Abbott 4 Series Service manual

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©Copyright 1995

Abbott Laboratories

All Rights^served

This document andthe subject matter disclosed herein are proprietary information. Abbott Laboratories retains all the exclusive rights^qtatesemination, reproduction, manufacture andsale. Anyparty using this document accepts it in confidence, and^agtises not to duplicate it in whole or in part nor disclose it to

others without the written consent of Abbott Laboratories.

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430-01858-003(Rev. 5/95)	LifeCare and HomeCare Model 4 Series

Change History

			Insert
		Remove and	Change
Part Number	Description of Change	Destroy Pages	Pages

430-01858-001 (Rev. 5/91)	Original issue
430-01858-002 (Rev. 2/93)	Second issue
430-01858-A02 (Rev. 4/93)	Updated cover and added
	copyright information to the
	reverse side

cover

cover

Updated Change History	i, ii	i, ii
Updated Contents	iii tox	iii tox
Section 1	1-1 to 1-10	1-1	to 1-10

Added Section 1.2,

Conventions

Deleted Section 1.6 and

renumbered subsequent

subsections

(

Note: Change page manuals assembled by Abbott Laboratories include a change page identifier in the part number on the cover page. This change page manual is identified on the cover page as 430-01858-A02.

430-01858-B02 (Rev. 6/93)	Updated cover page and	Cover	Cover
	copyright page on reverse side
	Updated Change History	i, ii	i, ii
	Section 7.2.4.3: Revised	7-7 to 7-10	7-7 to 7-10
	voltage and pressure readings
	in calibration test

Note: Change page manuals assembled by Abbott Laboratories include a change page identifier in the part number on the cover page. This change page manual is identified on the cover page as 430-01858-B02.

'*•- 436^01858-C02 (Rev. 11/93) Updated cover page and	Cover	Cover
reverse side page ., ",:, ...H.^	J, -	31 f;

s;ritr.r?2-.. n	?.; ^-	Updated Changeiijfeto^ ':[\	i, ii	i..U
"^jp/		Update Contents -\'-;^V: r.	iii. iv	iii, iv.
		Table 1-2: Updated table	1-7 to 1--10	1-7 to 1-8
LifeCare and HomeCare Model 4 Series			430-01858-003 (Rev. 5/95)

vita r

'

3':'

Change History

Part Number

		Insert
DesciiptiotfbF6naiige	Remove and	Change
	Destroy Pages	Pages
		s^ssr
Section 4.4.3.4: Updated	4-21, 4-22	4-21, 4-22
hardware watchdog information;
Section 4.4.3.5: Updated
hardware watchdog test

Section 4.5.4.1: Updated

4-31, 4-32

4-31,4-32

numeric and bar display digit drivers circuitry;

Section 4.5.4.2: Updated display enable stretcher and display protector circuitry;

Section 4.5.4.3: Updated numeric and bar display segment drivers information;

Section 4.5.4.4: Updated display

test

Section 5.2: Updated PVT	5-3, 5-4	5-3, 5-4
requirements
Section 5.2.5: Updated Step 5	5-5, 5-6	5-5, 5-6
Section 5,2.6: Added note;	5-7, 5-8	5-7, 5-8
Section 5.2.9: Update voltage
reading Step 3
Section 5.4.3: Added Step 3;	5-11,5-12	5-11,5-12
Section 5.4.4: Updated Step 3
Figure 7-3: Clarified vertical	7-7, 7-8	7-7, 7-8
distance between level of water
in container and midline of set
Section 7.2.4.4: Clarified vertical	7-9, 7-10	7-9, 7-10
distance between level of water
in container and midline of set
Section 7.3.1.3: Updated	7-11,7-12	7-11,7-12
materials
Section 7.3.1.3: Updated	7-23, 7-24	7-23 to 7-26
shroud assembly plunger guide
replacement procedure
Section 8: Updated specifications	8-1,8-2	8-1, 8-2
Updated back page part number	back page	back page

Note: Change page manuals assembled by Abbott Laboratories include a change page identifier in the part number on the cover page. This change page manual is identified on the cover page as 430-01858-C02.

430-01858-003 (Rev. 5/95)

Technical Sen/ice^Aaftiial

'•i-j'
430-01858-003.(Rev5/95)		iii	JJeCareandHomeCareModel4Series
.:t«0	..-,--•'•"l
	-•:	C./•^r

3(V»v.-

		Thirdissue	430-01858-003.(Rev5/95)
Pages	DestroyPages	DescriptionofChanger	PartNumber
Change	Removeand
Insert

ChangeHistory

TechnicalService;.:.Manualj

IV

430-01858-003.(Rev5/95)

Thispageintentionallyleft.blank

>i?3J..A~J;>

Change-History

					Contents	.••o
			Contents
^Il^/	Section 1
	INTRODUCTION				1-1
	1.1 SCOPE				1-1
	1.2 CONVENTIONS				1-2
	1.3 ACRONYMS AND ABBREVIATIONS				1-3
	1.4 USER QUALIFICATIONS				1-5
	1.5 ARTIFACTS				1-5
	1.6 SERIES SPECIFIC FEATURES				1-6
	1.7 INSTRUMENT INSTALLATION PROCEDURE				1-8
	1.7.1	UNPACKING			1-9
	1.7.2	INSPECTION			1-9
	1.7.3	SELFTEST			1-9
	Section 2
	WARRANTY				2-1
	Section 3
	SYSTEM OPERATING MANUAL				3-1
	Section 4
	THEORY OF OPERATION				4-1
	4.1 GENERAL FUNCTIONS			,.,.	4-1
	4.1.1	CASSETTE			4-1
	4.1.2 FLOWDETECTOR				4-2
	4.1.3	ALARMS			4-2
		4.1.3.1	AUDIBLEALARM		4-2
		4.1.3.2	NURSE-CALL ALARM		4-2
	4.1.4 NUMERIC AND BAR DISPLAYS				4-2
	43 EXTERNAL INTERFACE PORTS				4-3
	4^.1	ACC CONNECTOR J23			4-3
	4^.2	NURSE-CALL JACK J21			4-4
	4^.3	FLOW DETECTOR CONNECTOR J22			4-4
	4.2.4	RS-485 DATAWAY I/O CONNECTOR JlOl			4-5
	4.2.5	RS-232I/OPORT			4-5
	4.2.6	20-MAI/OPORT			4-5
	4.3 OPERATIONAL DESCRIPTION				4-6
	4.3.1	MODES OF OPERATION			4-6
		4.3.1.1	LOAD/OFF RECHARGE MODE		4-7
		4.3.1.2	SELFTESTMODE		4-8
		4.3.13	LOCAL CONTROL MODE		4-8
		4.3.1.4	REMOTE CONTROL MODE		4-9
		4.3.1.5	BATTERY DISCHARGED MODE		4-9
		43.1.6	SYSTEM FAILURE MODE		4-10
	43.2	SILENCE/ASK FUNCTION			4-11
	4.33 DATA RETENTION FUNCTION				4-12
	4.4 MONITORS AND DETECTORS				4-12
	4.4.1	FLOW MONITORING SYSTEM			4-12
		4.4.1.1	FLOWDETECTOR		4-13
		4.4.1.2	DROP SIGNAL PROCESSOR		4-14
		4.4.1.3	CURRENT AMPLITUDE MODULATOR		4-14
		4.4.1.4	SYNCHRONOUS DEMODULATOR		4-15

LifeCare and HomeCare Model 4 Series

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430-01858-003 (Rev. 5/95)

Contents

	4.4.1.5	DROP AMPLITUDE THRESHOLD DETECTOR	4-15
	4.4.1.6	FLOW DETECTOR PRESENCE DETECTION	4-15
	4.4.1.7	FLOW ALGORITHM	4-16
4.4.2	PRESSURE MEASURING SYSTEM		4-16
	4.4.2.1 PRESSURE SENSOR PWA (-004 AND HIGHER)		4-17
	4.4.2.2 PRESSURE SENSOR PWA (-003 AND LOWER)		4-17
	4.4.23	OCCLUSION ALARM ALGORITHM	4-17
4.43	MALFUNCTION DETECTION CIRCUITRY		4-18
	4.43.1	INTERNAL RAM TEST	4-18
	4.4.3.2	ROMTEST . . . . .	4-19
	4.43.3	POWER-UPTEST	4-19
	4.43.4	HARDWARE WATCHDOG	4-19
	4.4.3.5	HARDWARE WATCHDOG TEST	4-20
	4.4.3.6	SOFTWARE WATCHDOG	4-20
	4.43.7	MICROPROCESSOR SANITY CHECK	4-20
4.5 ELECTRONICS SUBSYSTEM PRINCIPLES OF OPERATION			4-20
4.5.1	MPUPWA		4-21
	4.5.1.1	MICROPROCESSOR CIRCUITRY	4-21
	4.5.1.2	MEMORY CIRCUITRY .	4-22
	4.5.1.3	MEMORY LATCH CIRCUITRY	4-22
	4.5.1.4	MEMORY PROTECTOR CIRCUITRY	4-22
	4.5.1.5	I/O PORTS	4-22
4.5.2	MOTOR DRIVER PWA ... - .		4-23
	4.5.2.1	I/O ADDRESS DECODER	4-26
	4.5.2.2	INPUT DATA BUFFERS	4-27
	4.5.2.3	A/DCONVERTER	4-27
	4.5.2.4	RS-485 DATAWAY PORT .	4-27
4.53	DISPLAYPWA		4-28
4.5.4	DISPLAY DRIVER PWA		4-29
	4.5.4.1	HARDWARE WATCHDOG CIRCUITRY	4-29
	4.5.4.2	NUMERIC AND BAR DISPLAY DIGIT DRIVERS CIRCUITRY ...	4-29
	4.5.43 DISPLAY ENABLE STRETCHER AND DISPLAY
		PROTECTOR CIRCUITRY	4-30
	4.5.4.4 NUMERIC AND BAR DISPLAY SEGMENT DRIVERS		4-30
	4.5.4.5	DISPLAYTEST	4-30
4.5.5	POWER SUPPLY PWA		4-31
	4.5.5.1	UNREGULATED DC POWER SUPPLY CIRCUITRY	4-31
	4.5.5.2	BATTERYPACK	4-31
	4.5.5.3	BATTERY CHARGER CIRCUITRY	4-32
	4.5.5.4 DIODE POWER SWITCH CIRCUITRY		4-32
	4.5.5.5	POWER CONTROL CIRCUITRY	4-32
	4.5.5.6	5 VDC REGULATOR CIRCUITRY	4-33
	4.5.5.7	5 VDC FAILURE DETECTOR CIRCUITRY	4-34
	4.5.5.8	MOTOR VOLTAGE REGULATOR	4-34
	4.5.5.9	BATTERY MONITOR CIRCUITRY	4-34
	4.5.5.10 MEMORY SUPPLY CIRCUITRY		4-35
4.5.6	CURRENT BOOST CHARGER PWA		4-35
	4.5.6.1	AC (MAINS) OPERATION	4-35
	4.5.6.2	DCOPERATION	4-36
4.5.7	CONTROL SWITCHES		4-36
	4.5.7.1	FRONT PANEL SWITCHES	4-36
	4.5.7.2	REAR PANEL SWITCHES	4-37
4.6 MECHANICAL SUBSYSTEM PRINCIPLES OF OPERATION			4-38
4.6.1	CASSETTE		4-38
4.6.2	PUMPMECHANISM . .		4-39
4.63	MOTOR AND MOTOR DRIVERS		4-40
4.7 BATTERY OPERATION OVERVIEW			4-40

430-01858-003 (Rev. 5/95)

vi

Technical Service Manual

Contents

	Sections			\
\jjyjj~	MAINTENANCE AND SERVICE TESTS			... ]; .		5-1
	5.1 PREVENTIVE MAINTENANCE			•'.'".'		5-1
	5.1.1	INSPECTING THE PUMP		..... "		5-1
	5.1.2	CLEANING THE PUMP		.... : ; .		5-2
	5.1.3	SANITIZING THE PUMP .... . .				5-3
	5.2 PERFORMANCE VERIFICATION TEST . . .					5-3
	5.2.1	EQUIPMENT AND MATERIALS REQUIRED				5-3
	5.2.2	PUMP INSPECTION		>: .		5-4
	5.2.3	DRY CASSETTE TEST		:		5-4
	5.2.4	TEST SETUP				5-4
	5.2.5	STARTUPTEST		:		5-5
	5.2.6	PRESSURE TEST AND SILENCE SWITCH TEST				5-6
	5.2.7 HIGH FLOW ALARM AND LOW FLOW ALARM (SIMULATED)
		AND AUDIBLE ALARM TESTS				5-7
	5.2.8	DELIVERY ACCURACY TEST . . . .				5-7
	5.2.9	PIGGYBACK TEST (MODEL 4P ONLY)				5-8
	5.2.10 BATTERY CHARGING TEST ....					5-9
	5.2.11 MALFUNCTION SIMULATION TEST .					5-9
	5.2.12 ELECTRICAL SAFETY TEST					5-9
	5.2.13 END OF PERFORMANCE VERIFICATION TEST					5-9
	5.3 BATTERY MAINTENANCE					5-10
	53.1	DEPTH OF DISCHARGE				5-10
	53.2	RECHARGING			.	5-10
	5.4 BATTERY CIRCUIT ALARM AND CHARGER TESTS . . .					5-11
	5.4.1	TEST EQUIPMENT REQUIRED			.. : .......	5-11
	5.4^	LOW BATTERY ALARM TEST			.	5-11
	5.4.3	BATTERY SHUTDOWN TEST ........ . .				5-11
	5.4.4	BATTERY CHARGING CIRCUIT TEST				5-12
	5.5 PVTDATAFORM				.	5-13
	Section 6
	TROUBLESHOOTING					6-1
	6.1 TECHNICAL ASSISTANCE					6-1
	6.2 AUDIBLEALARMS					6-1
	6.3 ALARM CONDITIONS					6-2
	6.4 ALARM CODES					6-2
	6.5 OBTAINING AN ALARM HISTORY					6-2
	6.6 PUMP TROUBLESHOOTING			v .		6-4
	6.7 FVTTROUBLESHOOTING			: .		6-17
	6.8 TEST CONNECTOR			. .		6-19
	Section 7
	REPLACEABLE PARTS AND REPAIRS			.		7-1
	7.1 REPLACEABLE PARTS LIST					7-1
	7.2 ADJUSTMENT PROCEDURES					7-3
	7.2.1	TOOLS AND MATERIALS REQUIRED				7-3
	7.2.2	SHROUD TAB CHECK				7-3
	7.2.3	SHROUD REAR TAB ADJUSTMENT .				7-4
	7.2.4 PRESSURE SENSOR CALIBRATION AND TEST					7-5
		7.2.4.1	PRESSURE SENSOR CALIBRATION SETUP			7-5
		7.2.4.2	CALIBRATION (PRESSURE SENSOR PWA-003 AND LOWER) ...			7-6
		7.2.4.3	CAUBRATION (PRESSURE SENSOR PWA-004 AND HIGHER) . .			7-8

LifeCare and HomeCare Model 4 Series

vii

430-01858-003 (Rev. 5/95)

Contents

	7.2.4.4	PRESSURE SENSOR TEST	7-10
7.3 REPLACEMENT PROCEDURES			7-11
7.3.1 SAFETY AND EQUIPMENT PRECAUTIONS			7-11
7.3.2	REQUIRED TOOLS AND MATERIALS		7-11
	7.3.2.1	STANDARD HANDTOOLS	7-12
	7.3.2.2	SPECIALTOOLS	7-12
	7.3.2.3	MATERIALS	7-12
7.33	BATTERY PACK REPLACEMENT		7-13
7.3.4	FUSE REPLACEMENT		7-14
	7.3.4.1	FUSE REPLACEMENT (115 V~)	7-14
	7.3.4.2	FUSE AND FUSE DRAWER REPLACEMENT (100 V~, 220 V~) ...	7-15
7.3.5	VELCRO ANCHOR PAD REPLACEMENT		7-15
7.3.6	AC POWER CORD STRAIN RELIEF BUSHING REPLACEMENT (115 V~) . .		7-16
73.7 AC POWER CORD PLUG REPLACEMENT			7-16
73.8	NURSE-CALL CABLE ASSEMBLY REPLACEMENT		7-17
73.9	FLOW DETECTOR ASSEMBLY REPLACEMENT		7-17
7.3.10 FLOW DETECTOR ASSEMBLY PLUG AND CLOSED ENTRY
	FEMALE TERMINAL REPLACEMENT		7-18
7.3.11 FLOW DETECTOR CONNECTOR HOUSING AND MALE PIN
	CONNECTOR(S) REPLACEMENT		7-19
73.12 MAIN CONTROL KNOB REPLACEMENT			7-20
73.13 POLE CLAMP KNOB REPLACEMENT			7-20
7.3.14 POLE CLAMP SHAFT REPLACEMENT			7-21
7.3.15 AUDIBLE ALARM LEVEL SWITCH REPLACEMENT			7-22
7.3.16 SHROUD ASSEMBLY PLUNGER GUIDE REPLACEMENT			7-23
73.17 ACCESSORY (ACC) CONNECTOR (OR PINS) REPLACEMENT			7-24
7.3.18 CASE REPLACEMENT			7-26
	73.18.1 ONE-PIECE CASE REPLACEMENT		7-26
	73.18.2 CLAMSHELL CASE REPLACEMENT		7-28
7.3.19 PWA REPLACEMENT			7-30
	73.19.1 POWER SUPPLY PWA REPLACEMENT		7-30
	73.19.2 DISPLAY PWA, DISPLAY DRIVER PWA, MPU PWA, AND
		MOTOR DRIVER PWA REPLACEMENT	7-31
	73.19.3 MOTHERBOARD PWA REPLACEMENT		7-33
73.20 AC POWER CORD REPLACEMENT (115 V~)			7-34
7.3.21 AC (MAINS) POWER CORD REPLACEMENT (100V-, 220 V~)			7-35
73.22 AC POWER CORD RETAINER CLIP REPLACEMENT (115 V~)			7-36
7.3.23 TOUCHSWTTCH PANEL REPLACEMENT			7-36
7.3.24 PIEZOELECTRIC ALARM REPLACEMENT			7-38
7.3.25 TRANSFORMER CONNECTOR P10 AND CLOSED ENTRY
	FEMALE TERMINAL REPLACEMENT		7-39
7.3.26 MAIN CONTROL SWITCH SHAFT ASSEMBLY REPLACEMENT			7-40
7.3.27 MAIN CONTROL SWITCH SHAFT ASSEMBLY LUBRICATION			7-43
73.28 MAIN CONTROL SWITCH WAFER REPLACEMENT			7-44
73.29 FUSEHOLDERREPLACEMENT(115V~)			7-45
7.330 NURSE-CALL JACK REPLACEMENT			7-46
7331 PRESSURE LEVEL SELECT SWITCH REPLACEMENT			7-46
73.32 SET TYPE SWITCH REPLACEMENT (MICRO ONLY)			7-47
7.3.33 RUBBER FOOT PAD REPLACEMENT			7-48
7.3.34 MAINS RECEPTACLE ASSEMBLY REPLACEMENT (100 V~, 220 V~) ...			7-49

Section 8

SPECIFICATIONS

8-1

430-01858-003 (Rev. 5/95)

viii

Technical Service Manual

			Rgures
	Section 9
	DRAWINGS		9-1
	Section 10
	INDEX		10-1
		Figures
	Figure 4-1.	Flow Detector Schematic Diagram	4-14
	Figure 4-2.	Power Control Circuitry	4-33
	Figure4-3.	Pump Cassette	4-39
	Figure 5-1.	Delivery Accuracy Test Setup	5-5
	Figure7-1.	Shroud Tab Check	7-4
	Figure7-2.	Pressure Sensor Adjustment Resistors	7-6
	Figure 7-3.	Calibration Test Setup	7-8
	Figure 7-4.	Battery Pack Replacement	7-14
	Figure7-5.	Main Control Knob Removal	7-20
	Figure7-6.	Pole Clamp Knob Removal	7-21
	Figure 7-7.	Shroud Assembly Plunger Guide Replacement	7-24
	Figure 7-8.	ACC. Connector Pin Arrangement	7-26
	Figure 7-9.	Rear Panel Screw Removal (One-Piece Case)	7-27
	Figure 7-10. Removing Chassis From Cover		7-28
	Figure 7-11. Case Screw Removal (Clamshell Case)		7-29
	Figure 7-12. Opening the Clamshell Case		7-29
	Figure 7-13. Shield Removal		7-30
	Figure 7-14. Heat Sink Screw Removal		7-31
	Figure 7-15. PWA Removal		7-32
	Figure 7-16. Motherboard PWA Removal		7-33
	Figure 7-17. AC Power Cord Replacement (115 Volt)		7-35
	Figure 7-18.Touchswitch Panel Replacement		7-37
	Figure 7-19. Piezoelectric Alarm Replacement		7-39
	Figure 7-20. Main Control Switch Shaft Assembly		7-42
	Figure 7-21. Main Control Switch Shaft Assembly with Switch Housing Removed		7-42
	Figure 7-22. Main Control Switch Shaft Assembly E-Ring Removal		7-43
	Figure 9-1.	Block Diagram, Series 4	9-3
	Figure 9-2. Schematic, System Interconnect, Model 4P		9-5
	Figure 9-3.	Schematic, System Interconnect, Micro 4/MDL 4	9-9
	Figure 9-4.	Schematic, Interconnect, International, Micro 4/MDL 4	9-13
	Figure 9-5.	Schematic, Pressure Sensor PWA, Micro 4/Model 4	9-17
	Figure 9-6.	Schematic, Motherboard PWA, Series 4 .	9-21
	Figure 9-7.	Schematic, MPU PWA, Series 4	9-25
	Figure 9-8.	Schematic, MPU PWA, Micro 4/Model 4	9-29
	Figure 9-9. Schematic, Motor Driver PWA, Micro 4/Model 4		9-31
	Figure 9-10. Schematic, Motor Driver PWA, Series 4		9-33
	Figure 9-11. Schematic, Display PWA, MDL 4		9-35
	Figure 9-12. Schematic, Display PWA, Micro 4		9-39
	Figure 9-13. Schematic, Display Driver PWA, Series 4		9-43
	Figure 9-14. Schematic, Power Supply PWA, Micro 4/Model 4		9-45
	Figure 9-15. Schematic, Current Boost Charger, MDL 4/PCA		9-65
^jjgs/	Figure 9-16. IPB for the Pump		9-69

LifeCare and HomeCare Model 4 Series

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430-01858-003 (Rev. 5/95)

Tables

Tables

Table 1-1.	Conventions	1-2
Table 1-2.	Model 4 Series CaseTypes and I/O Capabilities	1-6
Table 1-3.	Series Specific Features - Model 4 Series	1-7
Table 4-1.	ACC. Connector J23 Pin Arrangement	4-4
Table 4-2.	User Controls and Operating Modes	4-6
Table 4-3.	ASK Function Messages	4-11
Table 4-4.	I/O Address Table	4-24
Table 4-5.	Numeric and Bar Displays	4-29
Table 5-1.	Cleaning Solutions	5-2
Table 6-1.	Alarm Codes	6-3
Table 6-2.	Troubleshooting Audible Alarms	6-4
Table 6-3.	Troubleshooting Fluid Flow	6-5
Table 6-4.	Troubleshooting Battery Operations	6-9
Table 6-5.	Troubleshooting Core Failures	6-11
Table 6-6.	Troubleshooting the Pump Displays	6-12
Table 6-7. Troubleshooting External Controls		6-13
Table 6-8.	Troubleshooting the Pump Touchswitches	6-13
Table 6-9. Troubleshooting the Pump Mechanism		6-13
Table 6-10. Troubleshooting the Dataway Function (RS-485 Only)		6-15
Table 6-11.Troubleshooting the Nurse-Call Alarm		6-16
Table 6-12. Troubleshooting Miscellaneous Conditions		6-16
Table 6-13.Troubleshooting with the PVT		6-18
Table 6-14.Test Connector (J23) Pin Assignments		6-19
Table9-1.	Drawings	9-1
Table9-2.	IPB for the Pump	9-89

430-01858-003 (Rev. 5/95)

Technical Service Manual

^	Section 1
	INTRODUCTION
	LifeCare® and HomeCare Model 4 Series Infusion Pumps, herein referred to as the pump,
	are identified by the following model designations:
	•	LifeCare Model 4
	Q	LifeCare Model 4P
	•	LifeCare Micro
	•	HomeCare Model 4H

The LifeCare Model 4 is a baseline infusion pump. The LifeCare Model 4P is similar to the Model 4 except that Dual Rate automatic piggybacking is available on Model 4P. The LifeCare Micro features delivery rates from 0.1 to 99.9 milliliters per hour (ml/hr). The Model 4H version ofthe Model 4 has a limited delivery rate range for home care applications.

For details about the various pump configurations, refer to Section 1.6, Series Specific

Features.

1.1

SCOPE

The manual is organized into 11 sections:

•Section 1 Introduction

QSection 2 Warranty

•Section 3 System Operating Manual

•Section 4 Theory of Operation

•Section 5 Maintenance and Service Tests

QSection 6 Troubleshooting

• Section 7 Replaceable Parts and Repairs

•Section 8 Specifications

Q Section 9 Drawings

•Section 10 Index

•Technical Service Bulletins

The material in this manual is limited to technical information necessary for battery testing, various service tests, interpreting system alarm and status messages, field adjustment procedures, troubleshooting, and authorized repairs on the pump.

Specific instructions for pump operation are provided in the LifeCare and HomeCare system operating manuals.

Technical Service Manual

1-1

430-01858-003 (Rev. 5/95)

Section 1 INTRODUCTION

If a problem in pump operation cannot be resolved using the information in this manual, contact Abbott Laboratories (see Section 6.1, Technical Assistance).

Note: Figures are rendered as graphic representations to approximate the actual product; therefore, figures may not exactly reflect the product. Display screens and touchswitch labels may vary slightly, depending on the configuration of the pump system in use.

1.2

CONVENTIONS

The conventions listed in Table 1-1, Conventions, are used throughout this manual.

CONVENTION

Italic

[ALLCAPS]

Table 1-1. Conventions

APPLICATION EXAMPLE

Reference to a section, figure,	(see Figure5.1, DeliveryAccuracy
table, or publication	Test Setup)
In-text references to keys are	[SILENCE]
described in all caps and enclosed
in brackets

ALL CAPS	Screen displays	CHK DOSE
Bold	Emphasis	CAUTION: Use proper ESD
		grounding techniques when
		handling components.

loovl

When a description or procedure is	—d To replace the fuse in a
specific to a pump with a particular	j^vj 115 volt pump, proceed as
voltage rating, this is designated by	' follows:
an icon at the beginning of the

section.

115Vf

220V|

When a description or a procedure is specific to a particular series or version of the pump, the software version or final assembly dash number is shown in parentheses following the section heading.

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LifeCare and HomeCare Mode! 4 Series

1.3 ACRONYMS AND ABBREVIATIONS

Throughout this manual, warnings, cautions, and notes are used to emphasize important

information as follows:

WARNING

A WARNING CONTAINS SPECIAL SAFETY EMPHASIS AND MUST BE OBSERVED AT

ALL TIMES. FAILURE TO OBSERVE A WARNING IS POTENTIALLY LIFE

THREATENING.

CAUTION: A CAUTION usually appears in front of a procedure or statement. It contains information that could prevent irreversible equipment damage or failure.

Note: A note highlights information that helps explain a concept or a procedure.

1.3

ACRONYMS AND ABBREVIATIONS

Acronyms and abbreviations used in this manual are as follows:

A

ABSPRES

AC

ACC

A/D

ADC

Ah

AS

CMOS

dB

DIFPRES

DMM

DPM

DS

DSPLN

ECG

EEG

EMG

EMI

ESD

ETO

Hz

IC

Ampere

Absolute pressure

Alternating current

Accessory

Analog-to-digital

Analog-to-digital converter

Ampere-hour

Address strobe

Complementary metal oxide semiconductor

Decibel

Differential pressure

Digital multimeter

Digital pressure meter

Data strobe

Display enable

Electrocardiogram

Electroencephalogram

Electromyogram

Electromagnetic interference

Electrostatic discharge

Ethylene oxide

Hertz

Integrated circuit

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Nj|^j^

1.4 USER QUALIFICATIONS

RAM Random access memory

ROM Read only memory

RST Reset

RTS Request to send

SD Serial Data

SFTWRREV Software revision

SW Switch

TRE Transmit enable

UART Universal asynchronous receiver/transmitter

V Volt

VDC Volt direct current

VMEM Voltage memory

VMOT Motor voltage requester

WDSTB Watchdog strobe

HA Microampere

jiF Microfarad

\xs Microsecond

1.4

USER QUALIFICATIONS

The Model 4 Series infusion pumps are for use at the direction or under the supervision oflicensed physicians, and by licensed or certified healthcare professionals who are trained in the use of the pump and in the administration of intravenous (IV) fluids.

1.5

ARTIFACTS

Nonhazardous, low-level electrical potentials are commonly observed when fluids are administered using infusion devices. These potentials are well within accepted safety standards, but may create artifacts on voltage-sensing equipment such as ECG, EMG, and

EEG machines. These artifacts vary at a rate that is associated with the infusion rate. If the monitoring machine is not operating correctly or has loose or defective connections to its sensing electrodes, these artifacts may be accentuated so as to simulate actual physiological signals. To determine if the abnormality in the monitoring equipment is caused by the pump instead of some other source in the environment, set the pump so that it is temporarily not delivering fluid. Disappearance of the abnormality indicates that it was probably caused by electronic noise generated by the pump. Proper setup and maintenance of the monitoring equipment should eliminate the artifact Refer to the appropriate monitoring system documentation for setup and maintenance instructions.

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430-01858-003 (Rev. 5/95)

Section 1 INTRODUCTION

1.6

SERIES SPECIFIC FEATURES

Features specific to the Model 4 Series infusion pumps are summarized in Table 1-2,

Model 4 Series Case Types and I/O Capabilities, and Table 1-3, Series Specific Features -

Model 4 Series.

Note: Case type A: One-piece case

Case type B: Clamshell case

When pumps with Type A cases are factory refurbished, they are refurbished with a Type B

case .

Table 1-2. Model 4 Series Case Types and I/O Capabilities

	List		Case
Model	Numbers*	Final Assembly Number*	Type	I/O
Model 4	1814	850-01401-001	Type A	RS-232
	1914	850-01401-003	Type A	None
		850-01614-001,-002, -003, -007, -009,
		-011
	1915	850-01401-004	Type A	RS-485
		850-01401-013, -015, -016, -018, -020,	TypeB	RS-485
		-022
		850-01614-005, -006, -008, -010	Type A	RS-485
		850-01614-014 and above	TypeB	RS-485
Model 4P	2505	850-01401-005, -007, -009	Type A	None
	2506	850-01401-006, -008, -010, -011	Type A	RS-485
		850-01401-014,-017,-021	TypeB	RS-485
Micro	1815	850-01400-001	Type A	RS-232
	1916	850-01400-003	Type A	None
		850-01627-001, -002, -009
	1917	850-01400-004	Type A	RS-485
		850-01400-006, -007, -008	TypeB	RS-485
		850-01627-005, -006, 010	Type A	RS-485
		850-01627-015 and above	TypeB	RS-485

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LifeCare and HomeCare Mode! 4 Series

1.6 SERIES SPECIFIC FEATURES

Table 1-2. Model 4 Series Case Types and I/O Capabilities

	N||^/	List		Case
		Numbers*	Final Assembly Number*	Type	I/O
	Model
	Model 4H	22100	850-01557-001	Type A	20 mA
		24000	850-01557-004	Type A	RS-485
			850-01557-006, -007, -008	TypeB	RS-485

* List number and final assembly number are located on the rear of the pump.

Table 1-3. Series Specific Features • Model 4 Series

Model 4 Series Infusion Pump

Characteristic

List numbers

(see Table 1-2)

Piggyback pump set?

Set type switch?

Row alarms

Row detector required?

Pump cycle delivery

characteristics:

Number of drops falling in IV set drip chamber during filling stage

Average delivery increment during pumping stage

Model 4	Model 4P	Model 4	Model 4H
		Micro
1814	2505	1815	22100
1914	2506	1916	24000
1915		1917
No	Yes	No	No
No	No	Yes:	No
		Type A for 1/60 ml
		drops
		TypeB for 1/15 ml
		drops
Software version,	Software version	Software version,	Software version,
below 232:	232 and above:	below 232:	below 232:
FLOW	HI FLOW	FLOW	FLOW
KVO	LOW FLOW	KVO	KVO
	KVO
Software version		Software version	Software version
232 and above:		232 and above:	232 and above:
HI FLOW		HI FLOW	HI FLOW
LOW FLOW		LOW FLOW	LOW FLOW
KVO		KVO	KVO
Optional	Optional	Yes	Optional

Approximately	Approximately	Approximately	Approximately
one 1/15 ml drop	one 1/15 ml drop	four 1/60 ml drops	one 1/15 ml drop
Not to exceed	Not to exceed	Not to exceed	Not to exceed
5.6 u.L	5.6 uL	2.8 \iL	5.6 ^L

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430-01858-003 (Rev. 5/95)

Sectionl INTRODUCTION

Table 1-3. Series Specific Features - Model 4 Series

Model 4 Series Infusion Pump

Characteristic

	Model 4	Model 4P	Model 4	Model 4H
			Micro
KVO rate	4ml/hr	4ml/hr	1 ml/hr	4 ml/hr
Note: Rate may be
less if set delivery
rate is lower
Flow monitoring:
Operating angle	0° - 25°	0° - 25°	0°-15°	0°-25°
from vertical
Row alarm	Number of drops	Number of drops	Type A: Number	Number of drops
monitoring	minus number of	minus number of	of drops divided	minus number of
	pumping cycles is	pumping cycles is	by 4 minus	pumping cycles is
	> 5 with number of	> 5 with number of	number of	> 5 with number of
	drops and number	drops and number	pumping cycles is	drops and number
	of cycles both set	of cycles both set	> 5 with number of	of cycles both set
	to zero whenever	to zero whenever	drops and number	to zero whenever
	either reaches 12	either reaches 12	of cycles both set	either reaches 12
			to zero whenever
			either reaches 12
			TypeB: Same as
			Model 4

1.7

INSTRUMENT INSTALLATION

PROCEDURE

The instrument installation procedure consists of three steps: unpacking, inspection, and

self test.

CAUTION: Use of radio frequency emitting devices such as cellular telephones and two-way radios in close proximity of this device may affect its operation.

CAUTION: Product damage may occur unless proper care is exercised during unpacking, inspection, and self test. The battery may not be fully charged upon receipt of pump. Do not place the pump in service if it fails the self test.

Note: Do not place the pump in service if the battery is not fully charged. To make certain the battery is fully charged, connect the pump to alternating current (AC) (mains) power

for 24 hours.

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LifeCare and HomeCare Model 4 Series

1.7 INSTRUMENT INSTALLATION PROCEDURE

1.7.1

UNPACKING

mjy-y

Use care when unpacking the pump. Retain the packing slip and save all packing material for returning the pump to the factory in case it is damaged or fails the selftest. The shipping container also contains a copy of the system operating manual.

1.7.2

INSPECTION

Inspect the packing container for shipping damage. Should any damage be found, contact the delivering carrier immediately.

CAUTION: Inspect the pump for damage. Do not use the pump if it appears to be damaged; contact Abbott Laboratories (see Section 6.1, Technical Assistance).

1.7.3

SELF TEST

Note: Do not place the pump in service until the self test has been conducted. To conduct the self test, proceed as follows:

1.Connect the power cord to a properly grounded AC (mains) outlet.

2.Connect the flow detector to the FLOW DET. receptacle on the back of the pump.

3.Set the AUD. ALM. switch on the back of the pump to the desired volume level: low, medium, or high.

4.Turn the main control switch to LOCK/ON.

5.The pump automatically enters the self-test mode and performs the following operations:

-Initializes all data except history if the four-hour data retention interval has

been reached

-Tests random access memory (RAM) and read only memory (ROM)

-Checks failure monitor test status

-Illuminates all numeric elements, message display elements, and front panel legends

-Activates audible alarm

-Checks critical data integrity

If the pump fails the self test, do not place it in service; contact Abbott Laboratories (see

Section 6.1, Technical Assistance).

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INTRODUCTION

Section1

^

Section 2

WARRANTY

Subject to the terms and conditions herein, Abbott Laboratories, herein referred to as

Abbott, warrants that (a) the product shall conform to Abbott's standard specifications and be free from defects in material and workmanship under normal use and service for a period ofone year after purchase, and (b) the replaceable battery shall be free from defects in material and workmanship under normal use and service for a period of 90 days after purchase. Abbott makes no other warranties, express or implied, as to merchantability, fitness for a particular purpose, or any other matter.

Purchaser's exclusive remedy shall be, at Abbott's option, the repair or replacement of the product In no event shall Abbott's liability arising out of any cause whatsoever (whether such cause be based in contract, negligence, strict liability, other tort or otherwise) exceed the price of such product, and in no event shall Abbott be liable for incidental, consequential, or special damages or losses or for lost business, revenues, or profits. Warranty product returned to Abbott must be properly packaged and sent freight prepaid.

The foregoing warranty shall be void in the event the product has been misused, damaged, altered, or used other than in accordance with product manuals so as, in Abbott's judgment, to affect its stability or reliability, or in the event the serial or lot number has been altered, effaced, or removed.

The foregoing warranty shall also be void in the event any person, including the Purchaser, performs or attempts to perform any major repair or other service on the product without having been trained by an authorized representative of Abbott and using Abbott documentation and approved spare parts. For purposes of the preceding sentence, "major repair or other service" means any repair or service other than the replacement ofaccessory items such as batteries, flow detectors, detachable AC power cords, and patient pendants.

In providing any parts for repair or service of the product, Abbott shall have no responsibility or liability for the actions or inactions of the person performing such repair or service, regardless of whether such person has been trained to perform such repair or service. It is understood and acknowledged that any person other than an Abbott representative performing repair or service is not an authorized agent of Abbott.

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Section2WARRANTY

430-01858-003.(Rev5/95)

3-1

TechnicalServiceManual

Technical.Assistance) Ifanoperatingmanualisnotavailable,contactAbbottLaboratories(seeSection1,.6

appropriatesystemoperatingmanual.here Manualisincludedwithevery.pumpForconvenientreference,insertacopyofthe AcopyoftheLifeCareandHomeCareModel4SeriesInfusionPumpsSystemOperating

SYSTEMOPERATINGMANUAL

Section3

^

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Section3SYSTEMOPERATINGMANUAL

Section 4

THEORY OF OPERATION

This section describes the theory of operation for the Model 4 Series infusion pump. Related drawings are provided in Section 9, Drawings. The theory of operation describes general functions of the pump and provides a brief overview of external interface ports, operation, monitors and detectors, electronics subsystem principles of operation, and mechanical subsystem principles of operation.

Note: When a signal name is followed by an asterisk, such as INIT , the asterisk indicates an active low signal.

4.1

GENERAL FUNCTIONS

The Model 4 Series infusion pump contains electromechanical drivers with a cassette housed positive displacement pump. The motor driver is housed with all the electrical and mechanical subassemblies used for operation and control ofthe pump. The subassemblies include printed wiring assemblies (PWA), the battery pack, the display panel, and the pump

driver mechanism.

The pumping mechanism is stepper-motor driven to enable a simple control logic. The pumping volume is calculated as a function of the number of steps of the stepper motor (one motor revolution equals one pump stroke which equals displacement of

1/15 milliliter (ml) of fluid in a primed pump chamber).

The flow detector monitors fluid drops. The control logic compares the number of drops to the number of motor revolutions. When the number of drops exceeds the number of motor revolutions by more than four, or the number of motor revolutions exceeds the number of drops by more than four, a flow alarm is generated and the VOLUME DELIVERED light emitting diode (LED) display indicates the nature of the flow problem.

4.1.1

CASSETTE

The cassette is designed with an outlet valve that requires hydraulic pressure to operate.

An air-trap chamber holds air bubbles or outgassing from solution. If too much air is

	trapped in the chamber, an air bubble may be carried through the cassette to the pumping
	chamber. The compressibility of the air bubble prevents the outlet valve from being forced
	open, resulting in no delivery of solution. This outlet valve feature prevents air from being
	pumped to the patient.
	The cassette must be correctly primed. Incorrect cassette priming leaves air in the
	compression chamber or fails to clear sufficient air from the air trap, permitting the air to
N^ggi/	be carried into the compression chamber. In either case, if the flow detector is attached,
	pump operation stops and a flow/KVO alarm or low flow/KVO alarm sounds, depending
	on the model and version of the pump.

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Section 4 THEORY OF OPERATION

4.1.2
FLOW DETECTOR	^J
The flow detector performs dual functions: it indicates there is fluid flow in the line, and
provides a comparative value to the control logic so the pump can determine if the flow
rate is correct The flow detector is photoelectric. It is essential that the flow detector be
clean, dry, and correctly mounted on the IV set drip chamber assembly. Flow alarms are
often traced to dirty or improperly placed flow detectors.
Use of the flow detector is mandatory in some applications and optional in others {see
Table 1-3, Series Specific Features - Model 4 Series).
4.1.3
ALARMS
The operational failures described throughout Section 4 cause an alarm to sound. Alarm
messages are displayed on the VOLUME DELIVERED display on the front panel of the
pump.
4.1.3.1
AUDIBLE ALARM
Refer to Figure 9-14, Power Supply PWA Schematic, Micro 4/Model 4. The audible alarm	^J
isgenerated bythe piezoelectric alarm transducer, located on the side ofthe clamp casting.

The piezoelectric alarm transducer produces a 2.7 kilohertz (kHz) frequency after transistor

Q6 is activated. Q6 is turned on by the signals TONE or reset (RST) to produce the piezoelectric alarm transducer signals AUDIO, AUDIO 2, and AUDIO 1. Q6 is turned off by interrupt request (IRQ) whenever the main control switch is in the LOAD/OFF

RECHARGE position. The piezoelectric alarm transducer volume is controlled by the AUD.

ALM. alarm level switch on the back of the pump.

4.1.3.2

NURSE-CALL ALARM

Refer to Figure 9-14, Power Supply PWA Schematic, Micro4/Model 4. The nurse-call alarm is activated whenever the Kl nurse-call relay is de-energized while the master control switch is in the LOCK/ON position. Kl is controlled by signals nurse call (NCALL), RST, and initiate (INTT*). The purpose of IN1T* is to drive Kl when the power is turned on. An actively high RST at pin 5 of U7B or an actively high NCALL at pin 6 of U7B while INTT* is low de-energizes the Kl nurse-call relay, causing an alarm.

4.1.4

NUMERIC AND BAR DISPLAYS

Refer to Figure 9-11, Display PWA Schematic, MDL4, or Figure 9-12, Display PWA Schematic,

Micro 4. There are four numeric displays used in the pump: DOSE LIMIT, DOSE

DELIVERED, VOLUME DELIVERED, and DELIVERY RATE. Each display is a seven-segment, plus decimal, LED display. The LifeCare Micro LED display contains an

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LifeCare and HomeCare Model 4 Series

4.2 EXTERNAL INTERFACE PORTS

extra digit for displaying decimal points. Each LED display shares a common data bus to receive input/output data 0 (IODO) through IOD7.

The bar display provides colored backlighting. The legends BATT (DS4) and LOW (DS5) are backlighted by two LED bars, yellow and red, respectively, and contain two LEDs each. The legends REMOTE, OPERATING (Model 4 and 4H only), and PIGGYBACK (Model 4P only) are each backlighted by a yellow bar containing four LEDs. The legend NO FLOW

DET. contains four LEDs and is backlighted by a red bar.

4.2

EXTERNAL INTERFACE PORTS

External interface ports on the Model 4 Series infusion pump are located on the back of the pump and are shown in Figure 9-2, System Interconnect Schematic, Model 4P; Figure 9-3, System Interconnect Schematic, Micro 4/MDL 4; and Figure 9-4, Interconnect Schematic,

Micro 4/MDL 4 (International). External interface ports include the following: accessory

(ACC.) connector J23, nurse-call connector J21, and flow detector connector J22.

Additionally, certain pump versions are equipped with an RS-485 Dataway input/output

(I/O) connector JlOl, an RS-232 I/O port, or a 20-mA I/O port (refer to Table 1-2, Model 4 Series Case Types and I/O Capabilities). A description of Model 4 infusion pump external interface ports follows.

4.2.1

ACC CONNECTOR J23

ACC. connector J23 is a 12-pin, male connector that provides access to 7 pins on the power supply PWA connector J16. The ACC. connector allows external monitoring and control ofthe pump. Table 4-1, ACC. ConnectorJ23 PinArrangement, provides pin numbers, signal names, and descriptions.

The RATE 1* and RATE 2* signals are bidirectional and provide an external means for stopping and starting the pump. As outputs, RATE 1* and RATE 2* are low-going pulses that correspond with each incremental delivery step (32 per cycle) during the pumping stage. As inputs, when RATE 1* and RATE 2* are held below 0.5 volt direct current (VDC) pumping is inhibited. When only one of these rate signals is held below 0.5 VDC, the pump enters the failure mode.

The CYCLE* signal is transmitted at the completion of each pumping cycle.

The ALARM* signal goes low when the pump enters the alarm state or the failure mode.

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430-01858-003 (Rev. 5/95)

Section 4 THEORY OF OPERATION

Table 4-1. ACC. Connector J23 Pin Arrangement

Diagram	Pin	Signal Name	Description
	1	+5V	Digital +5 VDC supply
	2	AUDIO 2	Audible alarm signal
	5	GND	Digital ground
	6	BATTERY	Battery monitor
		MONITOR
7^" ~~^S 94F18027	8	CYCLE*	Pulse transmitted at the
ACC. CONNECTOR			completion of each pumping
			cycle
	9	RATET	External bidirectional pump
			start and stop control
	10	RATE 2*	External bidirectional pump
			start and stop control
	11	DOSE	Dose complete alarm signal
		COMPLETE*
	12	ALARM*	Alarm signal

4.2.2

NURSE-CALL JACK J21

The nurse-call jack J21 is a standard, two-contact phone jack. A right angle phone plug is used to clear the drip shield on the pump. A switch closure activates the hospital nurse-call system when the pump is in an alarm state.

An alarm signal is sent from the pump when the nurse-call relay Kl on the power supply PWA is energized. Depending on the hospital nurse-call system software, a normally open (NO) or a normally closed (NC) switch configuration is required. The factory setting is NO. For NC operation, the power supply PWA must be returned to the factory for jumper reconnection. See Section 4.1.3.2, Nurse-CaR Alarm, for more information.

4.2.3

FLOW DETECTOR CONNECTOR J22

The flow detector connector J22 is a 7-pin male connector that provides access to 4 pins on the power supply PWA connector J16. See Section 4.4.1, Flow Monitoring System, for

more information.

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LifeCare and HomeCare Model 4 Series