCMIA106BT CAL CHIP TAJB106M010R AVX T491B106M010AS KEMET 10 pc 0805W 18PF CAPACITOR 50V NPO 5 0805 GMC21CG180J50NT CAL CHIP 11 2 28 C50 0805W 0047UF CAPACITOR 50V X7R 10 0805 GMC21X7R472K50NT CAL CHIP 12 2 C32 C88 TANT A 1UF CAPACITOR 16V TANT 2096 5 A TCMICIOSAT CAL CHIP TAJA105MO16R AVX 13 4 C37 C38 C44 C60 TANT_D 22UF CAPACITOR 25V TANT 10 SMT_D TPSD226M025R0200 AVX T495D226M025AS 14 2 C45 C49 SMT_8X10_8 220UF CAPACITOR 35V ELECT 20 RA DIAL NACZ221M35V8X10 8TR13 35VCV220GX SURGE COM PONENTS 40 5648 5
34. Item 8 ring terminal is secured at secondary side mounting post of power supply 155 Assembly Drawings amp Parts Lists Case top assembly w plunger 40 5648 51C 156 Case top assembly w plunger parts list See also plunger case left service assembly note 1 below Assembly Drawings amp Parts Lists Ref Part Number Description Quantity 1 G6000067 Mount Plunger Head 1 ea 2 G6000068 Force Sensor 1 3 G6000069 Plate Plunger Float 1 ea 4 G6000755 Case Left Plunger See note 1 1 ea 5 G6000071 Cam Gear Plunger 1 ea 6 G6000725 Flipper Plunger 2 ea 7 G6000074 Case Right Plunger 1 ea 8 G6000180 Assy PCB Plunger Tested Service 1 ea 9 G6000925 Timing Plate Left 1 10 G6000926 Push Block 1 ea 11 G6000085 Screw M4 x 12 Button Head 2 12 G6000086 Spring 21 OD x 1 5 2 13 G6000669 Lever Plunger 1 ea 14 G6000089 Gear Plunger Flipper 2 16 G6000087 Gear Plunger Lever 1 17 G6000082 Seal Flipper 2 18 G6000927 Timing Plate Right 1 ea 19 G6000083 Seal Lever 1 ea 20 G6000103 Screw 4 40 x 78 Pan Phil SS l ea 21 G6000110 Pin Dowel 1 ea 22 G6000105 Screw 4 40 x 7 15 Pan Phil SS 2 ea 23 G6000749 Screw 4 40 x 18 FH SS 2 ea 25 G6000090 Seal Plunger Case 1 ea 26 G6000474 Washer Flat 44 SS l ea 27 G6000693 Screw Pan Phil 4 40 1 4 SS 2 28 See
35. Opening the pump housing 1 Unplug the AC power cord also disconnect any external DC power if in use 2 Ifthe 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 compart ment and disconnect its cable from the intercon nect 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 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 intercon nect 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 back side of the housing Align them and close the top amp bottom housings together 5 Screw in the 2 pan head screws which connect the 76 top amp bottom housings Torque these screws to 60 in oz 0 42 Nm 6 Orient the battery p
36. Plunger Printed Circuit Board Safety Class II Type CF Equipment Serial EEPROM Set View Last Next PM Date Stepper Motor System Failure Primary Speaker Update Firmware View Alarm History View Infusion History View Software CRCs View Software Versions A optical sensor on the main board senses the movement of the motor worm shaft The Neglected Pump or user call back alarm is a low priority alert which simply reminds you to finish what you started Once you begin programming any infusion the pump expects you to continue until programming is complete 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 occlu sion 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 memo ry which is used on the main board to store calibration configuration and infu sion history This allows viewing the last or Next on V4 pumps recorded preventive mainte nance date This is where you also set the date when completing annual preventive maintenance A sequentially steppin
37. Service old style barrel clamp head and no keyway G6000737 Case Top 3500 Service new style bar rel clamp with keyway For Medfusion 3500 International G6000624 3500 International Case Top Service English G6000438 Case Bottom Assembly Ser vice International G6000622 Case Bottom Assy Inter national 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 key pad 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 51C Assembly Drawings amp Parts Lists Barrel clamp assembly GREASE SILICONE III SOLDER NO CLEAN 40 5648 51C 161 Assembly Drawings amp Parts Lists Barrel clamp assembly parts list
38. Theory of Operation Power control description power control logic provides two functions power management and triggers alarms when the main micro processor fails Refer to the Power Control Logic section of the Main PC Schematic for details Test Superca Processor Reset to Processor Reset Circuit Monitor Super Capacitor Processor A D Channel AN1 Watchdog Buzzer Auxiliary Controller Alarm Circuit Detector Main Power On Power Control 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 bat tery 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 e The super capacitor voltage SUPERCAP_DETECT is monitored through the microprocessors 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 e instrument power loss while the instrument was malfunction of the main microprocessor or failure of the primary speaker 38 40 5648
39. This is a reminder to the user to conduct the Annual Maintenance Testing section 1 page 19 To clear this alarm reset the PM Main tenance date see section 5 Quick Maintenance Check out Test and follow the instructions 60 40 5648 51C System Failure Alarms Troubleshooting This section discusses the diagnosis of system failure alarms in the Medfusion 3000 Series pump and sug gests possible causes and remedies for these alarms System failure alarm A2D REFERENCE VOLTAGE BGND Test Cause or remedy Background self test measured an invalid range on analog to digital con verter reference voltage Use BIOMED gt DIAGNOSTICS to check the volt age Replace the main board if invalid voltage found ACU Power FAILURE 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 prob lem persists ACU WarcHDoc FAILURE ANALOG SuPPLY BGND Test 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 volt age Use BIOMED gt DIAGNOSTICS to check th
40. Use BIOMED gt DIAGNOSTICs and run MONITOR BATTERY STA TUS to review battery function Check battery con nections and battery charge circuit on the intercon nect board Battery Not WORKING System ADVISORY Medium Medium Pump has found no battery present no charge current and no battery gage communication Battery may be unplugged CALCULATED RATE OuT OF RANGE High The calculated rate is not valid Verify that all infu sion parameters have been entered correctly CHECK CLUTCH PLUNGER LEVER High Normal alarm message Software uses position po tentiometer 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 gt UTILITIES and run ViEW ALARM History to check if failure occurs at same position reading CHECK SYRINGE BARREL CLAMP Medium Certain syringe brands and sizes may cause the bar rel clamp sensor to have difficulty in verifying the clamp is in position Use BIOMED gt DIAGNOSTICS and run MONITOR DIGITAL SENSORS to check function of barrel sensor CHECK SYRINGE FLANGE SENSOR High At power up software has sensed the flange is load ed when no syringe is loaded in the pump as se
41. WHOXOL MOL L 5090 6 m K D3130 OV LL 8 9 EE o binc wi SOAS 5 5 biu Hs 80 AYALLVE MOTA 8 40 5648 51 Schematics amp PCB Assemblies 9 03130 douans K 0105 1019041 10 Main Board Power Control Logic Core ZN V 15 6080 19 MOL L INVL 02 L WHOY6 v9 9 Ord QNO 9015 uMd MYKE 07 quis 2105 0105 1019041 0105 woo 7 00 16 Wy 910 6 AS V 15 INVL 02 60405 fies 007 88 8 21881 304 LIWL6OINW e c 080 9815 uw 01 Ulo 9021 dn WHO 00Z ASC 960L 4 8 29141 9080 vsu 5080 MOL L 5 WHOWL 2105 1019041 0 104110 83M0d NIVW N51 5080 MOL L 968 43 801411 AlddflS NO 5 9021 105 04 8 LWS WX OL Me wur 02 DM MOLT 51 15414 AS 15 21501 a lt HDLIMS YIMOd 02 ZL dii N51 ZN 805 S oo 70805 IZL 218 OdN 5 39001 amp 80500104 16 gt gt 090 NV 02 lt 201 249 dd DW td9 g 19 5 0 49 ZH SSY 14 8 lt 557445 049 1250 549 Xx A QN51 gt gt 1250 mv 00 5080 4 3020 I LeungzeoXWW 11100 19001 76 6 YITIOWLNOD 9082 XVW 02 t0 MS OV OY AS lt DOGHDIVM 1341029
42. 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 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 51C 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 Using a metric 2 5mm hex wrench remove the screw holding the float plate Slide plunger case left toward pump until plunger board is access
43. inher ent noise rejection removes source input switching noise from it s regulated output 40 Analog Supply 5 volts Linear 40 5648 51C Theory of Operation Positive amp negative supply U36 The negative supply is a charge pump DC DC con verter doubles the input voltage then inverts the doubled voltage e Provides the contrast voltage to the graphic LCD display The low current load for the contrast volt age allows use of an operation amplifier controlled by the D A converter through the SPI bus e Provides negative supply for the amplifiers used in force and pressure sensing The charge pump doubles the Logic Supply volt age to achieve a 10V nominal positive supply volt age 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 Medfu sion 3500 pump the secondary LED for the backlight is controlled by Q45 40 5648 51 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 Exp 2 LED s Drive 7 Circuits C Row Scat LCD Input Data Control Circuits Flow Chart of Front Panel Function LED drive circuit Q
44. ment 77 Verify interconnect board function 78 Verify LCD amp 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 amp view software versions 72 W Watchdog 36 39 61 Alarm 9 37 39 44 Circuit 13 29 40 5648 51C Index 175 Index 176 40 5648 51C Smiths Medical ASD Inc St Paul MN 55112 USA 1 800 258 5361 USA 1 214 618 0218 www smiths medical com Smiths Medical International Ltd WD24 416 UK Tel 44 0 1923 246434 Smiths Medical Australasia Pty Ltd 61 Brandl Street Eight Mile Plains QLD 4113 Australia Tel 61 0 7 3340 1300 Medfusion PharmGuard and the Medfusion and Smiths Medical design marks are trademarks of the Smiths Medical family of companies The symbol indicates the trademark is registered in the U S Patent and Trademark Office and certain other countries All other names and marks are trademarks tradenames or service marks of their respective owners U S and foreign patents pending 2010 Smiths Medical family of companies All rights reserved 2010 01 40 5648 51C Smiths medtcal
45. move the clamp slightly back and forth to find the lowest size read ing then press Continue to calibrate large size SETUP HIGH STANDARD PRESS CONTINUE WHEN READY URLUE DATA 1624 COUNTS SYRINGE SIZE DATA 975 COUNTS MIN VALUE DATA 925 COUNTS SETUP HIGH STANDARD PRESS lt CONTINUE gt WHEN READY MA VALUE DATA 1824 COUNTS SYRINGE SIZE DATA 125 COUNTS MIN URLUE DATA 858 COUNTS 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 VALUE DATA 172 COUNTS PLUNGER POS DATA 125 COUNTS MIN VALUE DATA COUNTS SETUP HIGH STANDARD PRESS lt CONTINUE gt WHEN READY MAX VALUE DATA 959 COUNTS PLUNGER POS DATA 981 COUNTS MIN VALUE DATA 859 COUNTS E CONTINE 40 5648 51C Calibration amp Adjustment 6 You return to the CALIBRATION menu You may calibrate another mode choose SAVE CHANGES AND EXIT to exit calibration or press to return to the BIOMED menu 40 5648 51C 99 Calibration amp Adjustment Calibrate force sensor 1 100 From the CALIBRATION menu choose CAL FORCE SENSOR PRESS THE NUMBER TO SELECT THE MODE 1 CAL SIZE AND POSITION 5 CAL SYRINGE SIZE SENSOR 2 CAL FORCE SENSOR 6 ADJUST
46. 013 10 QV 01 102 QV 01 2102 QV lr 6014 0131102 gt 0130102 AYAN X 98741 TN 808 gt gt TM 0664 2 e 5080 5080 5080 5080 5080 5080 901 6080 5080 5080 5080 5080 MOL L MOLS MOLIS MOLS MOLS 106 MOL L MOLIS MOLL MOL L MOL L m m m mo mu m o v ait Mi ji 3n WHOL WHOL WHOL WHONL 8 1 0 1 8zi 5080 145201710018 SSPNZL 0194 AS 145 21901 5080 MOL L 6 WHOXL 5080 5080 5080 5080 MOL L MOL L MOL L MOL L 6 S S 6 WHOXL WHOWL WHOXL WHOXL EZY 658 098 CL tuo 19 gt gt 102 5 v10 NI Q gt 10 NI gt gt 10 Q S S S QvaA3 S AYAAN dA tt dA Gr Gr gt gt 0107 Wd Ay 40 5648 51C 122 Schematics amp PCB Assemblies lay Interface 9021 8 15 Ais Ao WX 9601 1NVL 9607 J ino anol om 0412 69 EINE v 5080 6 001 he LdSZOLWLZW18 G 1183 86541 e omm AS 1145 2801 JIOHNYHL 5080 AOS 11100 ids VIVd 0839 QES 6080 PVINT QUE MOL L WHOL CS 0 COA
47. 1 minute from power on for charge current reading to stabi lize e Unplug AC power if pump immediately shuts down then replace bat tery pack Ifpump continues to operate and gauge shows normal discharge cur rent 100 to 200 ma then perform a battery calibration If the indicator lights do not flash during startup or along with their ap propriate function or alarm then e Open the case and check the keypad connection to the Main Board If any connections are loose reconnect and re test e Otherwise replace keypad Keyclick Beep is faint or not present If the keyclicks beeps sound faintly or not at all they may have been configured to their lowest level or turned off Use PROGRAM to reset the audio to a higher level Keypad button does not work Use BIOMED gt DIAGNOSTICS and run the TEST If any keys do not pass this test open the case and check connections for the keypad Liquid Crystal Display LCD has poor contrast Use BIOMED CALIBRATION and run the ADJUST CONTRAST If the LCD contrast cannot be adjusted then check LCD negative supply and consider replacing display or main board 40 5648 51C 65 Troubleshooting Problem Libraries not available 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 Li braries from a correctly configured
48. 30 Rechargeable battery pack amp battery gauge 30 Plunger printed circuit board iones ets 30 Pl nger force BOE 30 Loaded nete tiat 30 Bord Schematic eoim tions 31 Logic Kernel 31 68HC11K4 Main Microprocessor Interface U19 31 Flash memory U22 mairinn an 34 Software upgrade method for programming flash MEMO Y 34 Static random access memory 017 34 Serial EEPROM U2 and 4 34 Timeo day 8 34 Infrared 34 Analog to digital converter 35 Digital to analog converter U20 eei 35 port expansion 03 1093 36 Expansion port 1 PORT 08 meinen 36 Expansion port 2 PORTA O8 37 Power control description 38 Always on supply UT 38 backup super eerte 38 Backup audio buzzer en entres 38 System reset 39 Power management U39 39 Power OPE State 39 Power ON state sis diem nentes 39 39 DC to DG Converter eee eee trees 40 supplu 40 Motor supply 40 Analog supply LL Sou 40 Positive amp negative supply U36 41 Table of Co
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51. 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 groupl 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 4 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 51C G Glossary 9 Graphical display circuit board 29 Graphic
52. ADJUST CONTRAST FA CAL FORCE SENSOR E VIEW CALIBRATION DATA CAL PLUNGER SRUE CHANGES AND EXIT CAL SYRINGE SIZE SENS ESS 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 URLUE DATA 175 COUNTS SYRINGE SIZE DATA 125 COUNTS MIN VALUE DATA 75 COUNTS SETUP LOW STANDARD PRESS lt CONTINUE gt WHEN READY MAX VALUE DATA 175 COUNTS SYRINGE SIZE DATA 982 COUNTS MIM URLUE DATA 75 COUNTS CONTINUE 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 URLUE DATA 1924 COUNTS SYRINGE SIZE DATA 972 COUNTS MIN VALUE DATA 925 COUNTS SETUP HIGH STANDARD PRESS lt CONTINUE gt WHEN READY MAX VALUE DATA 1924 COUNTS SYRINGE SIZE 125 COUNTS MIN VALUE DATA 850 COUNTS CONTINUE You return to the CALIBRATION menu You may calibrate another mode choose SAVE CHANGES AND EXIT to exit calibration or press to return to the BIOME
53. CONTR 4 STC T CAL PRESSURE SENSOR 7 CALIBRATION DATA CAL PLUNGER POSITION 8 SAVE CHANGES AND ERIT PRESS THE NUMBER TO SELECT FA CAL SIZE AND POSITION ADJUST CONTRAST FA CAL FORCE SENSOR E VIEW CALIBRATION DATA CAL PLUNGER POSITION SAVE CHANGES AND ERIT CAL SYRINGE SIZE SENSOR ED D Ensure nothing is loaded in the plunger head press Continue and wait until force sensor zero is fin SETUP LOW STANDARD PRESS CONTINUE WHEN READY MAS VALUE DATA s COUNTS FORCE DATA MIN VALUE DATA 24 COUNTS SETUP LOW STANDARD PRESS lt CONTINUE gt WHEN READY OFFSET DATA COUNTS VALUE DATA 38 COUNTS FORCE DATA MIN VALUE DATA 3 COUNTS The pump then auto zeroes the force sensor s offset this takes about 40 seconds Do not use arrow keys am wild mil gt gt e ADJUST THE FORCE OFFSET PRESS ENTER TO CONTINUE OFFSET DATA 138 COUNTS VALUE DATA 50 COUNTS FORCE DATA 44 COUNTS MIN VALUE DATA 3 COUNTS OFFSET DATA 138 COUNTS VALUE DATA 38 COUNTS FORCE DATA 44 COUNTS MIN VALUE DATA 3 COUNTS Press Enter when zeroing is complete 40 5648 51C Calibration amp Adjustment 5 Press the zero button on the force gauge Load the force gauge under th
54. Input provides a receptacle for con necting an IEC 320 type AC power cord to the inter nal universal input power supply This Power Supply Board provides 12 VDC to operate the pump and charge the batteries DC power input jack 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 e Always observe all cautions and warnings for con necting DC power to this input Speaker The primary speaker serves as the primary audio source for generating alarms e The microprocessor senses speaker current to determine if speaker is operational Rechargeable battery pack amp battery gauge A rechargeable NiMH battery pack NiCad battery pack on older model pumps allows operation on bat tery 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 pres ent 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 lo
55. LED lens toward the outside edge of the board Torque terminal block screws to 32 in oz 0 23 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 be fore returning it to use 82 Drive train assembly Tools Needed For this disassembly procedure you will need e Torque screwdriver with a Phillips head amp nut drive wrench e 002 051mm shim Always work at an electrostatic controlled work sta tion 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 Remove the main board per section above 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 Di
56. Medical will not accept returns for service without the assigned RA number clearly printed on the shipping package Mark the Return Autho rization RA number clearly on the outside of the shipping package used to return the pump 6 The shipment method must meet the environmen tal conditions of Shipping Storage Temperature 40 to 60 C 40 to 140 F 20 to 50 C 4 to 122 F Relative 5 to 95 non 5 to 95 non humidity condensing condensing Atmospheric 50 to 108 kPa 50 to 108 kPa pressure 7 3 to 15 4 7 3 to 15 4 psia psia 6 Ship the carefully packaged infusion pump to either of the addresses listed below United States Service Smiths Medical ASD Inc 1265 Grey Fox Road St Paul Minnesota 55112 1 800 258 5361 www smiths medical com Your local distributor or Smiths Medical International Ltd WD24 4LG UK European Service 44 0 1923 246434 67 Troubleshooting Using for trouble shooting 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 al lows you the ability to change the displayed language Two features within UTILITIES are very useful for investigating user complaint
57. RM10F1001CT CAL CHIP 39 1 0805W 2 0KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F2001CT CAL CHIP 40 1 R12 0805W 392 0 RESISTOR 1 10W TCR 100PPM 1 0805 RM10F3923CT CAL CHIP 41 1 R13 0805W 1000HM RESISTOR 1 10W TCR 200PPM 5 0805 RM10J101CT CAL CHIP 42 2 R18 R22 0805W 6 49KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F6491CT CAL CHIP 10 5648 51C 149 Schematics amp PCB Assemblies QTY REF Designator Package Value Part Spec 43 2 R20 R21 0805W 2200HM RESISTOR 1 10W TCR 200PPM 5 0805 RM10J221CT CAL CHIP 44 1 R25 0805W 475 00HM RESISTOR 1 10W TCR 100PPM 196 0805 RM10F4750CT CAL CHIP 45 1 R28 0805W 20 0KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F2002CT CAL CHIP 46 1 TVSI DO 204AC SA13CA On Semiconductor SA13CA Vishay Semiconductor 47 2 TVS2 TVS3 1206W VC120614D300D AVX 48 1 TVS4 0805W VC080505A150 AVX 49 1 UI LEADED IR 55042 STANLEY 50 1 U2 SOT23 5 LMC7111BIM5 NATION AL SEMICONDUCTOR MIC7111BM5 MICREL 51 1 U3 SOT23 MAX809LEURT MAXIM ADM 809LART ANALOG DEVICES 52 1 U4 SOT23 5 LMC7211AIM5 NATION AL SEMICONDUCTOR MIC7211BM5 MICREL 53 1 U5 SO8 LT1512CS8 LINEAR TECH 54 1 PCB N A INTERCONNECT PCB RAW Medfusion 3000 Series 150 40 5648 51C Assembly Drawings amp Parts Lists Assembly drawings The following section provides assembly drawings explode
58. SRUE CHANGES AND ERIT PRESS THE NUMBER SELECT FI CAL SIZE AND POSITION Ed ADJUST CONTRAST FA CAL FORCE SENSOR 4 CALIBRATION DATA RACAL PLUNGER POSITION SAVE CHANGES AND EXIT CAL 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 URLUE DATA 125 COUNTS SYRINGE SIZE DATA 125 COUNTS MIN URLUE DATA 75 COUNTS ____ CONTINUE SETUP LOW STANDARD PRESS lt CONTINUE gt WHEN READY MAX URLUE DATA 175 COUNTS SYRINGE SIZE DATA 982 COUNTS MIN URLUE DATA 75 COUNTS A CONTINUE 40 5648 51C 97 Calibration amp Adjustment 3 98 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 DATA COUNTS Fleer Fos DATA COUNTS VALU DATA COUNTS SETUP LOW STANDARD PRESS lt CONTINUE gt WHEN READY MAX WALUE DATA 208 COUNTS PLUNGERR POS 559 COUNTS MIN VALUE DATA 188 COUNTS CRUS Load the large calibration slug into barrel clamp Keeping the barrel clamp perpen dicular to the slug
59. a 6 8 hour recharge time 40 5648 51C Theory of Operation 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 e A separate charge control circuit is the voltage limit for the battery here a battery voltage moni toring 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 Charge detector A charge detector circuit generates the control sig nal 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 main microprocessor does not monitor the CuHARGE_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 pow er are removed from the pump or when these sources are below acceptable thresholds detailed above Innormal operation the battery voltage can be at a higher voltage than the external DC especially during battery charging Battery board sch
60. attempted to set a combination of infusion values that does not allow a valid flow rate to be calculated Press and enter a different set of values INVALID LIBRARY ENTRY 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 INVALID SYRINGE SIZE INVALID RATE FOR SYRINGE SIZE V3 pumps only Syringe size barrel clamp potentiometer sensor does not match selected manufacturer or when bar rel 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 li brary entries the library stores syringe size Chang ing this size may cause this message to appear refer to the Operation Manual for syringe size rate tables KVO IN Proaress Medium Normal alarm message Infusion has reached the set volume limit and delivery changed to KVO rate Limits ADJUSTED CANNOT Detivery ALL Doses Normal alarm message The limits on the parameter to be entered were adjusted to keep the resulting rate inside allowable limits Low EACH 1 DROP Low Low Normal advisory message Battery gauge has mea IN CAPACITY FOLLOWING INITIAL sured the capacity of the battery is less than 10 SIGNAL IF POWER CORD IS NOT The infusion rate will determine the run
61. battery pack with care Don t Over tighten Screws Never over tighten any screws in the pump Unless otherwise speci fied 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 51C Contents of this manual This is the technical service manual for Medfusion 3000 Series Syringe Infusion Pumps manufactured by Smiths Medical Its purpose is to provide the technical information necessary for maintenance troubleshoot ing and repair of these pumps e 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 e Overview of contents and purpose of this manual Scheduled Maintenance e List of tests for required annual maintenance and the procedure for completing each test Theory of Operations e Descriptions of the systems which control the operation of Medfu
62. 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 in fusion 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 to pause the audible alarm for the preset alarm silence period The infrared serial port interfaces directly with the main microprocessor s asyn chronous 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 in termittent 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 indi cate need for keypad replace
63. cable board Use BIoMED gt DrAGNOSTICS to check force sensor voltage readings DEPLETED BATTERY Battery is fully discharged below low voltage threshold Plug in the pump to AC power or external DC power to recharge the battery DisPLAY CONTROLLER Post Failure detected in testing the LCD display Check cabling between main board and display Replace LCD display ExTERNAL COM TASK TIMEOUT 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 exter nal RS232 adapter and observe if the problem is corrected FLASH Memory BGND Test 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 FLASH Memory Post CRC failure found in program memory during power up self tests Failure may occur during external re programming of the pump software Other wise failure is in flash memory of the main board and main board should be replaced Force Sensor BGND Test 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
64. circumstances requiring user attention The backup audio buzzer provides a means of generating an alarm during e instrument power loss while the instrument was e malfunction of the main microprocessor e failure of the primary speaker The backup audio buzzer activates during Watchdog Alarm anytime there is a mal function of the main microprocessor During power up self tests the buzzer func tion 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 gauge circuits monitor direction and magnitude of current flowing through the battery The battery current is sensed by the gauge 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 Introduction Battery Parameters Biomed Calibration Biomed Diagnostics Biomed Utilities Configuration Cloning CPI Capacity Inaccurate Depleted Battery Monitor EN 475 Alarms There are two battery parameters requiring periodic inspection to maintain good battery performance They can be accessed by selecting BIOMED gt DIAGNOSTICS gt MONITOR BATTERY STATUS LMD Last Measured Dis
65. 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 orienta tion of each guide Torque to 60 in oz 0 42 Nm 2 Carefully slide the extrusion drive train assembly back into case 3 Ensure right end plate on extrusion does not dam age 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 extru sion between boss by the motor and extrusion 6 Secure extrusion with 3 standoffs and 3 pan head screws Torque to 100 in oz 0 71 Nm 7 Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts Torque to 100 in oz 0 71 Nm 8 Reinstall main board per main board section above 9 Close pump housing per housing section above 40 5648 51C Parts Replacement Plunger case assembly Tools needed For this disassembly procedure you will need e Torque screwdriver with a Phillips head amp 2 5mm hex head e Needle nose pliers Safety glasses Always work at an electrostatic controlled work sta tion 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 se cure with pan head screw Torque to 60 in oz 0 42 Nm Plunger case disassembly WARNING While servicing the Medfusion
66. external DC jack must be IEC 60601 1 cer tified 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 Introduction While servicing the Medfusion 3000 Series infu sion pump you should wear safety glasses as it contains springs and other small parts which may be a hazard Cautions Avoid Organic Solvents Never use organic sol vents e g acetone quarternary ammonia com pounds 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 open ings 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 WD407 to clean or lubricate pump These chemi cals 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 amp 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 pumps
67. head and check plunger cable and force sensor cable on the plunger board Replace plunger board plunger cable or force sensor Force SENSOR BRIDGE TEST 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 gt DIAGNOSTICS gt MONITOR ANALOG SEN sors 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 62 40 5648 51C System failure alarm Troubleshooting Cause or remedy Force SENSOR TEST 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 INPUT TASK TIMEOUT Software timing failure A transient failure may have occurred in the soft ware if problem recurs replace the main board INTERNAL A2D FAILURE Software self test identified a failure in the 10 bit analog to digital convert er Use BIOMED gt DIAGNOSTICS gt CHECK ANALOG SENSOR readings If they are abnormal replace the main board INVALID INTERRUPT Software hardware failure Software attempted to execute invalid interrupt may be caused by main processor hardware failure bus failure or software flash memory failure
68. logic high selects the audio envelope time constant of 2 5 milli seconds Refer to the Main Speaker Drive description section WARNING LED PC7 A logic low turns the Caution LED indicator on INFUSING LEDL PC6 A logic low turns the left most when viewing the keypad Infus ing LED indicator on INFUSING_LEDM_ON PC5 A logic low turns the middle Infusing LED indicator on INFUSING LEDR ON PC4 A logic low turns the right most Infusing LED indicator on PCELL_LED_ON PC3 A logic low turns the Pressure Cell LED indicator on BATTERY LED ON PC2 A logic high turns the Battery LED indicator on CAUTION LED ON PCI A logic low turns the Caution LED indicator on LOCKOUT LED ON PCO A logic low turns the Tamper Feature Active LED indicator on KEYPAD COL 0 5 5 Senses 1 of 6 columns of the keypad matrix When the sense value is logic low the indication is the corresponding button for the col umn is being pressed PWR_SW_MCU PA6 Sense signal for the power switch The signal is at a logic high when the power switch is being pressed MTR_CURRENT_DE PA7 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 36 40 5648 51C Expansion port 2 2 5 Port Location Theory of Operation Description Signal name
69. pump functionality be fore returning it to use Speaker This section defines the steps for removing and replac ing the speaker for the Medfusion 3000 Series pump Tools Needed For this disassembly procedure you will need e Torque screwdriver with a Phillips head Always work at an electrostatic controlled work sta tion when disassembling the pump 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 intercon nect board at J2 4 Remove the 2 pan head screws amp 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 42 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 amp 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 self tests to complete If no system failure messages appear then the speaker is good
70. sensor away from the display 3 Secure the sensor with the pan head screw Torque to 100 in oz 0 71 Nm 4 Carefully slide the extrusion drive train assembly back into case 5 Ensure right end plate on extrusion does not dam age 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 extru sion between boss by the motor and extrusion 8 Secure extrusion with 3 standoffs and 3 pan head screws Torque to 100 in oz 0 71 Nm 9 Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts Torque to 100 in oz 0 71 Nm 10 Reinstall main board per main board section above 11 Close pump housing per housing section above Handle Removal 1 90 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 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
71. serial data SPEAKER FREQUENCY PHO PWI Sets the audio frequency of the main speaker Generated as a fixed 5096 duty cycle square wave with a variable frequency SPEAKER VOLUME PHI PW2 Fixed frequency variable pulse widths signal that the speaker driv er hardware converts into a DC voltage for volume control MTRPHA IREF PH2 PW3 Pulse width modulated output transformed by hardware into a DC level representing motor current for coil A of the motor MTRPHB_IREF 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 DAC 05 PGI Chip select signal for SPI communication to the 8 bit digital to ana log converter This signal is active low RESET_PIO PGO Allows the main processor to independently reset the two 24 bit I O expansion devices The reset is active high POWER_STROBE 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 PLUNGER DETECTI PA6 OC2 Logic sense signal for detecting the respective plunger flipper state A logic high indicates a syringe is loaded PLUNGER DETECT2 PA5 OC3 Logic sense signal for detecting the respective plunger flipper state A logic high in
72. sleeve over ear clip with hollow end of sleeve towards the spring 3 Ensure the ear clip faces the 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 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 re move 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
73. 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 51C Scheduled Maintenance Calibration verification From the pumps 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 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 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 1 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 2 Load the large C
74. 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 dam age 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 extru sion between boss by the motor and extrusion 7 Secure extrusion with 3 standoffs and 3 pan head screws Torque to 100 in oz 0 71 Nm 8 Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts Torque to 100 in oz 0 71 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 Remove the main board per section above Squeeze the plunger lever and fully extend the plunger head away from the case 40 5648 51C 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 tub ing 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
75. time clock A separate Real Time clock source provides the micro processor 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 x 64 pixel liquid crystal display provides the pri mary visual interface for pump operation always on LED driven back light in the LCD enhances viewing in low light areas Keypad The keypad is a multi layer polyester laminate provid ing 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 e plunger speed near end of plunger travel near empty alarm e end of plunger travel i e empty alarm 40 5648 51C Theory of Operation 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 micro processor measures the frequency of this signal to e Verify rotation speed against the set flow delivery rate It is not used for speed
76. 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 191 Turn off pump and disconnect from safety analyzer WARNING Safety Class II Type CF Medical Equipment The pump is listed as Safety Class 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 nec essary 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 1 Connect the AC power cord to the Safety Analyzer Set Safety Analyzer to Line Leakage mode of operation Press to turn the pump on 2 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 fo
77. 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 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 Verify the follow ing on power up 1 2 3 4 5 6 Verify alarm beeps Verify all the LED indicators are turn on and off except AC and battery Verify that battery capacity shown on screen is greater than 0 Verify that no self tests fail Verify the display is legible and contrast is acceptable Unplug
78. 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 prop erly loaded flange causes the optical path to become uninterrupted allowing a direct path from the infrared emitter to the detector e The emitter is enabled by the signal syRINGE_EAR_ SNSR_ENBL when set to logic low The sensor output SYRINGE EAR DETECT pro duces a high logic state when the flange is properly loaded state should be logic low anytime the syringe ear flange is not installed or SYRINGE EAR SNSR _ ENBL is inactive 40 5648 51C Theory of Operation 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 resis tance with the motion of the syringe plunger The sensing system requires calibration to deter mine offset and gain Calibration values are stored in non volatile serial EEPROM memory Speaker drive description The speaker sounds the warning and
79. washer can move spin freely if not loosen nut slightly 4 Slide carriage rod through carriage and seat into hole in right end plate 5 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 0 71 Nm 6 Align D of worm gear with leadscrew shaft and press onto leadscrew until gear is centered over the motor worm 7 Carefully slide the extrusion drive train assembly back into case 8 Ensure right end plate on extrusion does not dam age ear clip sensor 9 Ensure plunger cable comes out between middle boss and boss by the motor 10 Slide keypad ground tab black side toward extru sion between boss by the motor and extrusion 11 Secure extrusion with 3 standoffs and 3 pan head screws Torque to 100 in oz 0 71 Nm 12 Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts Torque to 100 in oz 0 71 Nm 13 Reinstall main board per main board section above 14 Close pump housing per housing section above Clutch or clutch cam Tools needed For this disassembly procedure you will need Safety glasses 40 5648 51C e Needle nose pliers Removal 1 Remove leadscrew per procedure above 2 Use needle nose pliers or hemostats to remove e ring from cam in carriage plate 3 Using 4 open end wrench and Phillips screw driver remove th
80. 040DIM3 4 1 NATIONAL SEMICONDUCTOR MICREL SEMICONDUCTOR 88 1 1017 SOP28 TC55257DFL85L TOSHIBA TC55257DFL70L TOSHIBA M5M5256DFP 70LL Mitsubishi LH52256CN 70LL Sharp 89 2 U18 U37 SOT23 5 LMC7211AIMS5 NATION AL SEMICONDUCTOR MIC7211BM5 MICREL 90 1 119 84PLCC_SKT 68HC11K1CFN4 OR 8 MOTOROLA 91 1 U20 SO8 MAX522CSA MAXIM 92 1 1721 SOT223 LT1121CST 5 LINEAR TECH 93 1 U22 32TSOP AT29C040A 12TU Atmel 94 1 U24 TSSOP16 SN74AHC138PWR TEXAS INSTR 95 1 U25 SO14 MC74HC4066AD OnSemi SN 74HC4066PW TEXAS INSTR 96 2 U26 U35 SOI6W A3953SLB ALLEGRO 97 1 U29 SO6 SFH9201 2 3 Osram Smiths Med ical catalog number G6000157 98 1 U31 SO8 LM386M 1 NATIONAL SEMI CONDUCTOR NJM386BM NEW JAPAN RADIO 99 1 U32 TSSOP20 SN74AHC573PWR TEXAS INSTR 10 5648 51C 137 Schematics amp PCB Assemblies QTY REF Designator Package Value Part Spec 100 1 U36 SSO8 MAX865EUA MAXIM 101 1 U38 SOT23 MAX6326UR31 T MAXIM 102 1 U39 SO8W PIC12C50804 SM MICROCHIP programmed 103 1 U40 SO8 LM393M NATIONAL SEMI LM393D TEXAS INSTR 104 1 U43 SOT23 MAX809LEURT MAXIM ADM 809LART ANALOG DEVICES 105 1 U44 TO236AB LM4040BIM3 4 1 NATIONAL SEMI 106 1 U45 SOT23 5 SN74AHCIGI4DBVR TEXAS INSTR 107 1 U46 SO16 MC74HC174AD MOTOROLA SN74HC174D TEXAS INSTR 74HC174D PHILIPS M74H C174M1R SGS 108 1 SMT_32KHZX 32KHZ MC306 32 768KA E
81. 080 68 138 eee ac MOL L 8 1Ws Q 5080 INYO wies EU _ SS mE moyi INYO 3345 Ln 1 49902 DA AND Syl 0006 5080 16641 9841 INYL 602 145005418019 x 30001 SCCN6L 881 19 AS 145 21901 SENGL QN51 ZS 22105 5080 T am sui A 65016 6018 0 04 P 5704 5080 WX 9601 840551 140001 5080 5080 ca 96240 01 MOL L 5 MOL L 5 Ey TORRE lt 4 7 WHONOL no MOL L e Md9907IHPZNS ams a oci cot pue t 9001 wh i an ig Ads SNA A 43195 0 0s 5080 60 E 080 Md990PJHPLNS MOL L 95 JA PIE WHOMOZL whl m 0 WHOXO NMOGLNHS ONY 2105 lt OH LL ZOOLNZ e 60 174 99ENGL L3d03AN3 43345 t TEENGI 5080 910 5080 MOL MOL L 5 9001 WHON Z SVINGL NOS WHONZ OF 78016 WX 601 181 olly 31170 6 SLL AS 4145 901 1123135 34013AN3 746 2901 lt KAWMIOA YAVAS 2 CK AININDIYS 37134550 129 40 5648 51C Schematics amp PCB Assemblies Main Board ACU ICE Socket QND1 _ TIOHNYHL 1320 o1 vinW3 D0OHDLVM 134 9 9915 500PD1VM 1 9 9415 WHY 9 HOLIMS Y3MOd CZL 9 050 TOV 9 1990 TOv 9 AdS TNN CL 9 EHW THW LHW 5310 DNILNNOW 131205 YOLVIN
82. 0905 Plate Carriage 1 ea 6 G6000044 Spring Clutch 1 ea 7 G6000045 Tube Plunger 1 ea G6000738 Insulated Tube 1 ea 8 0391331800 E Clip 1 ea 9 G6000378 Square Shaft See note below 1 ea 10 G6000063 Screw 4 40 x 31 PH Phillips 3 ea 11 G6000310 Nut Nylock 4 40 SS Small 3 12 G6000749 Screw 4 40 x 18 FH SS 2 13 G6000159 Assembly Plunger Cable 1 ea 15 070205 00 Grease STP 0 1 oz Notes In newer pumps square shaft item 9 is being superseded by SS Square Shaft P N G6000378 40 5648 51C 165 Assembly Drawings amp Parts Lists Accessories parts list Poleclamp assembly 166 40 5648 51C Assembly Drawings amp Parts Lists Poleclamp parts Catalog number 3000PC Ref Part Number Description Quantity 3 G6000284 Poleclamp C Bracket 1 ea 11 G6000286 Poleclamp Bracket 1 13 G6000774 Screw 8 32 x 7 16 Pan Head with Washer Stainless 4 ea 16 G6001456 Knob 12 13 25 Stainless 1 ea 18 6000345 Screw 4 40 x 16 Flat Head Stainless 4 Rotating poleclamp parts Catalog number 3000RPC Ref Part Number Description Quantity 1 G6000496 Mount Rotor Rotating 1 ea 2 0502003100 Shoulder Bushing lea 3 G6000284 Poleclamp C Bracket lea 4 G6000499 Screw 8 32 x 7 16 Flat 4 5 0482004400 Index Cam 2 e
83. 10J221CT CAL CHIP RESISTOR 1 10W TCR 100PPM 1 0805 RM10F2002CT CAL CHIP 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 CAL CHIP 59 12 R47 R55 R66 R74 R85 R99 R101 R108 R137 R152 R153 0805W 120KOHM RESISTOR 1 10W TCR 200PPM 5 0805 RM10J124CT CAL CHIP 60 R48 R91 R147 R151 0805W 10 0KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F1002CT CAL CHIP 61 R50 0805W 64900 RESISTOR 1 10W TCR 100PPM 1 0805 RM10F6490CT CAL CHIP 62 R51 R109 0805W 2 2 RESISTOR 1 10W TCR 400PPM 5 0805 RM10J225CT CAL CHIP 63 R53 R107 R138 R139 R154 R157 R158 R159 0805W 1600HM RESISTOR 1 10W TCR 200PPM 5 0805 RM10J161CT CAL CHIP 64 65 R56 R65 R69 R117 R148 R76 R116 R142 R161 R181 R136 0805W 0805W 47KOHM 40 2KOHM RESISTOR 1 10W TCR 200PPM 5 0805 10 473 CAL CHIP RESISTOR 1 10W TCR 100PPM 1 0805 RM10F4022CT CAL CHIP 66 R81 R100 0805W 825 00HM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F8250CT CAL CHIP 67 R110 R132 0805W 27KOHM RESISTOR 1 10W TCR 200PPM 5 0805 RM10J273CT CAL CHIP 68 R111 0805W 392 0KOHM RESISTOR 1 10W
84. 1C 133 Schematics amp PCB Assemblies QTY REF Designator Package Value Part Spec 15 2 C51 C53 TANT_D 1000 CAPACITOR 10V TANT 20 SMT_D TCMIA107DT CAL CHIP TAJD107M010R AVX T491D107M010AS KEMET 16 13 C58 C62 C86 C103 C105 C113 C155 0805W 1000PF CAPACITOR 50V NPO 5 0805 C156 C157 C158 C159 C162 C163 GMC21CG102J50NT CAL CHIP 17 1 70 CAP_200MIL 1UF CERAMIC 100V X7R 1096 LEADED SR401C105KAA AVX RPE114X7R105K100V MURATA ERIE 18 2 C91 C92 0805W 100PF CAPACITOR 50V NPO 5 0805 GMC21CG101J50NT CALCHIP 19 1 102 SMT_10X10_8 330UF CAPACITOR 35V ELECT 2096 RADIAL NACZ331M35V10X10 8TRHIL NIC 20 21 C131 C132 C133 C134 C135 C136 0805W 1000PF CAPACITOR 50V NPO 596 C137 C138 C139 C140 C141 C142 0805 GMC21CG102J50NT CAL C143 C144 C145 C146 C147 C148 CHIP C149 C150 C154 21 2 DLD23 SMC CMSH3 60 CENTRAL SEMI 30BQ060 INTERN RECTIFIER 28 18 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 SOT23 MMBD914LT1 MOTOROLA D12 D13 D14 D15 D16 D19 D20 D22 23 13 FB1 FB2 FB3 FB4 FB5 FB6 FB7 0805W BLM21A102SPT MURATA ERIE FB10 FB11 FB12 FB13 FB14 FB15 24 1 EB8 1206W BLM31P500SPT MURATA ERIE 25 1 GLI GNDLNK N A 26 2 J2J6 4P_059SMTH B4B ZR SM3 TE JST DR 27 1 3 _0795 4 5 3 JST DR 28 1 J4 4P_050THHDR 104071 7 AMP 29 2 J5J13 2P_THJMPR HTSW 102 06 T S SAMTE
85. 26 Q27 Q40 Q33 Q37 Each LED drive circuit has a logic controlled switch providing a pseudo current source to the LED when activated e 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 Apressed button is read from column signals KEY PAD_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 micro processor and the auxiliary controller 42 40 5648 51C 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 e The full scale range of 255 FF hexadecimal counts equals approximately minus 10 volts LCD backlight The primary backlight f
86. 3 EP TAL SON ECPSM29T 32 768KTR ECLIPTEK X1555 32 768KT R MTRON 109 1 X2 SMT 16MHZX 16MHZ EC2SM 16 000MHZ T amp R TAL ECLIPTEK 110 1 X3 SMT 455KHZ 455KHZ CSBFB455KJ58 R1 MURATA XTAL ERIE 111 1 XD1 TH_BUZZER HMB 06 STAR MICRONIX Smiths Medical catalog number 6940000100 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 1 015 TSSOP8 OP727ARU Analog Devices 115 1 R121 0805W 1 37KOHM CRCWO08051371F50 Vishay RK 73GC2ATTD1371F KOA 116 2 R9 R89 0805W 4 7KOHM RESISTOR 1 10W TCR 200PPM 5 0805 CRCWO0805472 Vishay Dale RK73B2ATTD472J KOA Speer 117 1 R88 0805W 1300HM 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 CRCW0805183 Vishay Dale RK73B2ATTD183 KOA Speer 138 40 5648 51C Schematics amp PCB Assemblies Plunger Board Schematic Plunger Board Force Preamplifier 9021 105 WX 9601 10 8 7105 ee LINZ 5080 MOL L 968 WHOOOL TIOHNYHL zed sn 139 TIOHNYHL 194 090 V 106 A9
87. 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 plung er 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 91 Parts Replacement turning counter clockwise With plunger lever po sitioned 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 42 Nm Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality be fore returning it to use
88. 338 0017 gt T SELNIL 568 19607 INO ASNS sogo 88 106 NOILV LDX3 805835 NOILISOd OdN 5 i 40 5648 51C 126 Schematics amp PCB Assemblies Main Board Force Sensing UNIT 611883 SuSNS YIONNTd gt 110 18545 14 A 5080 NOS WX 9601 31000 19 5080 5080 Q8 338 0017 aM 0 ut 9 5080 41000 6 450 304035 oo 5080 5080 5080 MOL L A0S MOL L 840551 WX OL 1 WHOXO OL 31000 1618 nan 9 TPSNZL 5 5080 9021 JOA 7 OLOT m lt OLAV 115310 ot WHOYO SL INTO 5080 QN51 sdo e 2 ow 1 5080 5 14 34 QN51 aNd A MOLL s 1S3 55 32803 anon A 68105 WHOXOZL 95D 15 vul 001 5000 BU SWIgLLLDWI vil 1dSzoLvLWIg 2 T 5080 OdN S 04V 32404 lt lt oats ela 340001 7 t h 9441 6080 140001 54 j in AS 1145 190 WHOYO OL 90 sry L 106 9 WX OL 310 Y 0912 901 mo CEST L INZI 91841 l z 7 66 431113 SSYd 2 9 14 90 sogo m aum ur n ux D nm muv zidQ 195 93NA am 5080 A 31000 195 DINA otdi MOL L
89. 4 40 x 31 Phillips 10 ea 13 G6001999 Case Handle 1 ea 14 G6000101 Backlight Fiber Optic Medfusion 3010A Series 1 ea G6000582 Backlight Fiber Optic Dual LED Medfusion 3500 Series 1 ea 15 G6000064 Standoff Hex 4 40 x 38 3 16 G6000043 Nut 4 40 Nylock 4 ea 18 G6000122 Seal Barrel Clamp Ear Clip 2 19 G6000077 Tube Seal 1 ea 21 G6000474 Washer 4 Flat 2 22 G6000715 Barrel Clamp Head 1 23 G6000802 Screw 4 40 x 25 BH Black 1 ea 27 G6000257 Clamp Stainless Steel 1 ea 28 G6000903 Screw Pan Phil 2 56 7 6 SS Nylock 1 ea 32 0382000000 Grease Silicone 111 0 1 07 33 G6000339 Lens Keypad Support 1 ea 35 G6000393 Sleeve Ear Clip 1 ea 36 G6000397 Spring Ear Clip 1 ea 37 G6000583 Spacer LCD Backlight see note 5 1 2 ea 38 039TT10200 Wire Tie Medfusion 3500 Series 1 ea 39 G6000585 Cable Backlight Dual LED Medfusion 3500 Series 1 ea 40 G6000692 Nylok Screw 3 ea 41 G6000238 Tube Holder 3 continued on next page 40 5648 51C 159 Assembly Drawings amp 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 avail able 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
90. 4K50NT CAL CHIP 2 4 C3 C4 C5 0805W 01UF CAPACITOR 50V X7R 1096 0805 GMC21X7R103K50NT CAL CHIP 3 1 C7 TANT B 10UF TCMIA106BT CAL CHIP TAJB106MO10R AVX T491B 106 010 5 KEMET 4 1 C8 TANT_D 22UF CAPACITOR 25V TANT 10 SMT_D TPSD226M025R0200 AVX T495D226M025AS KEMET 5 2 9 10 SMT_8X10_8 220UF CAPACITOR 35V ELECT 20 RA DIAL NACZ221M35V8X10 8TR13 NIC 35VCV220GX SURGE COM PONENTS 6 3 Cll C12 C13 1206W 0 220 CAPACITOR 25V X7R 10 1206 GMC31X7R224K25NE CAL CHIP 7 1 18 1825 1UF CERAMIC 1UE 50V X7R 10 1825 GMC45X7RL105K50NT CAL CHIP 8 1 C20 0805W 1000PF CAPACITOR 50V NPO 5 0805 GMC21CG102J50NT CAL CHIP 9 1 21 0805W 100PE CAPACITOR 50V NPO 5 0805 GMC21CG101J50NT CALCHIP 10 D1 D2 D3 D4 D5 D17 SOT23 MMBD914LT1 MOTOROLA 11 2 D9 D10 SMB_X MURS120T3 MOTOROLA 10 02 CENTRAL SEMI CONDUCTOR 12 2 DILDI2 SMC CMSH3 60 CENTRAL SEMI 30BQ060 INTERN RECTIFIER 13 1 014 LEADED_IR DN504 STANLEY 14 1 015 SOD 123 6 2V MMSZ5234BT1 MOTOROLA 15 1 016 SOD 123 5 6V MMSZ5232BT1 MOTOROLA 16 2 FBLFB2 0805W BLM21A102SPT MURATA ERIE 17 1 J 10P 079RATH 1306 10 R 02 SINGATRON HDR 18 1 2 079THHDR B2B PH K JST 19 1 3 2P 100THHDR 22 03 5025 MOLEX 20 1 4 Cable 26 pin 12121 09 A Singatron 21 1 5 DC_JACK DC 001 B CRSN POWER DY NAMICS 22 1 111 SMT_TOROID 10U 10UH 20 SMT TOR OID CTX10 1 COILTRONIX 618 100M 01 C
91. 51C 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 e 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 built in delay of the reset IC Power management U39 An embedded Auxiliary controller oversees the power control management and serves as the main micro processor watchdog The behavior of the power man agement system depends on pump states Power Off Power Watchdog Alarm anda 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 Th
92. 6 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 groupl 71 Monitor 6811 A2D group2 71 Monitor a2d selftest 71 Monitor analog sensors 70 Monitor digital sensors 70 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 amp date 72 View alarm history 72 View infusion history 72 View service data 72 View software CRCs amp view software versions 72 View EEPROM size 72 Bottom housing See Case Bottom assembly 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
93. 6 G6000016 Shield Power Supply 1 ea 7 G6000017 Lens IR Window 1 ea 8 G6000276 Cable AC Power 1 ea G6000102 Cable AC Power Medfusion 3500E 1 ea G6000695 Cable AC Power Medfusion 3500BC See note 9 1 ea 9 G6000693 Screw 4 40 x 31 PH Phillips 6 ea 10 G6000220 Clamp Cord Retainer 1 ea 11 G6000192 Locknut 6BA Nylock 2 ea 12 G6000410 Washer Shoulder Nylon 2 ea 13 G6000118 Pad Battery Bay 1 ea 14 G6000012 Cable DC Power 1 15 G6000387 Cable 1 ea 16 0340IF1400 Solder 17 G6000706 Feet Rubber glue type See note 5 See note 7 4 ea 18 G6000694 Label Functional Ground See note 8 1 ea Notes Notes continued 1 In newer assemblies the interconnect PCB assem bly item 4 P N G6000312 has superseded the older assembly P N G6000234 2 In older assemblies items 10 amp 11 are Screw 4 40 x 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 avail able as a service subassembly part number English G6000438 Case Bottom Assembly Ser vice USA International G6000622 Case Bottom Assy Ger man Service 5 Use with Loctite 401 part number 036LT40100 40 5648 51C 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
94. 74 CNTS PREU PROG FREU ENTRY NEAT ENTRY NEAT PROG 2007 04 04 12 88 48 PUD l 1238ML TRAVEL POS 958 CHTS RATE 8 ML ORCE 8 CHTS SYRINGE DIA 982 CHTS PREU PROG PREU ENTRY NEXT ENTRY NEXT PROG View Sortware CRCs amp View Software VERSIONS STOP THE INFUSION 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 lt BACK gt TO STOP ON TIME HOURS 1 MINUTES SINCE LAST CAL HOURS 1 MINUTES IMFUSE TIME 8 HOURS MINUTES MOTOR REUS 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 lt BACK gt STOP EEPROM INSTALLED SIZE 16 kILOBYTES 40 5648 51C gt Uppate Firmware not available on Medfusion 3500 pumps version 4 and higher Do Not Use this feature unless specifically autho rized 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 ae ary es Note pressing Yes does not erase any software in the pump The pump mus
95. 77 Replacing the battery 77 Verifying battery function after new battery BS ACCTING I 77 Interconnect board 78 Tools 78 Removing the interconnect DOSE erret ns 78 Replacing the interconnect board 78 Verify interconnect board 78 Speaker 78 Tools Needed 78 5 seran tics 78 Speaker replacement re ideis qbus itn 78 Verifying speaker 78 40 5648 51C AC power supply 79 JUS s T 79 Removing AC power supply 79 Replacing the AC power supply sisirin 79 Verify AC power supply function 79 AC input assembly 79 Tools Needed D A 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 80 Main board 81 Tools UI e 81 Removing the main 81 Repl cing th mainboard nig 81 Drive train assembly 82 Tools Needed ME mene naan 82 Motor unit motor worm worm gear 82 ir 82 PRS PACS PR 82 Reassemb
96. 8 9 472 MOTOR SUPPLY COUNT 68 17 4081 20 REFERENCE COUNT 127 4 864 40 5648 51C Troubleshooting 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 lt BACK gt TO STOP SUPERCAP DETECT CHTS 8 884 SPEAKER DETECT 8 CNTS 8 Baa POWER STROBE 8 CNTS B BAAL FORCE OFFSET CNTS 8 BAAL PRESS lt BACK gt STOP SUPERCAP DETECT COUNT GGG SPEAKER DETECT COUNT BBB POWER STROBE COUNT 255 4 8881 FORCE OFFSET COUNT 15 2 192 gt UTILITIES Within BIOMED gt UTILITIES the following selections are available Use the number buttons for selection PRESS THE NUMBER SELECT THE MODE i SET UIEM LAST PM DATE 5 VIEW SOFTWARE CRCS 2 SET 6 VIEW SOFTWARE VERSIONS 3 VIEW ALARM HISTORY VIEW SERVICE DATA 4 VIEW INFUSION HISTORY PRESS THE NUMBER TO SELECT SET UIEW NEXT PM DATE VIEW SOFTWARE CRCS TIME DATE VIEW SOFTWARE VERSIONS BA IEW ALARM HISTORY FA VIEW SERVICE DA
97. AOS OdN QND1 190001 00 19517 TIN WHOYOOL ti 5080 A 5080 5080 MOL L B MOL L 91 li WHOS au Ld 8141 11420717 20 907 1 eos O WH ore 85201810 D 0 0 g t 7183 aan 575 o xus sce E AOS WX 0L inl 81 m wm IWS n E qu SN Z 0 al wio 907 T 04 2 3 04 20 XMSNN gt 60 ANIYYND IDYVHD AYLLY MOTA lt lt 0 n gt gt AVIT 04 AYILLYS 2 IWS oor 145 40 5648 51C Schematics amp PCB Assemblies Interconnect Board Infrared Serial Communications oy lt lt 5010 5080 MOL L 6 00 vcd O 145 21901 5080 AOS u X 9601 31100 9 AldS 2901 1804 WWO 034 TVNd31X3 7 A 5080 MOL L 966 WHOOZZ Ll N51 TIOHNYHL TIOHNYHL 200654 vOSNG 1AX Ln 10 Q 145 21501 7105 LITVZO6ZLEWW N51 N51 901 901 IWS AOS M8 L 960L JnL0 WHOO 00L 9D l 9 AldS 2901 40 5648 51C 146 Schematics amp PCB Assemblies Interconnect Board Assembly Drawing
98. APID Occr DETECT if available If not available press Gack 40 5648 51 21 Scheduled Maintenance 4 Press 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 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 9 when TVD reaches 50 0 ml From the BEGIN INFUSION screen press to access the PRIME screen Press and hold 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 sy ringe plunger Record this measurement as the starting position 2 Press and ensure delivery begins Wait until the pump volume limit is reached in 10 minutes Press if volume limit is not active Press 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 s
99. C 30 1 7 2PINTH 30 870 002 OR 930 T DS 02 TERMBLK WECO 31 1 050RATH 53048 0810 molex HDR 32 1 9 26P 1306 26 S 02 SINGATRON 079THDRHDR 33 1 J10 24P_050RATH 1 104069 2 AMP DRHDR 34 i p 11P_059SMTH B11B ZR SM3 TE JST DR 35 i pns 20P_100THH 609 2027 THOMAS amp BETTS DR 36 gt 11 12 SMT_POT DT3316P 473 COILCRAFT CORE 37 1 13 SMT_POT DT3316P 333 COILCRAFT CORE 134 40 5648 51C Schematics amp PCB Assemblies QTY REF Designator Package Value Part Spec 38 13 Q1 Q3 Q11 Q12 013 014 021 024 SOT23 2N7002T1 SILICONIX TEMIC Q28 Q29 Q30 Q38 Q42 CENTRAL SEMICONDUCTOR 39 1 02 SO8 MMSF3P02HDR2G On Semi 40 7 04 06 08 010 016 019 041 SOT23 MMBT2222ALT1 MOTOROLA 41 16 Q5 Q7 Q15 Q17 018 020 022 026 SOT23 0610 Supertex TP0610T Q27 Q33 Q34 Q35 Q36 Q37 Q40 Q45 Vishay SILICONIX TEMIC obsolete 42 1 1206W 10MOHM RESISTOR 1 8W TCR 400PPM 5 1206 RM12J106CT CAL CHIP 43 1 1206W 2 700HM RESISTOR 1 8W TCR 400PPM 5 1206 RM12J2R7CT CAL CHIP IRC WCR1206 44 4 R3 R16 R17 R125 0805W 2 0KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F2001CT CAL CHIP 45 2 R4 R18 1206W 240HM RESISTOR 1 8W TCR 400PPM 5 1206 RM12J240CT CAL CHIP ERJ 8GEYJ240V PANA SONIC 46 12 R5 R8 R14 R19 R28 R37 R87 R162 0805W 1 0KOHM RESISTOR 1 10W TCR 100PPM R168 R182 R185 R186 1 0805 RM10
100. 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 Open the plunger case halves per above 2 Lift cam gear off of pin 3 Remove push block 4 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 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 tim ing gear Place the push block on top of the timing plate 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
101. D menu 40 5648 51C Adjust contrast voltage setting The factory default contrast voltage setting is OOBF 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 PRESS THE NUMBER TO SELECT THE MODE CAL SIZE AND POSITION 5 CAL SYRINGE SIZE SENSOR CAL FORCE SENSOR 6 ADJUST CONTRAST CAL PRESSURE SENSOR 7 VIEW CALIBRATION DATA CAL PLUNGER POSITION 8 SAVE CHANGES AND EXIT aa Bod IIO PRESS THE NUMBER TO SELECT SIZE AND POSITION ADJUST CONTRAST FA CAL FORCE SENSOR 3 VIEW CALIBRATION DATA CAL PLUNGER POSITION SAVE CHANGES AND ERIT CAL SYRINGE SIZE SENSOR sa 2 Use the and keys to setup the contrast volt age increases contrast ADJUST CONTRAST PRESS ENTER CONTINUE CONTRAST VOLTAGE 8986 ADJUST CONTRAST PRESS lt ENTER gt TO CONTINUE CONTRAST VOLTAGE 8986 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 to return to the BIOMED menu 40 5648 51C Calibration amp Adjustment 105 Calibration amp Adjustment View calibration data This feature allows you to displ
102. ENSL S 3215 39 9 5 lt lt 84 86101 5080 5080 6080 1 AOS MOL L NOS WX 9601 6 WX 01 suos 310000 WHOXOCL 1100 SWigLLLDWI s9 5080 58 1 MOL L 5 WHOOZZ 5141 OELNSL LL 8L 9L pL cc quid 438 001 gt 80123130 3715 9 O 9 Main Board Syringe Sensing N51 45 3715 JIOHNYHL 15110901 125 40 5648 51C Schematics amp PCB Assemblies Main Board Position Sensing 45 4545 NOLLOW 7 N51 S080 MOL L 60105 90 30153139 NOLLOW lt 080 5080 MOL L 006 TUNI WX OL WHON66 7 30100 919 6LZNIL 15041 5080 2080 MOL L 1019 7105 aciem 614 2901 2 D3130 lt lt WOSN3S 8300283 YOLOW qN51 5080 9021 905 MOL L 106 5080 1006146 YLX 9601 MOL L 6t WHOYDOL 3110 L 6919 089 woye m 166 WX 0L ii 06 3901 _ 8 ASTAS 2901 Tilo 6 WHOXOZL 93986 AVL 5080 Aet moll YLX OL Pn 11000 WHOXOZL 10 66 irala 4145 50 ang 5080 5080 5574 MO1ZH 9 5080 106 840551 Ot ws WX 0L 96220 99 NUM LEL J EWS uz tvd 0106 87 Lidl Wroocc 66001 L LL SL vL S 2 0838
103. EYPAD TEST ORIVE TRAIN TEST ee ES 40 5648 51C Troubleshooting Aupio Use the number buttons to select the test ALARM STYLE allows testing of the various alarm tones TEST SPEAKER is a factory engineering test PRESS THE NUMBER SELECT THE MODE 1 SET ALARM STYLE 2 TEST SPEAKER PRESS THE NUMBER TO SELECT BESET ALARM STYLE 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 STARTING THE DISPLAY TEST PRESS STOP ERIT STARTING THE DISPLAY TEST PRESS lt STOP gt ERIT INDICATOR TEST The INDICATOR TEST allows the individual control and testing of each indicator on the front panel ex cept battery and AC Use the number button for the indicator to toggle on or off PRESS THE NUMBER TO CHANGE LED STATE 1 REO ALARM OFF 5 MID IMFUSE OFF 2 YELLOW ALARM 6 RIGHT INFUSE OFF 3 PRESSURE CELL OFF f LOCK OFF 4 LEFT INFUSE OFF PRESS THE NUMBER TO CHANGE LED STATE RED ALARM OFF AMID INFUSE OFF YELLOW ALARM FRIGHT INFUSE PRESSURE CELL OFF LOCK OFF GA LEFT INFUSE OFF 69 Troubleshooting KEYPAD TEST The TEST allows each key to be tested ex cept 65 pressing turns the pump off to be tested Th
104. F1001CT CAL CHIP 47 R6 R15 R20 2010 0 50HM RESISTOR 1 2W TCR 100PPM 1 2010 WSL2010R500F DALE LR201001R500F IRC 48 13 R7 R11 R13 R21 R25 R26 R29 R46 0805W 4 99KOHM RESISTOR 1 10W TCR 100PPM R105 R106 R120 R144 R164 1 0805 RM10F4991CT CAL CHIP 49 24 R27 R30 R31 R41 R42 R61 R62 R78 0805W 10KOHM _ RESISTOR 1 10W TCR 200PPM R92 R96 R97 R103 R118 R123 R124 5 0805 RM10J103CT CAL R156 R170 R171 R172 R177 R178 CHIP R179 R187 50 2 R10 R40 0805W 64 9KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F6492CT CAL CHIP 51 8 R12 R43 R75 R93 R115 R141 R143 0805W 15 0KOHM RESISTOR 1 10W TCR 100PPM R149 1 0805 RM10F1502CT CAL CHIP 52 14 R22 R32 R36 R39 R54 R57 R58 R82 0805W 200KOHM RESISTOR 1 10W TCR 200PPM R83 R84 R94 R133 R146 R173 596 0805 RM10J204CT CAL CHIP 53 1 R23 0805W RESISTOR 1 10W TCR 200PPM 596 0805 RM10J105CT CAL CHIP 54 2 R24 R155 0805W 150 0KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F1503CT CAL CHIP 55 4 R33 R34 R167 R174 0805W 1000HM RESISTOR 1 10W TCR 200PPM 5 0805 RM10J101CT CAL CHIP 40 5648 51C 135 Schematics amp PCB Assemblies QTY REF Designator Package Value Part Spec 56 57 R35 R38 R49 R77 R95 R98 R166 R44 R104 R126 R140 R145 R169 0805W 0805W 2200HM 20 0 RESISTOR 1 10W TCR 200PPM 5 0805 RM
105. FRD ANO Input for main processor to verify the reference voltage used by the 10 bit analog to digital converter and system reference The nomi nal measured reference voltage is 2 048 volts SUPERCAP DETECT ANI 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 capaci tor is present PWR STRB ON AN2 Feedback signal is to check the proper operation of the power con trol circuit When power is on PWR_STRB_ON measures gt 4 0 volts nominally MOTOR SPLY MEAS AN3 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 ANALOG SPLY MEAS AN4 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 FORCE_PSV_ADJ AN5 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 SPEAKER_DETECT AN6 Feedback signal proportional to the current through the main speaker Its level depends on the volume setting for the speaker VPOS_SPLY_MEAS AN7 Signal is proportional to the positive supply voltage The nominal DC voltage for this signal is 2 397 volts exactly one fourth of the VP
106. I 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 set ting 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 resis tance test Protection against leakage current is the concern for any device be it Class I or Class 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 be tween wall AC side and grounded metal The Medfusion 3000 Series pump achieves protection by double isolating second ary power and exposed metal from AC power 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
107. L ON 1NYL 07 1904 dni T EIN 75 D See ee ano1 fdVSO dWv3ld 35803 N51 090 5090 090 000 090 A miS Ads o AS Ads 1901 ol AOS 1404 34027 OdN Z AldS DANA QN51 ND 5 380 D INS 1581 USNS 32803 p 090 090 199500119 199520171018 zene 93 981 or 6 5 8 SSINC Lu LINC 812 nit AS OMM INO CHSNS WIONAId tj N51 LLINC A B0LN Ep 090 090 106 090 NOS ON 189520070018 3 7 i 9 090 AOS 090 OdN 7 MOL L 3404 090 00 06 mE 04 K 0 45 DINA 140 6 9 Ex 30803 BENT 090 YOSNAS 32804 gt NI M A p lt WHOYOZ 9000 71806 SA Tos 5 AS AldS 2901 LO ONS 100 dWV3lid 32804 02929 Loy 00 9 34027 XIANDO 7 Sh 8 O ENS 35803 UNE 1 Mout WHOWLT 090 4 a 106 2 090 140 9 106 090 1D 106 57105 3404 QN51 b 101908 m 4 1531 USNS 32803 AS 1145 2901 1 L WHOYG VC ed AS 4 21901 40 5648 51C Schematics amp PCB Assemblies 40 5648 51C
108. Label Protege Logo 1 ea G6000541 Label Medfusion 3010A Logo 1 ea G6000605 Label Medfusion 3500 Logo 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 51C 153 Assembly Drawings amp Parts Lists Case bottom assembly 17 Medfusion 3500BC 154 40 5648 51C Case bottom assembly parts list See also case bottom service assembly note 4 below To obtain replacement labels with the CE mark and na tional language international customers must order the International Case Bottom Assy See note 4 below Assembly Drawings amp Parts Lists Ref Part Number Description Quantity 1 56000094 Case Bottom No Feet See note 4 1 ea 56000754 Case Bottom With Feet See note 4 1 ea 3 G6000014 Speaker Assembly 1 ea 4 G6000312 PCB Assembly Interconnect see note 6 1 ea 5 G6000773 Power Supply Conformal Coated 1 ea
109. Medium ALARM TO CONTINUE Normal alarm message User programmed callback alarm no remedy required PHARMGUARD DATA TRANSFER Medium Medium 15 RECOMMENDED 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 PRESSURE INCREASING CHECK INFUSION LINE Normal alarm message Backpressure in the infu sion line is increasing User should attempt to clear blockage in infusion line If blockage is not cleared occlusion alarm will result ProFile Does Not MATCH Last SETTINGS PROFILE 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 Pump 15 LOCKED Normal advisory message Press Unlock before changing settings during delivery Rate BeLow RECOMMENDED MIN FOR SYRINGE SIZE RESTRICTED FLow Botus Medium CANCELLED 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 reduc tion 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 40 5648 51C 5 Trou
110. OS_SPLY supply voltage MTR_TIMER PA7 OC1 Time base used by the main processor to control motor step timing and an input to the highest maskable interrupt source MOTION_DETECT PA2 IC1 Signal is the encoded output from the optical motor rotation detec tor BUZZER_DETECT PA1 IC2 Feedback signal from the audio buzzer detection circuit This signal is logic high whenever the audio buzzer is active TOD_INTRPT An independent time base provided by the time of day clock This is a 1 Hz frequency signal MOD_A These inputs configure special processor operational modes MOD_B 40 5648 51C 33 Theory of Operation Signal name Processor port RESET Reset Provided from the system reset circuit located in the Power Control Logic section of the Main PCB VRH 4 096V A D reference and VRL ence pins AVDD AVSS The main processors analog to digital conversion supply and refer Flash memory U22 Flash program memory is 512 K x 8 It is addressed as 16 pages of 32 K x 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 soft ware through the infrared serial port Static random access memory U17 Static RAM is 32 K x 8 bit Serial EEPROM U2 and U4 The
111. Plunger Board Flipper Sensor 140 Plunger Board Assembly Drawing 141 Plunger Board Assembly Parts listos nint 142 Battery Gauge Schematic 143 Interconnect Board Schematic 144 Interconnect Board Power Cobftol certet 144 Interconnect Board Battery Management 145 Interconnect Board Infrared Serial Communications cscs sais o irren tetris 146 Interconnect Board Assembly Drawing 147 Interconnect board assembly parts list 148 Assembly drawings 151 Vill Assembly Drawings amp Parts Lists 151 Medfusion 3000 series main pump assembly 152 Medfusion 3000 series main pump assembly parts 153 Case bottoni 154 Case bottom assembly parts 115 155 Case Top assembly PMI 156 Case top assembly w plunger parts list 157 Case top assembly without plunger 158 Case top assembly without plunger parts list 159 assembly dini etiim edet 161 Barrel clamp assembly parts list 162 Driye MP nun eina 163 Drive train assembly parts list een 164 Clutch aes ET esconde 165 Accessories parts list 166 Poleclatp assembly 4
112. R CMPT 2222ATR or TR13 CENTRAL SEMICONDUC TOR 8 1 Q2 SOT23 TPO610T Supertex Vishay Silconix TEMIC obsolete 9 2 R1 R10 0603 267 00HM RESISTOR 1 16W TCR 100PPM 1 0603 RM06F2670CT CAL CHIP 10 1 R2 0805 2 7MOHM RESISTOR 1 10W TCR 200PPM 5 0805 10 275 CAL CHIP 11 3 R3 R6 R8 0603 24 9KOHM RESISTOR 1 16W TCR 100PPM 1 0603 RM06F2492CT CAL CHIP 12 3 R5 9 0603 2 0KOHM RESISTOR 1 16W TCR 100PPM 1 0603 RMOGF2001CT CAL CHIP 13 1 R7 0805 1000HM RESISTOR 1 10W TCR 200PPM 5 0805 RM10J101CT CAL CHIP 14 1 UI SO8 LT1167CS8 LINEAR TECH NOLOGY AD620AR ANALOG DEVICES 15 2 U2 U3 RPI LEADEDOPTO RPI 352 ROHM 16 1 PCB N A PCB RAW 142 40 5648 51C Schematics amp PCB Assemblies Battery Gauge Schematic S080 MOL L S Meu eas ZLY S080 5080 MOL L MOL L S S yey 995 SLY 5080 MOL L S yeu LLY 5080 5080 5080 MOL L MOL L MOL L 6 6 6 yey eas yeyd eas gt 919 5080 MOL L S ieu 995 014 5934 1244 0115313 ALIDVdVD 5080 5080 MOL L AOS S OdN S OL 90001 68 11 8 5 105 S 8XVIN ZN 7 i YSA TO QV3T AH3LIV8 9021 DUE AOS S080 01 MOL L nro 6 62 001 9935 ol ZA 6 D us g
113. T 768 pA n 2105 9 GHI AHLIV8 T T amp D3I30 8 080 MOL L MOL L jd w WHOYOCC 491 9919 esd v sogo ut 0105 Mui ue 1015044 6LD WHOODL 0641 0Sldl a 01 331 Auillvg lt lt e X 7 Fi Ten t DILI uMd 8 9 S sa ZN 5080 0 80105 WHOMOZL 2 I e 8 9 S vd 7105 007 z 1 S oza 57105 gt TOT SOGHDLYM PL Z S a 10 S 031 DNINYYM b 62106 els MOL L 966 78541 WHO09L 26041 01 G37 5NINSVM QVdADI lt lt 31101 5 40 5648 51C Schematics amp PCB Assemblies Main Board Keypad Interface Continued OL XMSYMd AYAAN gt OL QV ol qv 0L LMOW QV 0L OMOY av 5080 MOL L S WHOYOL 55141 105 00 Lp L6daWww 029 145 SCSNCL r 7105 000 4 21901 4 N51 SS LL COOLNZ 820 S8SNCL wda 5080 MOL L 968 WHOXOL 198 o S 21501 MOL L 965 WHOYOL veld Mod 02 9 m Hd fH 01 5102 gt
114. TA GA VIEW INFUSION HISTORY VIEW EEPROM SIZE Set View Last Next PM Date Depending on your pump version this feature will either SET ViEW Last PM DATE or SET VIEW 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 Troubleshooting Note ensure current date and time are correct in SET TIME DATE ENTER LAST PM DATE PRESS ENTER CONTINUE CLEAR BACKSPACE ENTER ENTER NEXT PM DATE PRESS ENTER CONTINUE CLEAR BRCKSPRCE 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 23 88 13 52 MIN 80 08 BACKSPACE ENTER ENTER CURRENT TIME PRESS ENTER TO CONTINUE MAK 24 88 88 13 7 i MIN 80 00 00
115. TCR 100PPM 1 0805 RM10F3923CT CAL CHIP 69 R113 0805W 510HM RESISTOR 1 10W TCR 200PPM 5 0805 RM10J510CT CAL CHIP 70 R119 R131 R165 0805W 49 9KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F4992CT CAL CHIP 71 R150 0805W 24 9KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F2492CT CAL CHIP 72 136 R160 0805W 475 00HM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F4750CT CAL CHIP 40 5648 51C Schematics amp PCB Assemblies QTY REF Designator Package Value Part Spec 73 412 TP1 TP2 TP4 TP5 TESTPOINT N A 74 2 TVS15 TVS16 0805W VC080505A150 AVX 75 5 ULUI4 U23 028 042 TSSOP8 OP296HRU ANALOG DEVICES 76 2 U2 U4 SO8 AT25256AN 10SU 2 7 Atmel M95256 WMN6TP ST Microelec tronics M95256 WMN6 TGST Microelectronics 77 2 U3 U33 44PLCC 582 55 HARRIS INTERSIL MSM82C55A 2VJS OKI 78 1 U5 TSSOP 14 SN74AHCOOPWR TEXAS INSTR 79 U6 U41 TSSOP20 SN74AHC541PWR TEXAS INSTR 80 1 U7 SO8 LM2936M 5 0 NATIONAL SEMI 81 1 U8 SSOP8 RS5C316B RICOH 82 1 U9 SO8 AD623AR ANALOG DEVICES 83 U10 027 030 507 23 5 LMC7111BIM5 NATION AL SEMICONDUCTOR MIC7111BM5 MICREL 84 1 1011 TSSOP14 SN74ACH125PWR TEXAS INSTR 85 2 U12 U34 SO8 LT1372CS8 LINEAR TECH 86 1 U13 SO16 TLV1544CD TEXAS INSTR 87 1 06 TO236AB LM4
116. W NY 40 5648 51C 130 Schematics amp PCB Assemblies Main Board Assembly Drawing Top Side
117. WBV 992718 rile ai ii 90181 2 5080 i e 6 T WHOYoOc MOL L tie 6 lt 7 041899 o OV AS 40 5648 51C Schematics amp PCB Assemblies Main Board DC D Converter 9415 A 96141 mm 2 Ws 519 INY 602 9071 vid into ino 46 SONY mo T at 106 WHONE6 7 27 A 3l 9 5080 VLS X960 MOLS decal on i m MOL L 08416 Sel 9LLN8 805 ones cq ASE ASE t DI 02 40027 300027 IWS y Sp 6p 0 gjan 6EEdL 090090 NMGHS N51 T gza 1145 YOLOW 9071 8664 5 Alddfs YOLOW ALL 81D 167815 OLXOL IWS ASE anol 02 dnoge t 5080 QD AOS 01 PA 31 0 59 PA 5080 6541 MOL L l soso 500 WHOM66 MOL LS 9c 5 41 5000 96741 1014 WHOX0L 90 6 805 Lidio QHZOdEJSWW 1698 0 ML p ia WHOYO SL 5 jn mi DOMS oet w 114002 dV AOOL YX OL anl INS 91 Alddfs 21901 AS AS AMS 21501 001 080 A 14501970018 AS AMS 21501 2 VIV O viva 1WX MOd 24 XMSNN 199103130 9 AY3 LLY QN51 6 viva MALLE lt lt
118. a 6 0502002400 Compression Spring 4 7 G6000497 Rotor Base 1 8 046L050200 4 20 x 5 Button Head Hex 1 ea 9 G6000505 Indexing Plunger 24 Thread lea 10 6000538 Assy Plate Back lea 11 G6000286 Poleclamp Bracket 1 13 G6000774 Screw 8 32 x 7 16 PAN Head Phillips w Washer Nylock 5 4 14 6000551 Bracket Poleclamp Stop 15 G6000104 Screw 4 40 x 25 BH Black 16 6001456 Knob 13 x 27 Stainless 17 G6000288 4 External Conical Tooth Lockwasher 2 18 G6000345 Screw 4 40 x 16 FH Locking SS 2 ea Miscellaneous parts Part Number Description Quantity G6000329 AC Line Cord North American Class II 1 ea G6000193 AC Line Cord North American 3 Wire 1 ea G6000330 AC Line Cord United Kingdom Class II 1 ea G6000331 AC Line Cord Continental European Class II 1 ea 40 5648 51C 167 Assembly Drawings amp Parts Lists Calibration amp repair parts list Medfusion 3000 series calibration kit The Biomed Medfusion 3000 Series Calibration Kit contains the tools necessary for performing the peri odic maintenance and calibration of the Medfusion 3000 Series pumps Order kit number 3000CAL This kit contains the following items e lea Small Calibration Slug G6000216 lea Large Calibration Slug G6000215 e lea Analog Force Gauge G6000294 Other tools amp equipment required to service Medfusion 3000 series pumps The following tools are neces
119. ack 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 42 Nm 9 Ifusing the pole clamp reattach it to the pump with the 2 flathead screws Torque these screws to 160 in oz 1 13 Nm Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality be fore returning it to use 40 5648 51C Battery pack This section defines the steps for removing and replac ing the battery pack for the Medfusion 3000 Series pump Tools needed For this disassembly procedure you will need e Torque screwdriver with a Phillips head Always work at an electrostatic controlled work sta tion 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 2 Remove the 2 flat head screws from the battery compartment cover and then remove the cover 3 Carefully remove battery pack from the compart ment 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
120. aded sensors Plunger force sensor The plunger force sensor is a full bridge strain gauge which generates a voltage proportional to the force ap plied by the plunger driver to push the syringe plung er The allows the microprocessor to measure e Voltage proportional to force applied to the sy 30 ringe plunger i e occlusion detection e Uses self test control line to verify force sensor and circuitry are operating properly 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 e Reports a logic state to the microprocessor to indi cate proper syringe plunger loading e Uses self test signal to verify the sensor is not in an electrically stuck state 40 5648 51C 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 e 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 indi cate that those signals are active low In the block diagram
121. alibration 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 40 5648 51C Scheduled Maintenance Plunger position sensor check 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 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 to exit Biomed mode Load an air filled 50 or 60 cc sy ringe into the pump Use the number buttons to choose ML HR delivery mode and set the flow r
122. amp size Complete Mandatory Annual Mainte nance Testing Repair sensors Replace ear clip or ear clip sensor Recalibrate size Quick Check out amp Calibration Verifi cation Replace barrel clamp assy or size pot Recalibrate size Quick Check out amp Calibration Verifi cation Replace force sensor Recalibrate force Quick Check out amp Calibration Verifi cation Replace position pot Recalibrate position amp size Quick Check out amp Calibration Verifi cation amp Plunger Travel Test Repair electronics Replace speaker None Quick Check out Replace interconnect None Quick Check out cable Replace AC supply None Quick Check out Replace battery None Quick Check out amp after AC charging run Power up Tests Replace interconnect None Quick Check out board Replace keypad display None Quick Check out amp Calibration Verifi or backlight cation Replace main board Recalibrate all sensors Complete Mandatory Annual Mainte component nance Testing Replace plunger board Recalibrate force Quick Check out amp Calibration Verifi component cation Software Updates Reprogramming See update instructions See update instructions Repair case or case parts Replace case bottom None Quick Check out 108 40 5648 51C Calibration amp Adjustment Replace case top Recalibrate all sensors Complete Mandator
123. amp K MAGNETICS 40 5648 51C Schematics amp PCB Assemblies QTY REF Designator Package Value Part Spec 23 1 12 SMT_INDUC 3 3UH NL453232 3R3K CAL CHIP TORI IMC 1812 3 3UH 10 DALE 24 1 13 TH_10MMX7_ PLT2003C MURATA ERIE 5MM 25 1 PSI POLYSWX_RA RUE185 RAYCHEM DIAL 26 4 01 08 010 023 SOT23 2N7002 T1 TEMIC CENTRAL SEMICONDUCTOR 27 02 23 MMBT2907ALT1 MOTOROLA 28 04 05 SOT23 MMBT2222ALT1 MOTOROLA 29 1 06 SO8 IRF7201 INTERN RECTIER SI9410DY 30 1 07 SO8 MMSF3P02HD MOTOROLA SI9430DY SILICONIX 31 2 Q9 O11 SOT23 0610 Supertex Vishay SILI CONIX TEMIC Obsolete 32 2 RL R23 1206W 100 00HM RESISTOR 1 8W TCR 100PPM 1 1206 RM10F1000CT CAL CHIP 33 1 R2 1206W 220 RESISTOR 1 8W TCR 400PPM 5 1206 RM12J240CT CAL CHIP ERJ 8GEYJ240V PANA SONIC 34 1 R3 1206W 1 50HM RESISTOR 1 8W TCR 400PPM 1 1206 8 1 5 PANA SONIC RM12F1R5CT CAL CHIP WCR12062R49F IRC 35 1 R4 2010 0 5 RESISTOR 1 2W TCR 100PPM 1 2010 WSL2010R500F DALE LR2010001R500F IRC 36 6 R5 RIO R14 R19 R24 R26 0805W 200KOHM RESISTOR 1 10W TCR 200PPM 5 0805 RM10J204CT CAL CHIP 37 5 R6 R9 R15 R16 R27 0805W 10 0KOHM RESISTOR 1 10W TCR 100PPM 1 0805 RM10F1002CT CAL CHIP 38 4 R7 R8 R17 R29 0805W 1 0KOHM RESISTOR 1 10W TCR 100PPM 1 0805
124. ard 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 Ifthe back light has a 2nd fiber optic tail cut the wire tie anchoring its connecting cable and sepa rate the 2nd tail from the connecting cable 6 With 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 Ifthe backlight has one fiber optic tail then you will use two clear plastic spacers in the next step 86 If your backlight has two fiber optic tails then you will use only one clear plastic spacer in the next step 4 Place the clear plastic spacer s on top of the backlight with the white side of the back light fac ing up and the silver side down 5 Gently slide the back light and spacer together into the display with the clear plastic spacer toward the display glass 6 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 7 Slide the display onto the ribs
125. are diskette and instructions on certain models Understanding Biomed mode Periodic maintenance and troubleshooting on Medfu sion 3000 Series infusion pumps are aided by use of the Biomed software interface What is biomed e cal force sensor The following is an outline of the Biomed software Calibration Diagnostics cal size and position Audio test Display test The Biomed feature is the special utility intended for use only by trained biomedical service technicians pont chee tes cal pressure sensor cal plunger position Keypad test Biomed has its own security access code cal syringe size sensor Monitor analog sen Biomed is for calibration of the pump s sensors Biomed is for diagnosis of digital and analog sen 5 Gayest contrast Monitor digital sen sors contained in the pump sors view calibration data e Biomed allows access to infusion history log and save changes and exit Monitor battery status alarm history log stored in the pump 7 e Drive Train Test V4 Motor drive test Monitor a2d self test Monitor 6811 a2d Biomed is for testing of the pumps drive systems Biomed is for monitoring the status of the pump battery Biomed is for setting the pumps last V3 or next V4 preventive maintenance date groupl Biomed is for setting the time and date Monit
126. area towards the carriage turn con nector in line with the cable then thread the cable through the plunger tube 2 Plugthe 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 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 0 71 Nm Close plunger case per procedure below Replace lead screw per procedure above 85 Parts Replacement LCD and backlight This section defines the steps for removing and replac ing the LCD Display and Backlight for the Medfu sion 3000 Series pump Tools Needed For this disassembly procedure you will need open end wrench e Torque screwdriver with Phillips head amp small flat head Always work at an electrostatic controlled work sta tion 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 bo
127. ate to 20 ml hr Clear the total infused Press 1 Verify the three green infusing indicators are lit in repeating sequence from right to left Continue running until at least 0 033 ml has been infused 2 Press Lock and verify the Lock indicator lights Press Unlock and verify the Lock indicator turns off 3 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 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 to silence alarm If other alarms or system failures occur during this test use the troubleshooting guide for corrective actions Motor drive amp 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 1 Use the number buttons to choose ML HR mode and set the flow rate to the maximum rate as dis played on the ml hr entry screen From the BEGIN DELIVERY screen press to access the PRIME screen Press and hold to prime the tubing set for at least 0 2 ml priming volume Press Exit Close the stopcock to the syringe 2 Press Options use the number buttons to choose OVERRIDE Occr choose then press Enter 3 Press Options then use number buttons to choose DISABLE R
128. ay be inoperative and the stepper motor stalled when an occlusion occurred Motor 0 Vottace BGND Test Background self test measured an invalid range on motor supply volt age Use BIOMED gt DIAGNOSTICS to check the voltage Replace the main board if invalid voltage found Motor VoLuME Limit ERROR The motor has run more steps than should have been required to deliver the set volume limit PLUNGER SENSOR FAILURE Software sensed plunger sensor voltage out of range The plunger position sensor potentiometer may be unplugged or have an open connection Use BIOMED gt DIAGNOSTICS gt MONITOR ANALOG SENSORS to check operation of plunger position sensor Open pump case and check connec tions to plunger sensor Replace plunger position sensor Positive Supply BGND Test The power supply has malfunctioned Check the outputs of the supply 40 5648 51C 63 Troubleshooting System failure alarm Cause or remedy Primary ALARM BGND Test Background self test sensed no current flowing in the primary speaker Speaker may be unplugged or wire came loose from connector Check con nections from main board to interconnect and from interconnect board to speaker Replace speaker if wiring is intact PRIMARY AUDIBLE ALARM Post Power up self test sensed no current flowing in the primary speaker Speaker may be unplugged or wire came loose from connector Check con nections from mai
129. ay the pumps calibration data onscreen This screen is generally used in factory service or for troubleshooting 1 106 From the CALIBRATION menu choose VIEW CALI BRATION DATA CAL SIZE AND POSITION 5 CAL SYRINGE SIZE SENSOR CAL FORCE SENSOR 6 ADJUST CONTRAST CAL PRESSURE SENSOR 7 VIEW CALIBRATION DATA CAL PLUNGER POSITION 8 SAVE CHANGES AND EXIT td IO PRESS THE NUMBER SELECT THE MODE SIZE AND POSITION ADJUST CONTRAST FA CAL FORCE SENSOR E VIEW CALIBRATION DATA CAL PLUNGER POSITION SAVE CHANGES AND ERIT CAL SYRINGE SIZE SENSOR PRESS THE NUMBER TO SELECT When ready press Continue to return to the CALI BRATION menu You may calibrate another mode choose SAVE CHANGES AND EXIT to exit calibra tion or press to return to the BIOMED menu PRESS CONTINUE WHEN READY FORCE 42 COUNTS 75 COUNTS 8 PLUNGER POS 151 COUNTS 961 COUNTS PRESSURE COUNTS B COUNTS SYRINGE SIZE 125 COUNTS 975 COUNTS PRESS lt CONTINUE gt WHEN READY FORCE 42 COUNTS 472 COUNTS 138 PLUNGER POS 151 COUNTS 981 COUNTS SYRINGE SIZE 125 COUNTS 973 COUNTS CONTINUE 40 5648 51C Calibration amp Adjustment Save changes and exit This feature is the normal path to save the new cali bration values when exiting BIOMED gt CALIBRA TION If a mistake occurred in the calibration process press
130. ble alarm continues running from the super capacitor on the main board 6 After several minutes of recharging the gauge will show the learned capacity of the battery 7 Turn the pump on and select BIOMED gt DIAG NOSTICS gt MONITOR BATTERY STATUS 8 Verify LMD last measured discharge value is greater than 1600 ma hours 9 Press More and verify CPI is 0x00 or 0x01 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 gt DIAGNOs TICS gt MONITOR BATTERY STATUS 12 Verify the LMD is greater than 1600 mA hours At 1600 mA hours battery the pumps battery life is approximately 7 8 hours It is recommended that the battery be replaced if its capacity is less than 1600 mA hours Requirements for battery pack replacement The battery must be replaced only by a trained Bio medical 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 com ponents including batteries that may contain materi als which if disp
131. bleshooting Alarm priority infusing Alarm message programming RESTRICTED FLow LOADING CANCELLED Cause or corrective action 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 RESTRICTED FLow RATE Medium REDUCED 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 load ing dose will be cancelled Set Limit Normal Alarm Message In order to set a KVO rate you must first set a volume limit SYRINGE Does Nor MATCH LIBRARY ENTRY SYRINGE Empty 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 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 Empty MANUAL Normal alarm
132. buttons and what they are used for 40 5648 51C Introduction 0 11 Optional Poleclamp Mount If desired attach the optional poleclamp here 12 External DC Power Input Jack Plug approved exter nal DC power supply into jack 13 RS232 Connection Port Plug RS232 connector into the port to allow upload of data from and down load of data to a pump from a PC This port is also used to load the pump software Keypad closeup es 7 eo 89 6600 66006 40 5648 51 Introduction Button When pump is paused When pump is delivering Alarm Silence Silences audible alarm Allows Silences audible alarm Allows operator to tor to switch the display backlight from switch the display backlight from bright to bright to dim or dim to bright dim or dim to bright Power 69 Push and hold to turn pump Off Push and release then push and hold to turn pump Off Menu buttons Function is defined on the display Function is defined on the display Back Gack Reverts to a previous step or level Reverts to a previous step or level if adjusting settings Numbers amp Decimal Set number values or select options Set number values or select options Stop 6 Stops delivery pump remains Start Starts delivery N A Bolus Begins priming after confirmation Begins delivery of programmed bolus after confirmati
133. 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 Exp 1 PDO PD2 Frequency PW1 Speaker Amplification gt Volume PW2 gt A D Channel 6 Speaker Test Circuit Illustration of Speaker Drive Speaker control Tone duration is controlled by the interval the am plitude level is applied The SPEAKER_FREQUENCY signal is a fixed 50 duty cycle square wave with a variable frequency to 1 kHz The SPEAKER_VOLUME is a pulse width modulated signal converted by hardware to an analog voltage which controls the speaker volume e The rise and fall times of the volume are controlled by input signals from SPEAKER ENVELOPE 1 SPEAKER ENVELOPE2 and SPEAKER ENVELOPE 3 46 40 5648 51C Speaker test The return signal from the speaker detects whether current is flowing in the Speaker from analog condi tioning 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 e The SPEAKER_DETECT output signal from the conditioning circuitry goes to the microprocessor s analog input 40 5648 51C Theory of Operation Plunger board schematic level T
134. charge This the learned capacity of the battery by the gauge following a calibration cycle Replace the battery when this is lt 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 gt 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 Steps and processes for using BIOMED gt CALIBRATION functions are found in the Adjustment amp Calibration section A set of functions which allow the detailed examination of the pump s systems sen sors indicators and controls Steps for using BIOMED gt DIAGNOSTICS functions are found in the Scheduled Maintenance and Troubleshooting sections The set of BIOMED gt UTILITIES contain a mixture of adjustment and troubleshoot ing options These are Set View Last 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 pump memory This is a troubleshooting feature You may page backward and for ward through stored alarms in order to identify possible malfunction patterns View Infusion History Used to view programming and infusion information stor
135. 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 42 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 51C Parts Replacement greater than 95 then charge current is reduced to 50 ma or greater 4 If lt 0 ma then check connections to AC power Note negative current means the battery is dis charging 5 If there is no battery information on the Monitor Battery Status screen then check battery connec tion on battery pack or connection on the inter connect 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 be fore returning it to use 77 Parts Replacement Interconnect board This section defines t
136. correction Stepper motor stepper motor drives the syringe plunger driver Each motor step is controlled by the microproces sor using an open loop control method Syringe flange loaded sensor The syringe flange sensor requires the flange be in stalled in the flange locating device on the pump e Reports a logic state to the microprocessor to indi cate proper syringe flange loading e 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 e 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 indicat ing source of power supplied b Contains battery charger for charging the battery c Contains an infrared drivers for serial communi cation 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 amp power supply board This AC Power
137. criptions in section below DESCRIPTION SYSTEM FAILURE High High See detailed descriptions in section below DESCRIPTION Pump Medium Medium If pump is left in a user input screen e g set rate User CALL BACK or titrate rate for more than 30 seconds the pump alarms Go to pause screen or main screen to get longer alarm silence intervals 40 5648 51C 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 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 was lost and primary data was used to restore back up values No action is required DEFAULT CONFIGURATION RESTORED 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 PROGRAM gt 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 History DATA CORRUPTED Infusion history log is stored in non volatile serial EEPROM on the main board This mes
138. ction to verify pump functionality be fore returning it to use 80 Bottom housing plastic Tools Needed For this disassembly procedure you will need open end wrench e Torque screwdriver with a Phillips head and small flat blade Always work at an electrostatic controlled work sta tion 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 inter connect 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 bot tom 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 ap
139. d 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 reas sembling any Medfusion 3000 Series pump Note Part numbers and pricing are subject to change without notice See the website at www smiths medi cal com 40 5648 51C Assembly Drawings amp Parts Lists Medfusion 3000 series main pump assembly P Cal E 152 40 5648 51C Medfusion 3000 series main pump assembly parts list Assembly Drawings amp Parts Lists Ref Part Number Description Quantity 1 See following drawing Assembly Case Bottom 1 ea 2 G6000059 Screw 4 40 x 62 PH Phillips 2 3 No longer required Label Device Tracking 1 ea 4 G6000775 Label Warning 1 ea G6000763 Label Warning CE Mark 1 ea G6000354 Label Warning German 1 ea 5 G6000112 Door Battery Bay 1 6 G6002083 Label Serial Number Blank 1 ea 7 G6000117 Screw 4 40 x 31 FH SS 2 ea 8 G6001392 Battery Assy 3000 1 10 See following drawing Assembly Case Top w Plunger Head 1 ea 12 G6000979 Label Battery Warning 1 ea 16 See note 2 Label Date of Manufacture 1 17 G6000418 Label MRI Warning 1 ea G6000623 Label MRI Warning German 1 ea G6000631 Label MRI Warning Spanish 1 ea 18 G6000142
140. dicates a syringe is loaded ACU PWR STRB ON 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 gt 4 0 volts nominally ASYNC_BATTERY_ 5 The single wire asynchronous data communication between the DATA main processor and the battery gauge located on the battery pack This port pin is bi directional both input amp output iQ CSIO Chip select for the two 24 bit I O expansion devices This signal is active low RAM_CS CSGPI Chip select for the main processor external random access memo ry RAM This signal is active low EEPROMI 5 PH6 Chip select for SPI communication to the serial 2 PROM 1 This signal is active low FLASH CS Chip select for access to the main processors programmed memory FLAsH This signal is active low 39 40 5648 51C Theory of Operation Signal name Processor port Description WRITE E_CLOCK R w E XAD The main processor control bus signals that route to the memory XADDR 15 18 2815 XAD and I O expansion devices The address line addr15 is not used ADDR 0 14 7 DR18 ADDRO ADDR14 and DATAO DATA7 SPI CLOCK SPI MOSI SCK MOSI These signals are used for SPI bus communication to the Serial and sPI MISO MISO EEPROM Time of Day Clock Analog to Digital Converter and the Digital to Analog Converter ATOD REF B
141. display interface 43 123 H High priority 11 53 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 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 51C Index 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 Mot
142. e This chapter discusses battery maintenance as recom mended 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 per formance 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 fol lowing 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 calibra tion It is recommended that you recalibrate the battery when CPI is gt 80 hex i e gt 128 decimal Refer to the battery calibration section below Shallow discharge CPI record The battery gauge records the number of shallow di
143. e POWER_ENBL signal is verified by the main microprocessor monitor ing the BUZZER_ARMED signal Watchdog During a watchdog alarm the auxiliary controller has sole control of power off 40 5648 51C Theory of Operation 39 Theory of Operation DC to DC converter The circuits for the DC DC Converter provide all regu lated 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 opera tion from an unregulated DC source simplifying the requirements for the switched sources e Refer to the DC DC Converter section of the Main PCB schematic for details Switched DC Source Positive Supply 10 volts Negative Supply 10 volts Inverter LCD Contrast Supply LCD Backlight Control Flowchart of DC amp DC Converter Operation Logic supply U12 The Logic Supply current mode switching regulator provides a regulated output voltage of 5 volts 2596 for the system logic Motor supply U34 The Motor Supply is a current mode switching regula tor 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
144. e barrel clamp resting flush on the case top Ensure the flippers are below closed the force gage head and use the thumbscrew to ad just the gauge to 10 lbs 0 2 then press Continue The force calibration is complete 6 You return to the CALIBRATION menu You may librate another mode choose SAVE C cm calibrate anot er mode choose SAVE CHANGES oo e AND EXIT to exit calibration or press to return to the BIOMED menu 40 5648 51C 101 Calibration amp 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 PRESS THE NUMBER TO SELECT THE MODE CAL SIZE AND POSITION 5 CAL SYRINGE SIZE SENSOR CAL FORCE SENSOR 6 ADJUST CONTRAST CAL PRESSURE SENSOR 7 CALIBRATION DATA CAL PLUNGER POSITION 8 SAVE CHANGES AND EXIT td ba PRESS THE NUMBER TO SELECT FI CAL SIZE AND POSITION Rd ADJUST CONTRAST CAL FORCE SENSOR 3 VIEW CALIBRATION DATA CAL PLUNGER POSITION SAVE CHANGES AND EXIT CAL SYRINGE SIZE SENSOR eS 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 VALUE DATA 200 COUNTS PLUNGER POS
145. e force 100 Calibrate pressure sensor ODEDDBD 102 Calibrate plunger positionis 102 Calibrate syringe size 104 Adjust contrast voltage 105 View calibration data usce serre ISO Ei 106 chang s 107 Exit calibration without saving changes 107 Retest guidelines 108 System layout 111 VII Schematics amp PCB Assemblies 111 Main board schematics 112 Main board logic kernel iris 112 Main Board Power Control Logic Core 116 Main Board DC DC Converter usar teet 118 Board Keypad 120 Main Board Graphic Display Interface 123 Main Board Motor Drive 124 Main Board Syringe Sensing ausente tis 125 Main Board Position 126 Main Board Force Sensing 127 Main Board Pressure 128 Main Board Speaker Dive siisii 129 M n Board ACU ICE SORE 130 Main Board Assembly Drawing Top Side 131 Main Board Assembly Drawing Bottom Side 132 Main Board Assembly Parts list 133 Plunger Board Schematic 139 Plunger Board Force Preamplifier en 139
146. e only exit from this test is to press Exit PRESS THE KEY YOU WISH TO TEST RELEASED NUMBER FOUR ERE 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 lt BACK gt STOP FORCE 64 CHTS 256 1 8 5885 PRESSURE 8 CHTS PLUNGER POS 375 CNTS 1 5080 1 8981 SYRINGE SIZE 632 CNTS 2 5280 8 8531N a a PRESS lt BACK gt STOP FORCE COUNT B BBLB PLUNGER POS COUNT 95 5 2IN SYRINGE SIZE COUNT 982 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 in dicates 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 lt BACK gt STOP SYRINGE PLUNGER SENSOR TRUE SYRINGE EAR SENSOR TRUE PRESSURE CELL SENSOR TERUSE MOTOR RATE SENSOR FALSE
147. e voltage Replace the main board if invalid voltage found Aux CONTROLLER UNit Post 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 BACKGROUND CRC Test TIMEOUT BACKGROUND SELF TEST TIMEOUT Software timing failure A transient failure may have occurred in the soft ware if problem recurs replace the main board Software timing failure A transient failure may have occurred in the soft ware if problem recurs replace the main board Backup AubiBLE ALARM Post 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 REQUIRED 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 Switch BGND Test Key on keypad was found stuck on during continuous background self test Use BIOMED gt DIAGNOSTICS to determine which key is stuck If stuck key is found replace keypad Key SwitcH Post Key on keypad was found stuck on during power on self test Use BIOMED gt DIAGNOSTICS to determine which key is stuck If stuck key is found replace keypad CRiricAL Data BLock BGND Test De
148. ed 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 ver sion of software installed within the pump Two pumps can communicate through their built in infrared serial communica tions interface with one teaching and the other learning to copy pump configura tion settings and libraries 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 sec tion of this manual The circuitry which measures present battery charge status against stored battery capacity data to determine a depletion situation The EN 475 alarms use tones designed for use by customers following European standards These generate High Medium amp Low Priority Alarms 40 5648 51C 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 LMD Last Measured Discharge Low Priority Alarms Medium Priority Alarms 40 5648 51C Introduction Circuitry which determines when and if external power whether AC or DC has
149. eiie 70 Monitor Battery Status 70 Drive Train 70 BIOMED gt DIAGNOSTICS screen 2 2 70 Motor Drive Test esent 71 Monitor a2d sse 71 Monitor 6811 Group 71 Monitor 6811 A2D Group2 71 BIOMED gt UTILITIES 71 Set View Last Next PM 71 SET TIME DATE 72 View Alatt aee eso 72 View Infusion History 72 VIEW SOFTWARE CRCs amp VIEW SOFTWARE ten dest 72 Service 72 View EEPROM Size available only 3500 pumps version 4 and higher 72 BIOMED gt UPDATE FIRMWARE not available on Medfusion 3500 pumps version 4 and higher 73 Set Language Not available on Medfusion 3010 and 30104 etre tette tees Regen 73 Maintenance warnings cautions 75 SEF VICE WALMINGS m 75 Service CAUTIONS 75 V Parts Replacement 75 Opening amp closing the pump housing 76 TQS heeded P E 76 Opening the pump housing 76 Closing the 76 Battery pack 77 Tools neededi 77 Removing the battery pack
150. ematic level The battery reports to the Main system microproces sor present status and controls battery charge from the Interconnect PCB The battery PCB has a3 volt Linear Regulator e a Gauge IC anda Depleted Battery Monitor IC The local circuit allows the battery to maintain its cur rent capacity regardless of where the battery resides The referenced schematic signal nets of the main board electronics are identified using names in SMALLCAPS 52 Battery gauge function The gauge IC BQ2012 monitors direction and mag nitude of current flowing through the battery The current is sensed by the gauge as a voltage across R4 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 tempera ture CHARGE signal from the gauge controls the bat tery charger located on the Main PC board to charge at different rates depending on the state of the battery The gauge terminates standard charge in the event of the battery temperature exceeding 50 C or if the bat tery pack voltage is less than 5 7 volts Severely depleted battery monitor 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 w
151. en end wrench remove the 2 flathead screws amp Nylock nuts Medfusion 3500BC Remove screw holding earth ground con nection 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 wires oriented toward the bottom of the housing Medfusion 3500BC Install AC Input Module As sembly with 3 wires mains wires oriented toward the bottom of the housing earth wire oriented toward the top 2 Insert the 2 wires into the Terminal block on the power supply 3 Tighten the 2 screws of the Terminal block Torque to 32 in oz 0 23 Nm 4 Secure with the 2 flathead screws amp Nylock nuts Medfusion 3500BC Reinstall the earth wire from the A C inlet to the A C supply mounting post fur thest from the A C inlet Torque to 60 in oz 0 42 Nm 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 42 Nm 7 Replace the battery pack battery cover and secure with 2 flat head screws Torque to 60 in oz 0 42 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 se
152. en loosen the main board It is not necessary to remove the main board or discon nect all cables from it to access the keypad 8 With open end wrench remove the 2 Nylock nuts securing the display board and remove the display from the top housing 9 With 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 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 key pad 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 0 71 Nm 6 Slide the display assembly into the ribs on t
153. en set active low causes 2 to apply resistance parallel to the force sensors bridge resulting in a positive shift of the sensor output The sensing system requires calibration to de termine zero adjustment offset and gain Cali bration 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 sen sors on and off This is controlled by the signal PLUNGER_SNSRS_ENBL from the Main PCB 40 5648 51C 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 sup ply and the main PCB Speaker Decoupling Power Ex
154. es 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 pa tient or the user e 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 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 manufac turer recommended instructions in this Service Manual An improperly maintained pump may cause serious injury to a patient or user Safety Class Type CF Medical Equipment 40 5648 51C Introduction pump is listed as Safety Class Type CF equip ment 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 leak age test it is not necessary to measure leakage in both the open ground and closed ground setting Nor is it necessary to perfo
155. following drawing Assy Case Top w o Plunger l ea 31 G6000544 Screw 6 19 x 15 See note 3 2 ea 32 G232100076 Loctite Black Max 35 G6001656 O ring See note 2 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 mod els do not require this part 3 Use with Loctite Black Max part number G232100076 Item 32 40 5648 51C 157 Assembly Drawings amp Parts Lists Case top assembly without plunger i oo IJ 1 al Quy di 158 40 5648 51C Case top assembly without plunger parts list See also case top service assembly note 2 below Assembly Drawings amp Parts Lists Ref Part Number Description Quantity 1 See note 2 Case Top With Tubing Holders 1 ea 2 See note 4 Keypad 3000 1 ea 3 G6000021 Stud Self Clench 4 40 x 625 2 ea 4 G6000022 Spacer 25 OD x 31 Nylon 2 ea 5 G6001457L Display Liquid Crystal 1 ea 6 G6000023 Ear Clip 1 ea 7 See following drawing Assembly Barrel Clamp 1 ea 8 G6000034 E Ring 1 9 See following drawing Assembly Drive Train 1 ea 10 See note 3 Assy 3000 Main PCB 1 ea 11 G6000010 Optocoupler Assembly l ea 12 G6000692 Screw
156. g 88 Removing the main board 81 Replacing 81 174 Requirements for battery pack replacement 25 Returning a pump for repair 67 5 Safety Class 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 amp 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 51C View service data 72 View software CRCs amp view software versions 72 V Verify AC power supply function 79 Verifying AC input assembly module function 80 Verifying battery function after new battery replace
157. g motor used to drive the plunger head of the pump A high priority alarm indicating that the pump self tests have detected a failure in pump operation The main speaker located in the bottom housing of the pump All normal alarm alert tones are generated through this speaker The firmware is the software installed 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 gt 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 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 gt UTILITIES you may page backward and forward through the stored alarms in order to identify possible malfunctions This is a troubleshooting feature In BIOMED gt 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 in
158. g table Last PM Date of Alarm Enter Next PM Date Serial Numbers M001010 M001020 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 51C Scheduled Maintenance 1 ea Calibration Kit see service parts list Small Calibration Slug Large Calibration Slug amp 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 amp Standard bits 1 ea 4 open end wrench 1 ea 6 calipers with resolution of 0 001 Using a torque screwdriver You must always use a Torque Screwdriver when re assembling 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 42 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 e
159. he plunger PCB provides pre amplification of the force sensor output to the Main system PCB and contains two photo interrupters with supporting cir cuitry 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 The Main PCB provides additional gain to maxi mize 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 out put of this bridge The interface has sensor excitation electronic zero offset adjustment amplification and filtering and a sensor test control signal e FORCE SNSR EXH provides a constant voltage excitation of 4 096 volts DC to the sensor e Auto Zero Adjustment Circuit provides a voltage to zero the pre amplifier FORCE OSV from the 8 bit system D A converter Sensor Post Filter Amplifier is a second order low pass filter with a 3 68x gain The signal FORCE SNSR TEST wh
160. he 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 Da rE 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 bat tery This is recommended when the battery capacity is less than 90 look at battery gauge dis played on the bottom of the power up screen Scheduled Maintenance Cleaning and care Standard cleaning of Medfusion 3000 series pumps Follow your institutions guidelines for cleaning and disinfecting of devices The syringe pump can be safely cleaned with the following agents Common chlorine bleach diluted with water e Mild detergent mixed with water e Isopropyl alcohol 70 solution e Other surface disinfectants which are compat ible 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 Cleaning cautions Below are standard cautions you should follow when cleaning Medfusion 3000 Series pump CAUTIONS Avoid Organic Solvents Never use organic sol vents e g acetone quarternary ammonia com pou
161. he steps for removing and replac ing the interconnect board for the Medfusion 3000 Series infusion pump Tools needed For this disassembly procedure you will need e Torque screwdriver with a Phillips head Always work at an electrostatic controlled work sta tion 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 inter connect board 4 Disconnect the speaker cable from the intercon nect 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 42 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 Adjustment section to verify
162. he 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 42 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 gt 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 23 Nm If present connect the 2nd back light 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 be fore returning it to use 88 Syringe barrel clamp as sembly Tools Needed For this disassembly procedure you will need e Torque screwdriver with a Phillips head amp 1 16 hex head wrench e Small vise grip pliers Always work at an electrostatic controlled work sta tion when disassembling the pump Barrel clamp head Removal 1 Lift barrel clamp head until screw is accessib
163. he 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 Carefully slide the extrusion drive train assembly back into case Ensure right end plate on extrusion does not dam age ear clip sensor Ensure plunger cable comes out between middle boss and boss by the motor Slide keypad ground tab black side toward extru sion between boss by the motor and extrusion Secure extrusion with 3 standoffs and 3 pan head screws Torque to 100 in oz 0 71 Nm Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts Torque to 100 in oz 0 71 Nm Reinstall main board per main board section above Close pump housing per housing section above 83 Parts Replacement Clutch assembly Tools needed For this disassembly procedure you will need e Torque screwdriver with a Phillips head amp nut drive wrench 002 051mm shim Always work at an electrostatic controlled work sta tion when disassembling the pump 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 tra
164. hich disconnects all battery loads with the exception of the battery monitor circuit The battery charger provides the signal CHARGE TECT which resets this monitor IC reconnecting the battery back to the system 40 5648 51C 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 gener ated by the Medfusion 3000 Series pumps with sug gested remedies and solutions 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 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 yel low indicator and an audible signal Pressing silences the audible alarm for the programmed alarm silence period Low priority 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 permanently silences this alarm Limit
165. i VOLUME TIME OSE KG MIN DOSE MIN DOSE HR QUICK CAT BRE CHG PROFILE 2 Press More until the appears onscreen If E Plates Libraries are enabled you will have to press Main Menu before using More to lo cate 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 SELECT THE MODE CUSTOM PROGRAM 2 BIOMED BEGINNING PRESS THE NUMBER TO SELECT WI PROFILE SETTINGS BIOMED QUICK CAT E TEES BEGINNING 3 Use the number button to choose BIOMED 4 Use the number buttons to enter the Biomed Passcode 2580 then press Enter ENTER BIOMED PASSCODE PRESS ENTER CONTINUE 9999 8 CLEAR ENTER Now you may select PRESS THE NUMBER SELECT THE MODE 1 CALIBRATION 5 SET LANGUAGE 2 DIAGNOSTICS 3 UTILITIES 4 UPDATE FIRMWARE Ss Sere PRESS THE NUMBER TO SELECT CALIBRATION DIAGNOSTICS UTILITIES SET LANGUAGE ae e CALIBRATION to check calibration values re calibrate sensors or set display contrast DIAGNOSTICS to examine analog and digital sig nal readings or test the speaker motor or display function 40 5648 51C e UTILITIES to review alarm history to review infu sion history to set time and date to update peri odic maintenance timestamp
166. ible 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 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 02 0 71 Nm Connect force sensor cable to the plunger board at connector J1 and press excess cable flat against board Connect plunger cable to plunger board connec tor J2 and check to ensure cable remains in slot through force mount and plunger tube 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 0 71 Nm then remove shim 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 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 51C Parts Replacement Removal 1 Disassemble plunger case and remo
167. ies pump 5080 MOL L 5 WHO0L 2019 9 NO auis uMd nov X Main board logic kernel ano7 PT 5080 5080 5080 5080 8 1Ws 5080 AOS 706 AOS 05 AOL MOL L YLX 9601 YLX 9601 OL OL INVI 9607 3 100 3nioo 30100 3100 WHO66 9212 oz 52 812 128 a 805532084 5080 541 MOL L 1 QN51 WHOM66 21501 L_x auis GOL 6171 5 661dL 222 L A A uaav evivd 5080 2080 AOS MOL L s uaav S YLVA ux foi bt 9viva dni00 WHOWOL 1 aav viva 1012 8H 8 5080 1 6 gt 2 0 viva EL OSIW ZQ d 1ds s 5 LL 15 d ISOW 145 S gt 5 2075 145168 mn L P 1 edl p iind rad INV 34 E 123130 9 Aids ZNY Z 8315 uMd 9 5080 ENV E 3d Lisa 9 d d YAVI Aldo YOLOW ZL d SNY S d 5 2145 QV ASO 32404
168. in 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 acces sible 6 Pull the plastic worm gear off the end of leadscrew near motor 7 Remove three flat head screws holding motor as sembly on extrusion and pull off motor assembly Slide carriage rod out of the carriage 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 4 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 grease to leadscrew Squeeze plunger lever to open clutch and insert leadscrew until it sticks slightly through the carriage 2 Install thrust bearing assembly flat washer bear ings 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 3 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
169. in the top of the top housing and over the spacers studs Secure the display assembly with the 2 Nylock nuts and tighten with wrench 8 Reconnect the display cable to the main board at J12 9 Ifa 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 tails 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 10 Insert the back light wires into the main board terminal block When replacing the back light trim the LED leads to about 1 2 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 23 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 51C Verify LCD amp backlight assembly function 1 Plug the pump into AC power and t
170. ing any of these numbers please have the following ready e Model name number of pump e Pump serial number e Purchase date if pump is within warranty period e Description of problem in as much detail as pos sible 3 service representative will give suggestions in an attempt to help solve the problem 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 out side the United States contact your local distribu tor 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 Ifthe problem cannot be resolved through the as sistance of the Technical Service Department then you will be assigned a Return Authorization RA number 40 5648 51C Troubleshooting 2 Clean and decontaminate the pump and acces sories prior to returning items to Smiths Medical This is required before shipment according to United States Occupational Safety amp Health Ad ministration 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 Package the infusion pump carefully for shipment 5 Smiths
171. ing 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 Main System Board Logic Core Buzzer Force Transducer amp PreAmp Board Syringe Plunger Loaded Sensor Plunger Travel Sensor Syringe Ear Loaded Sensor Syringe Size Sensor Motor Rotation Sensor Stepper Motor 40 5648 51C 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 watch dog alarm through a dedicated back up audible alarm which is separate from the primary speaker If a watchdog or SysTEM FAILURE alarm is gener ated then watchdog circuit turns on the red alarm indicator and backup audible alarm and turns off the motor current DC power converter 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 volt ages and will detect failures in any system voltages Real
172. ion 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 pro vide a valid logic high level when external DC power is applied The active voltage for EXTRNL_PWR_DE TECT is nominally 5 volts The threshold detector U3 provides immediate detection through the signal BATTERY SWX of the external DC source being removed e battery switch toggles to internal battery if both AC and external DC power are removed e 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 commu nication pins The infrared port supports short trans mission 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 DATA is at a logic high during its inactive state A logic low on IR_ DATA enables the transmitting IR diode through the transistor Q3 50 40 5648 51C Battery management description The battery management c
173. ip sensor cable at J2 e Barrel clamp flex circuit at JA e Plunger cable at J11 and unscrew the cable clamp 6 If present clip the wire tie securing the 2nd back light 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 42 Nm 40 5648 51C 8 Parts Replacement 3 Reconnect all cable and wire connections on the main board These include e Keypad ribbon cables at J10 e Motor cable at J3 e Position pot cable at J6 e Display cable at J12 e Ear clip sensor cable at J2 e Barrel clamp flex circuit at JA e Plunger cable at J11 Install the cable clamp over the exposed braid of the plunger cable and se cure with small pan head screw Torque screw to 16 oz 0 12 Nm 4 Ifa 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 an chor 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
174. ircuits are a 2 stage constant current battery charger a charge detector and a bat tery switch over control circuit The interconnect board interfaces to a 6 cell NiMH battery pack NiCad bat tery pack on older model pumps with a smart battery gauge 2 Step Constant Current Battery Charger Battery Charge Gauge Detector Battery Communication Very Low Battery Battery Board Interconnect Board Main Processor 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 in ternal DC supply or external DC is present The charger provides a charge current determined from three condi tions Innormal operation the charge current is controlled by the gauge providing two levels of constant charge current If the battery capacity is less than 9496 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
175. lace the main board SuPERCAP Post 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 SYRINGE FLANGE SENSOR FAILURE Software sensed syringe sensor voltage out of range The sensor poten tiometer may be unplugged or have an open connection Use BIOMED gt DIAGNOSTICS gt MONITOR ANALOG SENSORS to check operation of syringe sensor Open pump case and check connections to syringe sensor Replace syringe sensor Time Base BGND Test 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 oscil latory for real time clock If problem recurs replace main board Time Day Clock Post 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 Day CLock TIMEOUT Time of day clock failed to communicate If problem recurs replace main board 64 40 5648 51C Troubleshooting General troubleshooting This section discusses some potential problems which may be encountered with the Medfusion 3000 Series pump and suggests remedies for those
176. le 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 42 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 be fore 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 wrench and Phillips screwdriver remove two pan head screws with Nylock nuts which hold the barrel clamp assembly These 40 5648 51C screws are located on the right end plate of the drive train assembly 4 Unplug the barrel clamp flex circuit from J4 of the main board 5 Gently slide barrel clamp assembly out of the case avoiding the fingers extending from the right end plate around the plunger tube 6 Remove small screw holding the pot to the barrel clamp assembly 7 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 cla
177. le motor 82 Position potentiometer nmt 83 oos ene moi OPE 83 Replacement M 83 Clutch assembly 84 84 E nr 84 84 Replacement cere 84 Cl teh or clutch 84 TOOTS HCCC EG 84 rn 85 Beplacemehit 85 nung 85 R moyal 85 aiani 85 LCD and backlight 86 Tools Dede 86 Removing LCD and or backlight assembly 86 Replacing the LCD and or backlight assembly 86 Verify LCD amp backlight assembly function 87 Keypad 87 NOEL M 87 Removing the Keypad 87 Replacing the Keypad 88 Syringe barrel clamp assembly 88 Tools Needed rr ra rta nanan 88 40 5648 51C Table of Contents Barrel clamp head osi tme 88 Demy I 88 Replacement dedu 88 Verify iD m 88 Barrel clamp body assembly 88 lip c MMC Q raie 88 Replacement 89 Ear clip handle amp guide 89 MOOS Needed 89 Par dip m 89 Remi OW alliage eiie attese 89 89 Ear clip optical Sensor
178. lectronic 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 includ ing a grounded mat and wrist strap 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 pres ent within the pump Manufacturer Recommended Maintenance Al ways maintain this pump following manufacturer recommended instructions in this Service Manual An improperly maintained pump may cause serious injury to a patient or user 40 5648 51C 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 func
179. livery settings are stored in a critical data block of RAM on the main board This message will occur if background self test showed the criti cal data block was corrupted RAM cyclic redundancy test failed Run power on self test which executes extensive RAM testing if problem recurs replace the main board 40 5648 51C Troubleshooting System failure alarm CRiricAL Data BLock Post 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 PROGRAM gt TEACH LEARN to copy configuration from a known good pump to restore settings Replace main board if serial EEPROM has failed CRiriCAL DATA FAILURE 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 set tings Alternatively this alarm may indicate a software data failure where critical flags are found invalid If problem recurs replace the main board D2A BGND Test 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
180. llustrations showing the various controls connectors and features of the Medfusion 3000 Series pump 1 LCD Display All pump operating and status infor mation 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 Tubing Holders Thread infusion set tubing be tween holders to prevent kinking at syringe tip 3 Carrying Handle 4 Syringe Barrel Clamp The clamp holds the syringe barrel securely in place Syringe Barrel Flange Clip When loading a syringe slide the syringe flange into the clip Syringe Plunger Holders Holds the syringe plunger securely in place Syringe Plunger Driver Once loaded and delivery is started the driver pushes the syringe plunger for ward at a controlled precise rate to deliver fluid 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 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
181. lunger driver controls the infusion rate The motor receives electrical pulses from microcontroller with pulse frequency deter mined from the programmed flow rate e Forty eight motor pulses turn the motor one full revolution e Five hundred and sixty full motor revolutions move the plunger driver one inch e 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 amp safety functions Two sensors are used to verify that the infusion pro ceeds at the programmed rate Specifically the micro controller 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 sy ringe plunger driver is running at a speed not equiva lent 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 pres 40 5648 51C Theory of Operation ence and syringe size d A force sensor in the plunger driver head detects and reports the amount
182. ment 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 amp manufacturer The limit priority alarms sound a tone and display an advisory message on screen for seconds To re display the message press 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 in tervention Low Priority alarms are announced with a continuous yellow indicator and an intermittent audible signal Pressing permanently silences this alarm Ifthe front panel controls are locked when 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 yel low indicator and an audible signal Pressing will silence the audible alarm for the programmed alarm silence period Ifthe front panel controls are locked when a medium priority alarm occurs the pump controls do not unlock Introduction Motor Rotation Sensor Neglected Pump or User Call Back Occlusion
183. message After reaching SYRINGE position the user can press to resume infusion in cases where there is a small amount of fluid left in the syringe Here the pump delivers un til the force sensed on the plunger driver reaches the set occlusion limit as the plunger pushes against the end of the syringe barrel SYRINGE FLANGE IN PLACE Medium or Low SYRINGE NEAR Empty 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 gt DIAG NOSTICS and run MONITOR DIGITAL SENSORS to check function of flange sensor Normal advisory message Notice that only a few 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 Pharm Guard Toolbox software 58 40 5648 51C Troubleshooting Alarm message Alarm Cause or corrective action priority programming infusing SYRINGE PLUNGER IN PLACE High High 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 gt DIAG NOSTICS and run MONITOR DIGITAL SENSORS to check function of both plunger sensors System ADVISORY Low See detailed des
184. mp 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 0 71 Nm 5 Plug barrel clamp flex circuit into J4 of the main board Close pump housing per housing section above Replace barrel clamp head and verify function per above 40 5648 51C Parts Replacement Ear clip handle amp guide Tools Needed For this disassembly procedure you will need e Torque screwdriver with a Phillips head amp nut drive e Needle nose pliers two pairs Always work at an electrostatic controlled work sta tion 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 sec ond 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 Ist 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
185. n board to interconnect and from interconnect board to speaker Replace speaker if wiring is intact Pump Motor Drive Orr Post 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 gt DIAGNOSTICS gt MOTOR DRIVE TEST to check motor operation If motor does not run replace the motor or the main board Pump Motor Drive Phase Post 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 Pump Motor Drive Phase Post 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 RAM BGND Test 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 contami nation is shorting the board then replace the main board SERIAL EEPROM Timeout 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 SPI BUS Timeout 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 rep
186. nds 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 WD407 to clean or lubricate pump These chemi cals can damage the plastic of the pump Never Autoclave or Gas Sterilize Never steril ize 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 war ranty 40 5648 51C 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 1 2 3 4 5 6 7 8 9 CCCG LJ LJ EJ ET E ET EL If not already performed clean and disinfect the pump as described in the Cleaning and Care sec tion see previous page Inspect for obvious physical damage including cracked housings or torn keypads Repair any physi cal damage Verify smooth operation of syringe plunger driver syringe release lever syringe flange clip and sy ringe barrel clamp Clean and or repair any damaged components Verify the three tubing guides hooks on
187. nsed by the barrel clamp size sensor Use BIOMED gt DI AGNOSTICS and run MONITOR DIGITAL SENSORS to check function of flange sensor 54 40 5648 51C Alarm message CHECK SYRINGE PLUNGER SENSOR programming Troubleshooting Alarm Cause corrective action priority infusing 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 gt DIAGNOSTICS and run MONITOR DIGI TAL SENSORS to check function of both plunger sensors CLEAR TVD To START INFUSION Normal advisory message Total volume delivered TVD or total dose delivered TDD needs to be cleared to start an infusion when TVD TDD ex ceeds the volume limit setting COMPLETING SYSTEM INITIALIZATION Normal advisory message At power up if all set tings are entered by the user and is pressed before background self tests are completed then this message appears Wait a few seconds until self testing is completed and then press to begin infusion Data Does Previous ENTRY DEPLETED BATTERY SYSTEM FAILURE Normal advisory message In cases where confirma tion of user entered data is required the confirma tion value did not match Re enter the value High High Normal alarm message Battery voltage measured by the gauge on the battery pack is too low Software then stops delivery and allows watchdog to gene
188. ntents LCD backlight supply UT 41 Front panel interface description 42 LED drive circuit 026 027 040 Q33 Q37 42 Keypad matrix interface unsure ridet 42 Power switch Interface osuere oot ribs 42 Graphic display interface description 43 Data output to LCD U32 data input from LCD m M 43 LGD contrast aoi triente ere 43 FSI s o C 43 Motor drive description sse 44 Coil amp PWM current 44 Motor current regulators 026 035 44 Motor current detector 44 Sensors interface description 45 Motor speed saver i Insertar tah 45 Syringe sensing description eccentric 45 Syringe size sensing rie resani 45 Syringe flange ear sensing ise ttes 45 Plunger position sensing description 46 Speaker drive description sss 46 Speaker cohtrol dede 46 Speaker t st eee ei 47 Plunger board schematic level trn 47 Force preamp litter DUDCDDOB 47 Force sensing interface 47 Plunger flipper sensor function 48 Interconnect board schematic level 49 AC power detec
189. number buttons to choose Biomed you may need to press More to find it if libraries are en abled 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 ae ae es PRESS THE NUMBER TO SELECT CALIBRATION DIAGNOSTICS UTILITIES SET LANGUAGE ES Use the number buttons to select CALIBRATION PRESS THE NUMBER TO SELECT THE MODE 1 CAL SIZE AND POSITION 5 CAL SYRINGE SIZE SENSOR 2 CAL FORCE SENSOR 6 ADJUST CONTRAST 3 CAL PRESSURE SENSOR UIEW CALIBRATION DATA 4 CAL PLUNGER POSITION 8 SAVE CHANGES AND EXIT aaa A A P I PRESS THE NUMBER TO SELECT CAL ae AND POSITION Ed ADJUST CONTRAST FA CAL FORCE SENSOR 3 VIEW CALIBRATION DATA CAL PLUNGER POSITION SAVE CHANGES AND EXIT Gi CAL SYRINGE SIZE SENSOR 40 5648 51C Calibration amp Adjustment 95 Calibration amp Adjustment Below is table which summarizes the options available for calibration What it Controls Calibration Option Calibrate Syringe Size and Position Performs concurrent adjustment of syringe size amp position sensors settings This requires Smiths Medical calibration slugs Calibrate Force Sensor Performs adjustment of force sensor settings Calibrate Pressure Sensor This is a future option of the Medfusion 3000 Series pumps
190. oard connec tor J2 and check to ensure cable remains in slot through force mount and plunger tube 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 as 93 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 0 71 Nm then remove shim 6 Ifseal was damaged replace with a new seal Place small drops of Loctite 454 cyanoacrylate adhe sive 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 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 otherwi
191. of force exerted on syringe plunger head A large amount of force indicates an occlusion in the patient line to the microcon troller A Watchdog device checks for microcontroller mal function including timebase errors and can shutdown the motor and generate an alarm independent of the microcontroller operation An internal power source 1 Farad super capacitor allows the pump to alarm should failure occur in the pumps power sys tem or internal battery 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 240x64 Graphical Display Board Keypad amp Indicator Lights Speaker h Rechargeable Battery Pack amp Battery Gage Interconnect Board DC Power Input Jack AC Power Input IR Serial Comm amp Power Supply Link Block Diagram for Medfusion 3000 Series Infusion Pump Main circuit board Main microprocessor The main circuit board has one main microprocessor 8 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 Controll
192. ogic low and only one row at a time KEYPAD SEL ROW2 PC2 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 KEYPAD SEL ROWI PCI 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 KEYPAD SEL ROW O PCO 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 BUZZER ARMED PAO 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 WATCHDOG_ALARM PAI A logic high indicates the watchdog alarm state is true EXTRNL_PWR_DETECT PA2 A logic high indicates an external power source is connected to the pump A series resistor is provided to prevent latching AC_PWR_DETECT PA3 A logic high indicates AC line power is connected to the pump A series resistor is provided to prevent latching SYRINGE_EAR_DETECT 5 A logic high indicates the syringe flange ears are installed properly in the pump and SYRINGE EAR SNSR ENBL is active SET IN DETECT PA6 A logic high indicates the pressure cell is installed and SET_IN_ SNSR_ENBL is active VLOW_BATTERY 7 A logic high indicates the battery voltage has fallen below a fixed 10 5648 51 voltage level independent of the battery being charged 37
193. on Indicator Alarm 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 Ac Line 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 Battery o Infusing The Battery indicator green blinks On amp 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 4 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 40 5648 51C Introduction Update Firmware to reprogram the pumps soft ware version through the serial interface only available with service upgrade softw
194. ons port on pump Operating voltage range for alternating cur rent i e AC or mains power source Medfusion 3500BC pumps designa tion F2 indicated on the label which is located on the AC input module connec tor 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 infu sion 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 40 5648 51C Introduction Glossary of Technical Terms This is a glossary of technical terms relating to the Medfusion 3000 Series pumps Term AC Line Leakage Test Alarm History Alarm Message Backup Audio Buzzer Backup Super Capacitor Battery Gauge 40 5648 51C Definition The pump is listed as Safety Class II Type CF equipment Medfusion 3500BC pumps are listed as Safety Class I
195. or 6811 a2d group2 Authorized biomed access Um Never use Biomed features unless you are trained in Pressure sensor test maintenance on the Medfusion 3000 Series pumps and have been authorized by your facility to use the Biomed program V3 Update Firmware Utilities Biomed software program major options The Biomed utility has four major modes on its SE LECT THE 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 51C set view last pm date OR set view next pm date set time date view alarm history view infusion history view software crcs view software versions view service data view EEPROM size V4 Special use only for software update Not available on all pumps Set Language Medfusion 3500 Only 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 Serial number Attention See instructions for use Type CF equipment protection from elec tric shock Equipment in which protection agains
196. or supply 40 71 N Negative supply 41 NiCad battery pack 30 NiMH battery pack 30 Nominal voltage 52 Opening the pump housing 76 Overview of operation 27 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 Replacin
197. or 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 51C Theory of Operation 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 Direction Coil A Enable Motor Current Motor Current Control Count Reference zl Phase A A Motor Current Phase B B Direction gt Coil B Enable Motor Current Control Current Reference Motor Current Detect Flowchart of Motor Drive Description The main microprocessor controls which motor wind ing is active designated as A or B the direction of cur rent in each winding and the magnitude of the current Coil A amp 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 e The WATCHDOG ALARM signal activates the N chan nel MosrET to disable the motor current in both windings
198. osed of with general waste could be damaging to the environment 40 5648 51C Scheduled Maintenance In accordance with Directive 2002 96 EC Waste Electrical and Electronic Equipment residents of the European Union must follow specific disposal or recy cling 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 re cycle 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 25 Scheduled Maintenance 26 40 5648 51C Section 2 Theory of Operation of the manual con tains definitions and descriptions of standard opera tion 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 p
199. p period where 2 millisec is the fastest rate and 1000 millisec is the slowest rate then press to start the motor and 2 to stop All other features are for factory engineering use PRESS THE NUMBER TO SELECT THE MODE i SET MOTOR STEP PERIOD 5 REVERSE MOTOR 2 SET MOTOR MAX CURRENT 3 SET MOTOR MAX RUM TIME 4 REVERSE MOTOR STEPS PRESS THE NUMBER TO SELECT SET MOTOR STEP PERIOD REVERSE MOTOR SET MOTOR MAX CURRENT SET MOTOR MAX RUN TIME El 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 2 Group 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 PRESS lt BACK gt TO STOP ANALOG SUPPLY 68 CNTS 2 176 POS SUPPLY 8 CNTS PAAY MOTOR SUPPLY 152 CNTS 38 9120 A20 REFERENCE 125 CHTS 4 8980 SSS ESS ESS eee PRESS lt BACK gt TO STOP ANALOG SUPPLY COUNT 156 4 992 POS SUPPLY COUNT 14
200. plication 5 Install the AC Power Supply the AC Input As sembly the Power Supply Shield the speaker and the Interconnect Board into the replacement hous ing 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 51C Parts Replacement and reinstall the battery pack M ain b oar d Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality be This section defines the steps for removing and replac fore returning it to use ing the Main Board for the Medfusion 3000 Series pump Tools needed For this disassembly procedure you will need e Torque screwdriver with Phillips head amp small flat head Always work at an electrostatic controlled work sta tion 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 e Keypad ribbon cables at J10 e Motor cable at J3 Position pot cable at J6 e Display cable at J12 e Ear cl
201. priority A limit alarm occurs whenever an invalid entry is attempted on a numerical en 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 set ting the pump expects you to continue until setup is complete If you leave the pump paused too long gt 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 pumps alarm history record 40 5648 51C 59 Troubleshooting Alarm messages amp priorities The following table defines alarm message alarm prior ity and cause for each alarm condition Alarm message Alarm priority programming infusing Cause or corrective action BATTERY COMMUNICATION Timeout System 5 Low Low Pump has sensed battery current present but the battery gauge on the battery pack is not commu nicating Check connections from main board to interconnect to battery pack Battery Not CHARGING System ADVISORY Low Low Pump has sensed AC or DC external power is pres ent but the battery is not charging
202. 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 low est level Use Custom PROGRAM to change the audio alarm volume to a higher level b Use BioMED gt 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 Indica tors Do Not Flash below b Use BIOMED gt DIAGNOSTICS and run the MONITOR BATTERY STATUS test Determine whether battery is charging at 50 MA or greater Battery Problem Battery not working message a Open the battery door in the case bottom and check the connection of the battery ribbon cable to the interconnect board b Use BIOMED gt DIAGNOSTICS and run the MONITOR BATTERY STATUS test If no information appears then replace the battery pack Battery Problem Battery does not hold charge Indicator lights do not flash 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 gt DIAGNOSTICS and run the MONITOR BAT TERY STATUS test Check whether battery is charging at least 50 wait at least
203. pump See Configuration Manual Maximum rate not available Maximum rate may be set low in pump configuration Use CusroM PROGRAM SET FLow RATE to configure the pumps maximum flow rate See Configuration Manual Occlusion alarms occur frequently Occlusion alarm limit may be set too low in pump configuration Use CUSTOM PROGRAM SET OCCLUSION LIMIT to configure the pumps occlusion alarm level See Configuration Manual Pump won t turn on 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 e Connections of main to interconnect ribbon cable e AC power connections e Battery connections e Keypad cable connections Syringe Manufacturer not available Syringe manufacturer may have been turned off or cleared in pump con figuration See Configuration Manual if available or Operations Manual 66 40 5648 51C 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 Depart ment at one of the following telephone numbers 1 800 258 5361 Toll free in the United States Outside the 1 214 618 0218 continental United States In Europe Contact Your local distributor or Smiths Medical International Ltd 44 0 1923 246434 2 When call
204. put Wires to J1 and tighten the 2 terminal screws Torque to 32 in 2 0 23 Nm 4 Reconnect the interconnect board cable to J2 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 42 Nm 40 5648 51C Parts Replacement 7 Replace the battery pack battery cover and secure with 2 flat head screws Torque to 60 in oz 0 42 Nm Verify AC power supply function After you replace the AC Power Supply you must verify its function with the following steps 1 Plug 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 be fore returning it to use AC input assembly This section defines the steps for removing and replac ing the AC Input Assembly Tools Needed For this disassembly procedure you will need open end wrench e Torque screwdriver with a Phillips head amp small flat blade Always work at an electrostatic controlled work sta tion 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 Remove power supply shield Use small flat blade screwdriver to loosen the 2 screws on the Terminal Block of the power supply 5 With screwdriver amp op
205. r this device 3 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 pump is listed as Safety Class II with functional earth Type CF equip ment Protection against electrical shock does not rely only upon basic insulation but instead relies on double or reinforced insulation As such this equip ment utilizes a third wire ground earth ground lead of the power cord as earth return for electro magnetic energy and does not serve as a safety func tion Therefore it is neither possible nor necessary to per form a ground resistance test 40 5648 51C 23 Scheduled Maintenance Battery maintenanc
206. rate alarm Plug pump into AC power cycle power on the pump then use RECALL LAST SETTINGS to re call delivery settings and resume delivery If problem is chronic check battery pack function or perform battery calibration Force Sensor BGND TEST High High Normal alarm message Press 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 gt DIAGNOSTICS gt MONITOR ANALOG SENSORS to check operation of plunger force sen sor Open plunger head and check plunger cable and force sensor cable on the plunger board Replace plunger board plunger cable or force sensor INFUSION COMPLETE High Normal alarm message Infusion has reached the set volume limit and delivery has stopped INPUT Our RANGE GREATER THAN Max VALUE Limit Normal advisory message User attempted to enter a number greater than the maximum value allowed See also maximum rate in general problems be low Try a lower value 40 5648 51C 55 Troubleshooting Alarm message INPUT Our RANGE Less THAN MIN VALUE Alarm priority infusing programming Normal Advisory Message User attempted to enter a number less than the minimum value allowed Try Cause or corrective action a higher value INVALID INFUSION PARAMETER COMBINATION Normal advisory message The user has
207. ree pan head screws with Nylock nuts holding the carriage plate 4 Use needle nose pliers to remove either e the clutches use caution in separating clutches because of spring thecam pull straight out and separate from square shaft Replacement 1 For replacement of e thecam first ensure the shaft is seated to the plunger lever then press the cam gear on the shaft clutches put the clutch halves together closed and press the spring into place then slide the clutch halves into the carriage 2 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 0 71 Nm 3 Snap e ring over cam sticking through carriage plate 4 Replace leadscrew per procedure above Plunger cable Removal 1 Remove leadscrew per procedure above 2 Using 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 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 Atthe carriage turn plunger cable connector in line with the cable and pull cable out through 40 5648 51C Parts Replacement plunger head Replacement 1 Take the new plunger cable with the smaller exposed braid
208. rm a ground resistance test Safety Class with functional earth Type CF Medical Equipment The pump is listed as Safety Class II with functional earth Type CF equip ment 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 ap plicable local regulations Collect Separately There are potential health haz ards associated with improper disposal of batter ies electronics and contaminated used infusion sets and syringes Dispose of used batteries infu sion 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 thor oughly before performing maintenance on it This is recommended by the United States Occupa tional Safety amp Health Administration OSHA as a protection from potential biohazard External DC Power Any power source connected to the
209. s the pump VIEW IN FUSION HISTORY and VIEW ALARM HISTORY VIEW INFUSION HisTORYy 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 many features under DIAGNOSTICS which allow the examination of various sensors and compo nents within the pump The speaker motor keypad indicators and display may be tested individually through this program The battery gauge status in formation and charging discharging current may be viewed Numerous digital and analog inputs may also be viewed Accessing 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 ver sion 4 type screen if they are different Also depend ing on the personalization performed on your pump the items listed in some of the menus may be different than those shown 1 Turn the pump on and allow the power on self testing 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 PRESS THE NUMBER TO SELECT THE MODE 1 2 VOLUUME TIME 3 MICROGMS MINUTE 4 RECALL LAST SETTINGS 68 PRESS THE NUMBER TO SELECT GENERAD BE MISCELLANEOUS E
210. s 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 sig nal 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 Time of Day Infrared IC X Ceiver PA4 SPI PH6 SPI TxD RxD 4 Mb Flash N 10 Bit A D Memory 7 8000 FFFF_ SPI 7777 Converter 68HC11K1 Main Processor _ 0 7 P X PGI SPI O 1000 O 1200 8 Bit D A Converter 32Kb Static 4 RAM Flowchart of Logic Kernel for Medfusion 3000 Series infusion pump 24 1 O Bit Port 1 Expansion 82C55 24 1 O Bit Port 2 Expansion 82C55 68HC11K4 Main Microprocessor Interface 019 The main microprocessor s direct signal interfaces are described in clockwise order taken from the Medfu 40 5648 51C 31 Theory of Operation sion 3000 Series Main PC Schematic of the micro processor The following table summarizes some of the microprocessor input output signals Signal name Processor port Description IR_XMT_DATA PD1 TxD The IR DATA is used for transmitting asynchronous serial data IR_RCV_DATA PDO RxD The IR RCV DATA is used for receiving asynchronous
211. sage will occur if this data is lost No action is required IMPROPER SHUTDOWN IMPROPER SHUTDOWN INVALID INTERRUPT amp System ADVISORY 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 CRITICAL DATA CORRUPTED 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 PHARMGUARD DATA CORRUPTED The PharmGuard Safety Data is stored in non volatile serial EE PROM on the main board This message will ocur if this data is lost No action is required PRIMARY CRITICAL DATA CORRUPTED Configuration and library settings are stored redundantly in non volatile serial EEPROM on the main board This message will occur if primary data was lost and backup data was used to restore pri mary values No action is required SeT TIME AND DATE 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 gt UTILITIES and run SET TIME DATE to restore date and time settings No functionality of pump is affected by date time set ting MAINTENANCE Is RECOMMENDED
212. sary for performing the maintenance parts replacement and diagnosis of the Medfusion 3000 Series pumps e 1 50 or 60cc syringe see Operations Manu al for list of acceptable types e 1 Medium bore tubing set Smiths Medical 53 60 225 or equivalent e lea 3 Way Stopcock e lea Torque Screwdriver with 1 Phillips bit 0 Flat bit amp 2 5mm Hex bit e 1 16 nut driver e 1 open end wrench nut driver e lea 002 shim or feeler gauge e lea Pliers standard amp needle e lea Calipers 168 40 5648 51C Assembly Drawings amp Parts Lists Notes 40 5648 51C 169 Assembly Drawings amp Parts Lists 170 40 5648 51C 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 amp power supply board 30 79 AC power supply 79 Removing 79 Replacing 79 Verifying 79 Adjust contrast display 105 Adju
213. sassemble motor unit as required 1 For motor or worm remove two pan head screws and Nylock nuts holding the motor Remove mo tor 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 0 71 Nm 40 5648 51C For worm gear align D with shaft and press onto leadscrew until centered over worm Attach e clip Carefully slide the extrusion drive train assembly back into case Ensure right end plate on extrusion does not dam age ear clip sensor Ensure plunger cable comes out between middle boss and boss by the motor Slide keypad ground tab black side toward extru sion between boss by the motor and extrusion Secure extrusion with 3 standoffs and 3 pan head screws Torque to 100 in oz 0 71 Nm Secure the barrel clamp assembly to the extrusion with 2 pan head screws and Nylock nuts Torque to 100 in oz 0 71 Nm Reinstall main board per main board section above 10 Close pump housing per housing section above Position potentiometer Removal l Open pump housing per pump housing section above and set
214. scharge 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 gt DIAGNOSTICS gt MOTOR DRIVE TEST and set motor step period to 2 msec and press This should deplete the battery within approximately 3 hours A third method is to disconnect AC power turn the pump on and run BIOMED gt DIAGNOSTICS gt MONITOR STATUS This discharges the battery at about 130 ma and takes approxi mately 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 51C 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 dis connect condition occurs At this point the audi
215. scharges A shallow discharge happens whenever the battery is partially discharged and then returned to AC power The number of the shallow discharges ap pears on page two of the MoNITOR BATTERY STATUS menu in the BIOMED gt DIAGNOSTICS menu This displays CPI as OxDD where 0xDD is hexadecimal number representing the number of shallow discharges cycles he value is reset to zero each time the battery is calibrated It increments to a maximum count of OxFF hex 255 decimal 24 During the annual periodic maintenance if the num ber of shallow discharges CPI is 0x80 hex or higher e g 0x90 0xA5 OxBB 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 amp 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 gt DIAG NOSTICS MONITOR BATTERY STATUS 3 After the Charge Level gauge reaches 99 to 10096 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 TERY DEPLETED alarm not the Low BATTERY alarm You can interrupt the di
216. se 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 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 10 11 Install flippers and flipper gears per above into new plunger case left Transfer plunger board into new plunger case Slide new plunger case left onto plunger tube En sure case is correctly oriented Thread plunger cable through force mount as sembly and slide assembly onto plunger tube align screw holes and cable slot Apply mild thread locking adhesive Loctite 242 to flat head screws and secure the force mount to the plunger tube Torque to 100 in oz 0 71 Nm Be careful not to cross thread screws 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 0 71 Nm Connect force sensor cable to the plunger board at connector J1 and press excess cable flat against board Press plunger cable into
217. ser is responsible for compliance with IEC 60601 1 standards Refer all questions to Smiths Medical Technical Service department Collect Separately There are potential health haz ards associated with improper disposal of batter ies electronics and contaminated used infusion sets and syringes Dispose of used batteries infu sion 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 Service cautions Disconnect AC Mains amp 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 pumps battery pack with care Don t Over tighten Screws Never over tighten any screws in the pump Unless otherwise speci fied 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 amp closing the pump housing Tools needed For this disassembly procedure you will need e Torque screwdriver with a 1 Phillips head Always work at an electrostatic controlled work sta tion when disassembling the pump
218. serial EEPROMs are used for storing manufactur ing 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 40 5648 51C Analog to digital converter U13 A four channel unipolar 10 bit converter obtains high resolution analog measurements The high resolution measurements in ascending chan nel order are e pressure sensing amplifier e plunger force sensing amplifier e syringe size sensing amplifier e plunger travel sensor The converter uses precision 4 096 volt reference equating to a bit resolution of 4 millivolts The con verter interfaces to the Serial Peripheral Interface of the 68HC11 Digital to analog converter U20 A dual channel 8 bit digital to analog converter e Generates the contrast voltage for the Liquid Crys tal display
219. sion 3000 Series pump Troubleshooting e Tables of failure messages together with problem descriptions and possible solutions Also includes an overview of Biomed Diagnostics amp Utilities Parts Replacement e 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 e Contains board level schematics amp PCB assembly drawings Assembly Drawings and Parts Lists e Contains mechanical assembly parts lists and replacement parts lists for repairs Appendices e Contains technical information relevant to Medfusion 3000 Series pumps 40 5648 51C Introduction 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 criti cal medical devices WARNINGS Attempts to repair or maintain a pump by person nel 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 Introduction About the pump Features and Controls Following are several i
220. slot though plunger tube force mount and plunger case left Ensure ex posed braid of cable touches metal on force mount or plunger tube Connect plunger cable to plunger board connec tor J2 and check to ensure cable remains in slot through force mount and plunger tube If you did not remove the float plate seal skip to step 11 Place the float plate into opening in plung er case left and start 2 5mm hex screw into this as sembly Slide 002 shim between float plate and the wall of the plunger case Tighten screw and torque to 100 in 0 71 Nm then remove shim 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 Install timing plates and reassemble plunger case per above 40 5648 51C Using gt CALIBRATION This section explains the use of Biomed Calibration for the calibration of internal sensors of the Medfu sion 3000 Series pumps BIOMED gt 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 e Large Calibration Slug e Force Gauge Note The equipment supplied in the Calibration Kit should be added to your annual calibration and maintenence schedule To access BIOMED gt CALIBRATION from the Main menu use the
221. st 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 Backlight 6 11 43 82 86 87 88 108 159 Removing 86 Replacing 87 Supply 41 40 5648 51C Index 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 9
222. stalled in the Medfusion 3000 Series pump Pumps with V4 1 5 software also shows the build number 40 5648 51C 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 e The main microprocessor periodically issues the AC signal PET WATCH DOG 40 5648 51C 13 Introduction 14 40 5648 51 Section 1 Scheduled Maintenance of the service man ual 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 al lows you to service pumps in batches as their anniver sary 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 Scheduled Enter Last Date of Numbers PM PM Alarm 001010 M001020 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 followin
223. t electric shock relies on double or reinforced insulation instead of basic insulation Acces sible 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 function al earth return for electromagnetic energy e Date of manufacture ONLY CAUTION Federal USA law restricts this device to sale by or on the order of a physi cian Catalog number E Collect Separately 69 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 Oy UL Mark for Canada and the United States Indicates the product was manufactured in accordance with the requirements of UL Underwriter s Laboratory 4 Temperature limitation Humidity limitation Atmospheric pressure limitation IPX3 Pins of connectors and other areas identi fied 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 communicati
224. t be connected to a host person al computer running a Medfusion 3000 Series down load program and a download must be initiated on the PC in order to update the pumps 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 us ing the new language PRESS THE NUMBER SELECT THE MODE 1 ENGLISH 3 PORTUGUESE 2 FRENCH SPANISH 3 GERMAN 4 ITALIAN SS ENTER PRESS THE NUMBER SELECT TSH fl PORTUGUESE FRENCH A SPANISH GERMAN ITALIAN ENTER To select a language press the number button corre sponding to the language and press Enter The display will immediately change to the selected language Some pumps may not have all languages implement ed 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 51C Troubleshooting 73 Troubleshooting 74 40 5648 51 Section 4 Parts Replacement provides procedures for disassembly parts replacement amp 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
225. ternal DC Jack External Power Filtering Detector Infrared Smart Battery Smart Charger 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_DE TECT 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 e 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 51 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 differ ential mode noise suppression and transient voltage protect
226. the Calibration and Adjustment section to find any re calibration or re testing required before returning pump to use 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 thor oughly before performing maintenance on it This is recommended by the United States Occupa tional Safety amp Health Administration OSHA as a protection from potential biohazard Pump Maintenance Only trained biomedical ser vice 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 work station 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 cer tified for medical equipment Type CF Safety Class Connecting external power to the pump creates 40 5648 51C Parts Replacement a medical system therefore the u
227. through the BRAKE pin of the regulator 1 Motor current detector U40 The watchdog alarm function is tested at power up by verifying the MrR_CURRENT_DETECT signal is at a logic high when the watchdog alarm condition is active e Similarly the MrR_CURRENT_DETECT signal should be at a logic low when either motor winding has suf ficient current and the watchdog alarm condition is not present 40 5648 51C Sensors interface description Motor speed detection The digital sense signal is created by using a reflective infrared optical sensor to sense a motor coupled en coder as the motor rotates The microprocessor mea sures the period of the signal created by the encoder Syringe sensing description The syringe sensing system senses the syringe bar rel size senses the plunger end cap is secured by the mechanical flippers and the syringe flange ears are located in the pumps 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 potenti ometer which changes its resistance with the barrel diameter The potentiometer is excited with a preci sion 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 deter mine offset and gain Calibration values are stored in non
228. time re PLUGGED IN maining on the battery Low BATTERY INITIAL SIGNAL Medium Medium Normal advisory message Plug in the power cord and run the pump on AC Mains while recharging battery Motor Rate ERROR High High Normal advisory message The stepper motor ing at the wrong speed Clear any obstructions to proper motor operation If the message reoccurs you may need to replace the motor 56 40 5648 51C Alarm priority infusing Alarm message programming OCCLUSION CHECK INFUSION LINE Troubleshooting 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 soft ware use Configuration Manual to change settings pumps with v4 software use the PharmGuard Software to change settings or b change the infu sion set up high rates through micro bore tubing can cause high backpressures OutsiDE RANGE SILENCE Medium ALARM TO CONTINUE 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 ques tioned value or press and change values so that the infusion stays inside the established limits PERIODIC CALLBACK SILENCE
229. tion description sess 49 External DC power conditioning detection description e 50 Infrared serial data port description 50 Battery management 51 Battery gauge interface 51 Battery arBet 51 Charge detector 52 Battery dip 52 Battery board schematic 52 Battery gauge function econtra 52 Severely depleted battery monitor ree 52 Problem solving alarms alerts 53 Types or alas Alors Lusso 53 IV Troubleshooting 53 Alarm messages 54 System Advisory aret reda ra iori 60 System Pallute 61 General troubleshooting sa 65 Smiths Medical service and support 67 Using Smiths Medical service 515 67 Returning a pump for repair suene 67 Using for troubleshooting 68 Accessing BIOMED 68 BIOMED gt CALIBRATION 69 BIOMED gt DIAGNOSTICS screen 1 2 69 Audio Soon tien rrr 69 rir Ap 69 Indicator Edere E 69 70 Monitor Analog Sensors cosa ie eri teri peperere 70 Monitor Digital SOHSOEG oen on tein
230. tionally checked before being placed into service The following procedure is provided to meet this need Quick check out test O O 3 4 5 OLI 40 5648 51C 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 amp 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 pumps 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 Pumps with 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 Pumps with V4 software Set the date to the date you want the PM alert to occur This message does not prevent normal operation of t
231. to exit BIOMED gt CALIBRATION with out saving any new calibration values 1 From the CALIBRATION menu choose SAVE CHANGES AND EXIT PRESS THE NUMBER TO SELECT THE MODE 1 CAL SIZE AND POSITION 5 CAL SYRINGE SIZE SENSOR 2 CAL FORCE SENSOR 5 ADJUST CONTRAST 4 CAL PRESSURE SENSOR 7 CALIBRATION DATA CAL PLUNGER POSITION 9 SAVE CHANGES AND EXIT a PRESS THE HUMBER TO SELECT FA CAL SIZE AND POSITION ADJUST CONTRAST FA CAL FORCE SENSOR 3 VIEW CALIBRATION DATA CAL PLUNGER POSITION SAVE CHANGES AND EXIT CAL SYRINGE SIZE SENSOR eS SSS SSS 2 Press to exit BloMED 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 to exit and the following screen appears SAVE CHANGES Ee SSS eec L 2 Press No to exit without saving new calibration values 40 5648 51 107 Calibration amp Adjustment Retest guidelines The following are minimum guidelines for re calibra tion and re testing after repair Repair Type From Biomed gt Calibration From Periodic Maintenance perform perform Pump Opened None Quick Check out Repair drive train Replace motor None Complete Mandatory Annual Mainte nance Testing Replace clutches square rod lead screw or plunger cable Recalibrate position
232. 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 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 as sembly on extrusion and rotate out of way 9 Slide position pot out of the extrusion 40 5648 51C Parts Replacement Replacement 1 2 10 11 12 Slide new position pot into extrusion 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 12 Nm Secure motor assembly on extrusion with three flat head screws Torque to 100 in oz 0 71 Nm 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 pots post and t
233. urn 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 a darkened area and verify the back light is func tioning Follow retest guidelines listed in the Calibration and Adjustment section to verify pump functionality be fore returning it to use 40 5648 51C Parts Replacement Keypad This section defines the steps for removing and replac ing the Keypad Tools needed For this disassembly procedure you will need open end wrench e Torque screwdriver with a Phillips head amp small flat blade Always work at an electrostatic controlled work sta tion 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 th
234. ve timing plates per above Gently pull on the plunger cable unplugging it from connector J2 Unplug force sensor cable from on plunger board Using a Phillips screwdriver remove pan head screw with washer from the force mount assembly 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 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 Using a metric 2 5mm hex wrench remove the screw holding the float plate Slide plunger case left toward pump until the hex head screw is accessible on the force mount as sembly 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 0 71 Nm 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 0 71 Nm Connect force sensor cable to the plunger board at connector J1 and press excess cable flat against board Connect plunger cable to plunger b
235. y Annual Mainte nance Testing Replace case handle Recalibrate position amp size Quick Check out amp Calibration Verifi cation Replace plunger head or flippers Recalibrate force Quick Check out amp Calibration Verifi cation Replace IR lens None Quick Check out Replace plunger lever None Quick Check out Replace pump labels None Quick Check out Replace feet None Quick Check out Replace tubing holders Recalibrate size Quick Check out amp Calibration Verifi cation 40 5648 51C 109 Calibration amp Adjustment 110 40 5648 51C Schematics amp PCB Assemblies System layout Ya Wads 358VHO 2 AW1dSI0 Silva 8 vilvaG 8 t3lvd 8 8 lalva 8 013831114 195 21501 1SWYLNOD_GI1 vt 2 NOLLV2INQWWOO 1V2ILdO 5 VNH31X3 82d LOANNODYALNI S AfidNI DY 1155 12 4 5 8 te a 5 m 2 1 2 1 5 E 1 i HINO USNS 39155394 5 TINO USNS 34055384 7 J NDISS 2 1 2 USNS NI 13S 8 1 1 a gt 1 uOSN3S 13S vr 7 6r pc
236. yringe plunger Record this measurement as the ending position 3 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 Maximum travel Manufacturer Minimum travel Nominal travel B Braun Perfusor 50cc 3 146 79 92mm 3 211 81 55mm 3 275 83 18mm B Braun Ominifix 50cc 3 146 79 92mm 3 211 81 55mm 3 275 83 18mm B D 60cc 3 473 88 22mm 3 544 90 02mm 3 615 91 82mm Fresenius 50cc 2 904 73 76mm 2 964 75 27mm 3 023 76 77mm Monoject 60cc 3 473 88 22mm 3 544 90 02mm 3 615 91 82mm Terumo 60cc 2 901 73 70mm 2 961 75 20mm 3 020 76 70mm Table of acceptable syringe travel for 50 and 60 cc syringes If this test fails use the troubleshooting guide for correc tive action AC line leakage test 1 Connect the AC power cord to the Safety Analyzer Set Safety Analyzer to Line Leakage mode of operation Press to turn the pump on 2 Using 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 22 40 5648 51C Scheduled Maintenance If you wish

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