Abbott Gemstar Service Manual

For use with the following list numbers:

13000, 13100, 13150

All codes

®

Technical Service Manual

430-600203-003, A (Rev. 05/2007)

©

Hospira, Inc.

This document and the subject matter disclosed herein are proprietary information.
Hospira retains all the exclusive rights of dissemination, reproduction, manufacture, and sale.
Any party using this document accepts it in confidence, and agrees not to duplicate it in whole
or in part nor disclose it to others without the written consent of Hospira.

430-600203-003 (Rev. 07/05) GemStar

®

Change History

Part Number Description of Change

430-600203-001
(Rev. 04/00)

430-600203-002
(Rev. 12/02)

430-600203-A02
(Rev. 08/03)

430-600203-003
(Rev. 06/05)

Original issue

Second issue

Change Page issue

Updated cover and
copyright pages

Updated change history

Updated equipment
needed for Operation Test
in Section 5

Third issue

Incorporated Hospira
name change and updated
to current style

Updated cover, copyright,
and back page

Updated Section 1
and Section 4

Updated to include
EMC/IEC requirements

Added Appendix

Remove
and Destroy
Pages

cover

i to ii

5-19 to 5-20

Insert
Change
Pages

cover

i to ii

5-19 to 5-20

Technical Service Manual i 430-600203-003 (Rev. 07/05)

CHANGE HISTORY

This page intentionally left blank.

430-600203-003 (Rev. 07/05) ii GemStar

®

Contents

Section 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 CONVENTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 ACRONYMS AND ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . 1-2

1.4 USER QUALIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5 ARTIFACTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.6 ELECTROMAGNETIC COMPATIBILITY . . . . . . . . . . . . . . . . . . . 1-5

1.7 INSTRUMENT INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . 1-5

1.7.1 UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.7.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.7.3 SELF TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.8 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.8.1 THERAPIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.8.2 CONFIGURATION DIFFERENCES . . . . . . . . . . . . . . . . . . . 1-7

1.8.3 SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.8.4 POWER SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.8.5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Section 2

WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Section 3

SYSTEM OPERATING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Section 4

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 ELECTRO-MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.1 CPU SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.1.1 CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.1.2 MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.1.1.3 FPGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.1.2 CPU SUPERVISORY FUNCTIONS . . . . . . . . . . . . . . . . . . . 4-4

4.1.2.1 SUPPLY MONITORING . . . . . . . . . . . . . . . . . . . . 4-4

4.1.2.2 POWER-ON RESET . . . . . . . . . . . . . . . . . . . . . . 4-5

4.1.2.3 MEMORY AND TIME RETENTION . . . . . . . . . . . . . . . 4-5

4.1.2.4 WATCHDOG FUNCTION . . . . . . . . . . . . . . . . . . . 4-5

4.1.2.5 CPU ERROR CHECKING/WATCHDOG CIRCUITRY . . . . . . . 4-5

4.1.2.6 WDT PIC/BEEPER PIC/BEEPER DRIVER. . . . . . . . . . . . . 4-6

4.1.3 DISPLAY MODULE/BACKLIGHT . . . . . . . . . . . . . . . . . . . 4-6

4.1.4 KEYPAD/LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.1.5 BOLUS SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.1.6 TIME-OF-DAY CLOCK . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.1.7 POWER INPUT SENSING/SELECTION CIRCUITRY . . . . . . . . . . . 4-8

4.1.8 INTERNAL POWER SUPPLIES. . . . . . . . . . . . . . . . . . . . 4-10

4.1.9 INFUSER ON/OFF CONTROL . . . . . . . . . . . . . . . . . . . . 4-10

4.1.9.1 POWER ON . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.1.9.2 POWER OFF. . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.1.10 MOTOR DRIVE CIRCUITS . . . . . . . . . . . . . . . . . . . . . 4-12

4.1.10.1 SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . 4-14

4.1.10.2 POWER CONSERVATION . . . . . . . . . . . . . . . . . . 4-15

Technical Service Manual iii 430-600203-003 (Rev. 07/05)

CONTENTS

4.1.10.3 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.1.10.4 TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.1.10.5 REDUNDANT MOTOR CONTROL. . . . . . . . . . . . . . . 4-15

4.1.11 MOTOR TACHOMETER POWER CONSERVATION . . . . . . . . . . 4-16

4.1.12 OUTPUT SHAFT ENCODER . . . . . . . . . . . . . . . . . . . . . 4-16

4.1.13 AIR-IN-LINE SENSING. . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.1.14 PROXIMAL PRESSURE MEASUREMENT . . . . . . . . . . . . . . . 4-17

4.1.15 DISTAL PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . . 4-18

4.1.16 RS-232 INTERFACE SYSTEM . . . . . . . . . . . . . . . . . . . . . 4-18

4.2 CASSETTE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.2.1 BODY AND TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.2.2 DIAPHRAGM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.2.3 FLOW STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Section 5

MAINTENANCE AND SERVICE TESTS . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 ROUTINE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.1 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.1.1 SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.1.1.2 CLEANING THE CASSETTE POCKET

AND TUBING CHANNEL . . . . . . . . . . . . . . . . . . . 5-3

5.1.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.1.2.1 MATERIALS REQUIRED . . . . . . . . . . . . . . . . . . . 5-4

5.1.2.2 LABEL INSPECTION . . . . . . . . . . . . . . . . . . . . . 5-4

5.1.2.3 LATCH MECHANISM INSPECTION . . . . . . . . . . . . . . 5-6

5.1.2.4 AIR SENSOR INSPECTION . . . . . . . . . . . . . . . . . . 5-7

5.1.2.5 PLUNGER AND PRESSURE SENSOR INSPECTION . . . . . . . 5-8

5.1.2.6 TOP CAP INSPECTION . . . . . . . . . . . . . . . . . . . . 5-9

5.1.2.7 BOTTOM CAP INSPECTION . . . . . . . . . . . . . . . . . 5-10

5.1.2.8 BEZEL, GRIP, AND KEYPAD INSPECTION . . . . . . . . . . . 5-11

5.1.2.9 BATTERY DOOR AND COMPARTMENT INSPECTION . . . . . 5-12

5.1.2.10 POWER-ON TEST. . . . . . . . . . . . . . . . . . . . . . . 5-15

5.1.2.11 RECHARGEABLE BATTERY PACK (OPTIONAL) . . . . . . . . 5-16

5.1.2.12 DOCKING STATION (OPTIONAL) . . . . . . . . . . . . . . 5-17

5.1.2.13 AC ADAPTOR (OPTIONAL) . . . . . . . . . . . . . . . . . . 5-19

5.1.2.14 REMOTE BOLUS CORD AND SWITCH (OPTIONAL) . . . . . . 5-20

5.2 OPERATION TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5.2.1 EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . . . . . . 5-21

5.2.2 TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5.2.3 PERFORMING THE OPERATION TEST . . . . . . . . . . . . . . . . 5-21

5.2.3.1 POWER TEST. . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5.2.3.2 KEYPAD TEST . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5.2.3.3 DISPLAY TEST . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5.2.3.4 LED TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5.2.3.5 VOLUME ACCURACY TEST. . . . . . . . . . . . . . . . . . 5-23

5.2.3.6 DISTAL OCCLUSION TEST . . . . . . . . . . . . . . . . . . 5-23

5.2.3.7 PROXIMAL OCCLUSION TEST . . . . . . . . . . . . . . . . 5-23

5.2.3.8 AIR-IN-LINE TEST . . . . . . . . . . . . . . . . . . . . . . 5-24

5.2.4 PRINTING THE TEST RESULTS. . . . . . . . . . . . . . . . . . . . 5-24

5.2.5 OPERATION TEST CHECKLIST. . . . . . . . . . . . . . . . . . . . 5-26

5.2.6 RESTORING THE INFUSER FOR USE . . . . . . . . . . . . . . . . . 5-27

5.3 PERIODIC MAINTENANCE INSPECTION. . . . . . . . . . . . . . . . . . 5-27

430-600203-003 (Rev. 07/05) iv GemStar

®

FIGURES

Section 6

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 TECHNICAL ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 TROUBLESHOOTING REFERENCES. . . . . . . . . . . . . . . . . . . . . 6-1

6.2.1 TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.2 ALERT/ALARM MESSAGE INDEX . . . . . . . . . . . . . . . . . . . 6-2

6.2.3 PRINTING DEVICE HISTORY . . . . . . . . . . . . . . . . . . . . . 6-4

6.3 SERVICE ALARM CODES . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3.1 SERVICE ALARM CODES - QUICK REFERENCE . . . . . . . . . . . . 6-4

6.3.2 SERVICE ALARM CODES - DETAILS . . . . . . . . . . . . . . . . . 6-8

6.4 OPERATIONAL ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Section 7

REPLACEABLE PARTS AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . . 7-1

Section 8

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Section 9

DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Technical Service Manual v 430-600203-003 (Rev. 07/05)

TABLES

Figures

Figure 1-1. Illustration of the Infuser . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Figure 4-1. GemStar Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Figure 4-2. Board Connector References. . . . . . . . . . . . . . . . . . . . . . . 4-3

Figure 4-3. Power Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Figure 4-4. Power On/Off Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Figure 4-5. Motor Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Figure 4-6. Detail of Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Figure 5-1. Cassette Pocket and Tubing Channel . . . . . . . . . . . . . . . . . . . 5-3

Figure 5-2. Label Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Figure 5-3. Cassette Retention and Ejection . . . . . . . . . . . . . . . . . . . . . 5-6

Figure 5-4. Air Sensor Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Figure 5-5. Plunger and Pressure Sensor Inspection . . . . . . . . . . . . . . . . . 5-8

Figure 5-6. Top Cap Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Figure 5-7. Bottom Cap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Figure 5-8. Bezel, Grip, and Keypad Inspection . . . . . . . . . . . . . . . . . . . 5-11

Figure 5-9. Battery Door Engagement . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Figure 5-10. Battery Door Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Figure 5-11. Battery Compartment Inspection. . . . . . . . . . . . . . . . . . . . . 5-14

Figure 5-12. Power-On Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Figure 5-13. Rechargeable Battery Pack . . . . . . . . . . . . . . . . . . . . . . . 5-16

Figure 5-14. Docking Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Figure 5-15. AC Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Figure 5-16. Remote Bolus Cord and Switch . . . . . . . . . . . . . . . . . . . . . 5-20

Figure 5-17. Sample Test Result Printout . . . . . . . . . . . . . . . . . . . . . . . 5-25

Figure 7-1. GemStar Infuser Exploded View. . . . . . . . . . . . . . . . . . . . . 7-1

Figure 9-1. GemStar Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Figure 9-2. GemStar Top Board . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Figure 9-3. GemStar Middle Board . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Figure 9-4. GemStar Bottom Board . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

Tables

Table 1-1. Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Table 1-2. Configuration List Numbers. . . . . . . . . . . . . . . . . . . . . . . 1-7

Table 1-3. Safety Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Table 5-1. Cleaning Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table 5-2. GemStar Operation Test Checklist . . . . . . . . . . . . . . . . . . . . 5-26

Table 6-1. Troubleshooting Tools . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Table 6-2. Alert/Alarm Message Index . . . . . . . . . . . . . . . . . . . . . . . 6-2

Table 6-3. Service Alarm Codes - Quick Reference. . . . . . . . . . . . . . . . . . 6-4

Table 6-4. Service Alarm Codes - Details . . . . . . . . . . . . . . . . . . . . . . 6-8

Table 6-5. Operational Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Table 9-1. Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Table A-1. Guidance and Manufacturer’s Declaration - Electromagnetic Emissions . . . A-1
Table A-2. Guidance and Manufacturer’s Declaration - Electromagnetic Immunity . . . A-2
Table A-3. Guidance and Manufacturer’s Declaration - Electromagnetic Immunity

for Life-Supporting Equipment and Systems . . . . . . . . . . . . . . . A-3

Table A-4. Recommended Separation Distances Between Portable and Mobile RF

Communications Equipment and the GemStar . . . . . . . . . . . . . . A-6

430-600203-003 (Rev. 07/05) vi GemStar

®

Section 1

INTRODUCTION

The GemStar® is a single-channel infuser designed for use in home care and hospital
settings.

The infuser kit contains the following components:

-GemStar

- Two AA disposable batteries

- System Operating Manual

®

infuser

 Note: Some international configurations contain a table-top 220 V

with a separate power cord.

1.1

SCOPE

This manual is organized into the following sections:

❏ Section 1 Introduction

❏ Section 2 Warranty

❏ Section 3 System Operating Manual

❏ Section 4 Theory of Operation

❏ Section 5 Maintenance and Service Tests

❏ Section 6 Troubleshooting

❏ Section 7 Replaceable Parts and Repairs

❏ Section 8 Specifications

❏ Section 9 Drawings

❏ Appendix

❏ Index

❏ Technical Service Bulletins

mains adaptor

AC

If a problem in device operation cannot be resolved using the information in this manual,

contact Hospira (see Section 6.1, Technical Assistance).

Specific instructions for operating the device are contained in the GemStar
Operating Manual. Provision is made for the inclusion of the system operating manual
in Section 3 of this manual.

®

System

 Note: The terms “infuser” and “device” are used interchangeably throughout

the manual.

 Note: Figures are rendered as graphic representations to approximate actual product.

Therefore, figures may not exactly reflect the product.

Technical Service Manual 1 - 1 430-600203-003 (Rev. 07/05)

SECTION 1 INTRODUCTION

1.2

CONVENTIONS

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

Table 1-1. Conventions

Convention Use Example

Italic Reference to a section, figure,

table, or publication

[ALL CAPS] Keys Press [YES/ENTER]

ALL CAPS Display messages The infuser displays

Bold Emphasis CAUTION: Use proper ESD grounding

Throughout this manual, warnings, cautions, and notes are used to emphasize important
information as follows:

WARNING:

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

A WARNING CONTAINS SPECIAL SAFETY EMPHASIS AND MUST
BE OBSERVED AT ALL TIMES. FAILURE TO OBSERVE A WARNING
MAY RESULT IN PATIENT INJURY AND BE LIFE-THREATENING.

(see Section 6.1, Technical Assistance)

to continue.

END OF INFUSION

techniques when handling
components.

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

1.3

ACRONYMS AND ABBREVIATIONS

This section contains the acronyms and abbreviations that appear in the text of this
manual.

A Ampere

AC Alternating current

A/D Analog-to-digital

ADC Analog-to-digital converter

CPU Central processing unit

CRC Cyclic redundancy check

DC Direct current

430-600203-003 (Rev. 07/05) 1 - 2 GemStar

®

1.3 ACRONYMS AND ABBREVIATIONS

DMM Digital multimeter

ECG Electrocardiogram

EEG Electroencephalogram

EEPROM Electrically erasable programmable read-only memory

EL Electroluminescent

EMC Electromagnetic compatibility

EMG Electromyogram

EMI Electromagnetic interference

ESD Electrostatic discharge

ETO Ethylene oxide

FET Field effect transistor

FPGA Field programmable gate array

hr hour

Hz Hertz

IC Integrated circuit

IO Input/output

IV Intravenous

kHz Kilohertz

LCD Liquid crystal display

LED Light emitting diode

mA Milliampere

mcg Microgram

mg Milligram

MHz Megahertz

mL Milliliter

ms Millisecond

mV Millivolt

PFI Power fail input

PIC Programmable integrated circuit

PWA Printed wiring assembly

PWM Pulse width modulator

RAM Random access memory

ROM Read-only memory

RPM Revolutions per minute

TPN Total parenteral nutrition

UART Universal asynchronous receiver/transmitter

Technical Service Manual 1 - 3 430-600203-003 (Rev. 07/05)

SECTION 1 INTRODUCTION

V Volts

Volts alternating current

V

AC

V

Collector voltage supply

CC

V

Volts direct current

DC

V

VTBI Volume to be infused

Primary power source

PWR

V

Volts root mean squared

rms

µA Microampere

µs Microsecond

1.4

USER QUALIFICATION

The infuser is intended for use at the direction or under the supervision of licensed
physicians or certified healthcare professionals who are trained in the use of the infuser
and the administration of parenteral fluids or drugs. Training should emphasize
preventing related IV complications, including appropriate precautions to prevent
accidental infusion of air.

1.5

ARTIFACTS

Non-hazardous, 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 infuser instead of some other source in the environment, set the device
so that it is temporarily not delivering fluid. Disappearance of the abnormality indicates
that it was probably caused by the electronic noise generated by the infuser. Proper setup
and maintenance of the monitoring equipment should eliminate the artifact. Refer to the
appropriate monitoring system documentation for setup and maintenance instructions.

430-600203-003 (Rev. 07/05) 1 - 4 GemStar

®

1.6 ELECTROMAGNETIC COMPATIBILITY

1.6

ELECTROMAGNETIC COMPATIBILITY

The GemStar® is compliant with IEC/EN 60601-1-2 (2001), and has been tested and found
to comply with electromagnetic compatibility (EMC) limits for the Medical Device Directive
93/42/EEC (EN 55011 Class B and EN 60601-1-2:2001). These limits are designed to
provide reasonable protection against harmful interference in a typical medical installation
(see the system operating manual).

CAUTION: Portable and mobile RF communications equipment, such as cellular
telephones, two-way radios, Bluetooth
proximity to the infuser may affect or degrade performance of the device. Operation
of the infuser under such conditions should be avoided.

There is a shared responsibility between manufacturers, customers, and users to assure
that medical equipment and systems are designed and operated as intended. Medical
electrical equipment requires special precautions regarding electromagnetic compatibility.

The electromagnetic environment should be managed to permit the infuser to perform as
intended without disturbing other equipment. The infuser should not be used adjacent to
or stacked with other equipment. If the device must be used adjacent to or stacked with
other equipment, monitor the equipment to assure there is no electromagnetic
interference, and verify normal infuser operation.

®

devices, and microwave ovens in close

1.7

INSTRUMENT INSTALLATION PROCEDURE

CAUTION: Infuser damage may occur unless proper care is exercised during
unpacking and installation.

CAUTION: Do not place the infuser in service if it fails the self test.

The instrument installation procedure consists of unpacking, inspection, and self test.

1.7.1

UNPACKING

Inspect the shipping container as detailed in Section 1.7.2. Use care when unpacking the
infuser. Retain the packing slip and save all packing material in the event it is necessary
to return the infuser to the factory. Verify the shipping container contains a copy of the
system operating manual.

Technical Service Manual 1 - 5 430-600203-003 (Rev. 07/05)

SECTION 1 INTRODUCTION

1.7.2

INSPECTION

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

CAUTION: Inspect the infuser for evidence of damage. Do not use the device if it
appears to be damaged. Should damage be found, contact Hospira (see Section 6.1,
Technical Assistance).

Inspect the infuser periodically for signs of defects. Also inspect the infuser after repair
or during cleaning. Replace any damaged or defective external parts.

1.7.3

SELF TEST

CAUTION: Do not place the infuser in service if the self test fails.

At power-on, the infuser immediately enters an initialization mode and performs the
following self tests:

-RAM test

- ROM checksum calculation

- Motor control test

- Stuck key test

- PIC watchdog test

- CONFIG register test

- Battery voltage test

- Power loss completion test

- CRC verifications on all RAM areas protected by CRCs

- CRC on calibration data stored in the EEPROM

- Calibration data verification

The initialization mode completes in approximately 30 seconds. During this time the
infuser displays a message that the self tests are being performed. If any test fails,
the infuser alarms.

 Note: The device does not infuse during the initialization mode.

After successful completion of the initialization mode, if there is not a current program
in the infuser, the device enters programming mode so the user can enter a new program.

If a program is already in the infuser, the user may:

- Use the current program. The infuser enters stop mode after the program is reviewed.

- Enter a new program. The infuser enters programming mode, then enters stop mode
after the program is reviewed.

 Note: If the infuser has been powered-off for less than five minutes, a program

review is not required.

See Figure 1-1 for an illustration of the infuser.

430-600203-003 (Rev. 07/05) 1 - 6 GemStar

®

1.8 OVERVIEW

1.8

OVERVIEW

The following sections describe therapy options, differences between therapies, safety
features, power sources, and basic operation of the infuser.

1.8.1

THERAPIES

The GemStar® offers the following seven types of therapy:

- Pain Management

- Total Parenteral Nutrition (TPN)

- Intermittent

-Weight Dosed

-Continuous

- mL/hr Only

-Variable Time

 Note: The availability of these programs may vary, depending upon the configuration

of the infuser in use.

1.8.2

CONFIGURATION DIFFERENCES

The infuser is shipped from the factory with one of the configurations described
in Table 1-2. The infuser configuration is easily identified by the end cap color.

Table 1-2. Configuration List Numbers

Therapies 13000 (Blue) 13100 (Gray) 13150 (Yellow)

Pain Management

TPN

Intermittent

Weight Dosed

Continuous











mL/hr Only

Variable Time

Technical Service Manual 1 - 7 430-600203-003 (Rev. 07/05)





SECTION 1 INTRODUCTION

1.8.3

SAFETY FEATURES

Table 1-3 describes the special safety features of the GemStar®.

Table 1-3. Safety Features

Safety Feature Description

Proximal occlusion detection Strain gauge

Distal occlusion detection Strain gauge

Settings: low, medium, and high sensitivity

Air-in-line detection Ultrasonic settings: 0.5 mL, 2 mL, and Off

Motor monitoring circuit Redundant and independent monitoring

systems

Motor parameter monitoring Motor encoder and camshaft flag monitored

by optical sensor

Self tests Initialization and self test at power-on

Continuous self tests during operation

1.8.4

POWER SOURCES

The infuser can be powered by two internal AA disposable batteries, an external
rechargeable battery pack, AC mains adaptor, or docking station. External supply voltage
must not exceed 3.3 V

Install two fresh, disposable AA batteries for backup power when using an external power
source. The infuser will continue to operate on backup power if the external power
source fails.

CAUTION: To assure proper operation when using internal batteries, always
replace both batteries with fresh, disposable AA batteries when a change is required.
Use of rechargeable batteries in the battery compartment is not recommended.

CAUTION: Always connect to a grounded AC outlet when using the AC adaptor.
Use only an AC adaptor specifically labeled for use with the GemStar
battery pack. During charging, if the battery pack becomes hot to the touch,
immediately disconnect from AC power and contact Hospira Technical Support
Operations.

CAUTION: Do not touch exposed connectors on the bottom of the infuser. Exposed
connectors are susceptible to electrostatic discharge (ESD) damage.

DC

.

®

to charge the

430-600203-003 (Rev. 07/05) 1 - 8 GemStar

®

1.8 OVERVIEW

1.8.5

OPERATION

The infuser is microprocessor-based and is programmed using a 23-key keypad on
the front of the device (see Figure 1-1). The 16-character-by-4-line backlight display
indicates the status of the infuser.

The infuser has up to seven therapies available, depending on its configuration. Delivery
rates and bolus dosage amounts are programmed in one of three units of measure:
milliliters (mL), milligrams (mg), or micrograms (mcg). A loading dose is programmable for
immediate delivery or delayed delivery. Bolus doses can be programmed to begin delivery
on-demand.

To program the infuser, the operator selects the following:

- Therapy type

- Delivery type: volume delivery (mL) or mass delivery (mg or mcg)

- Concentration (only if mass delivery is selected)

- Delivery rate

- Loading dose, if desired

- Bolus dose, if desired

- Total amount to be delivered: volume to be infused (VTBI)

If mass delivery is selected, the infuser automatically converts mg or mcg to the closest
number of tenths-of-mL. The amount of fluid delivered is shown on the display.
When a bolus is programmed, a minimum lockout time between boluses must also
be programmed. In addition to the lockout time, the operator can also program the
maximum total volume that can be delivered in a selected period.

The infuser contains a time-of-day clock and event history storage capability. The program
settings, significant events that take place while a protocol is running, and the associated
time and date, can be reviewed on the display. The event history can be printed to a
compatible printer or downloaded as an ASCII text file to a computer with the use of the
GemStar

For specific instructions regarding infuser operation and optional system components,
refer to the system operating manual.

®

serial printer cable.

Technical Service Manual 1 - 9 430-600203-003 (Rev. 07/05)

SECTION 1 INTRODUCTION

BOLUS (BUTTON)

TOP CAP

GRIP

KEYPAD

SILENCE

1

4
7

PURGE

TOP VIEW

START

STOP

2
5

3

6
89
0

NOHELP

POWER

ON/OFF

BACK-UP

CHANGE

OPTIONS

YES

ENTER

CASSETTE EJECT

BUTTON

TOP CAP

BEZEL DISPLAY WINDOW

BEZEL ASSEMBLY

BOTTOM CAP

FRONT VIEW

BATTERY DOOR RECESS

BATTERY DOOR VOID LABEL

BATTERY DOOR

BATTERY PACK CONNECTOR

3 VDC BOLUS

BOTTOM VIEW

AC POWER CONNECTOR

DATAPORT CONNECTOR

BOLUS CONNECTOR

CONNECTOR LABEL

BOTTOM CAP

04K02001

Figure 1-1. Illustration of the Infuser

430-600203-003 (Rev. 07/05) 1 - 10 GemStar

®

Section 2

WARRANTY

Subject to the terms and conditions herein, Hospira, Inc., herein referred to as Hospira,
warrants that the product shall conform to Hospira's standard specifications and be free
from defects in material and workmanship under normal use and service for a period of
one year after purchase. Hospira 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 Hospira's option, the repair or replacement
of the product. In no event shall Hospira'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 Hospira be liable for
incidental, consequential, or special damages or losses or for lost business, revenues,
or profits. Warranty product returned to Hospira 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 Hospira'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 Hospira and using Hospira
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
of accessory items such as batteries, flow detectors, detachable AC power cords, and
patient pendants.

In providing any parts for repair or service of the product, Hospira 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 a Hospira
representative performing repair or service is not an authorized agent of Hospira.

Technical Service Manual 2 - 1 430-600203-003 (Rev. 07/05)

SECTION 2 WARRANTY

This page intentionally left blank.

430-600203-003 (Rev. 07/05) 2 - 2 GemStar

®

Section 3

SYSTEM OPERATING MANUAL

A copy of the system operating manual is included with every GemStar® infuser.
Insert a copy here for convenient reference. If a copy of the system operating manual is not
available, contact Hospira (see Section 6.1, Technical Assistance).

Technical Service Manual 3 - 1 430-600203-003 (Rev. 07/05)

SECTION 3 SYSTEM OPERATING MANUAL

This page intentionally left blank.

430-600203-003 (Rev. 07/05) 3 - 2 GemStar

®

Section 4

THEORY OF OPERATION

This section describes the theory of operation for the GemStar®. The theory of operation
details the electro-mechanical and cassette systems. Related drawings are provided
in Section 9.

4.1

ELECTRO-MECHANICAL SYSTEMS

The following sections describe the functions and electronic circuitry of the infuser.

4.1.1

CPU SYSTEM

The central processing unit (CPU) system consists of the following components:

❏ CPU: controls infuser operation

❏ Memory

- RAM: stores temporary therapy program data; stores ROM program during
software updates

- ROM: stores the operating program

❏ Field programmable gate array (FPGA): provides auxiliary logic functions to operate

the infuser

®

See Figure 4-1, GemStar

4.1.1.1

Block Diagram, and Figure 4-2, Board Connector References.

CPU

The CPU (U2) is a Motorola MC68L11K1 8-bit processor powered by 3.3 VDC. It operates
at 2 MHz using a self-contained buffer and crystal Y1. The clock is divided by four to
provide a 500 kHz bus clock (E-clock). Capacitors C9 and C11 provide the proper loading
of the crystal.

The CPU provides the following:

- Separate data, address, and extended
address lines

- On-chip 8-channel, 8-bit
analog-to-digital converter

- On-chip EEPROM for non-volatile
configuration status

- Serial UART port

- Serial peripheral port

- 4-channel, 8-bit pulse-width
modulated output

- Non-maskable and maskable
interrupt inputs

Technical Service Manual 4 - 1 430-600203-003 (Rev. 07/05)

- General purpose input and output
lines (I/O)

SECTION 4 THEORY OF OPERATION

Audio

Driver

Backup Power

U7

ROM

512K x 8

(29BV040)

FLASH MEM

D

XA

CS

A

R/W

U8

32K x 8

D

CS

SRAM

A

LED

LED

(Red)

Alarm

Power

(Yellow)

Bolus Jack

Interface

U9

FPGA

A

D

CS / IRQCS/IRQ

R/WR/W

Keypad

LED Drive

/Shaft IRQ

Encoder Signal

Digital Port I/O

CS

E-CLK

Bolus Switch

/TOD IRQ

/RST/RST

U10

DRIVER

BACKLIGHT

CS

IRQ

/TOD

CLOCK

D

CS

A

EL Backlight

CS

DISPLAY

D

E-CLK

A0

/RST

R/W

Backup Power

U3

XA

TIME-OF-DAY

Y2

Address Bus

Data Bus

XA(13..18)
Bus
Ext Addr

Digital Ports

Y201

U105

U201

+5V

+5V

DC-DC

PIC

BEEPER

Power Select

12C508

WD Fault

U202

WDT PIC

+3.3V

U108

Switch

12C508

WDTri

-5V

-5V

DC-DC

To motor drive

Y1

/RST

SUPERVISOR

+3.3V

VPWR

Backup Power

WDTri

g

Backup Battery

RAMCS

/XIRQ

RAMCS1

U1

MICRO-P

g

+5V

VPWR

+3.3V

PWM3

/XIRQ

RAMCS1

Ext-Addr

CS Flash

g

WDTri

U2

68L11K1

SDI

Microcontroller

E-CLK

A/D Input

A/D Input Ports

Digital Ports

U109

+3.3V

DC-DC

BT201

Battery

Lithium

Air

Ultrasonic

Piezo

Air Transmit

Circuit

U101, U102,

U103, U104

AA

Internal

Batteries

Power Sensing

Proximal

Pressure

Pressure

Proximal

Circuit

Sensor

Distal

Circuit

Pressure

MOTOR DRIVE

Motor

Addr

Digital I/O

and

CIRCUIT

Data

PW1

D/C-D/C

CONVERTER

WD Fault

Motor

/Shaft IRQ

SCI

Encoder

Motor Encoder Signals

Output Shaft Encoder Signals

RS232

INTERFACE

LT1331

Connector

Distal

Ext

Power

Signal

Ext_Pwr

Sensor

Pressure

Piezo

Air Receive

Drive

Mechanics

Output

Shaft

Encoder

Serial Data

Figure 4-1. GemStar® Block Diagram

430-600203-003 (Rev. 07/05) 4 - 2 GemStar

04K02010

®

000

TOP BOARD

CPU, MEMORY, RTC, SERIAL PORT

4.1 ELECTRO-MECHANICAL SYSTEMS

J1

DISPLAY

CHASSIS GROUND

CONTACT

BATTERY SPRING

BATTERY CONTACT

MOTOR

J101

J104

J108

J106

J2

J102

J105

J3

J103

100

MIDDLE BOARD

MOTOR CONTROL,

POWER CONVERSION

J4

J110

J109

J107

PUMP BOTTOM

EXTERNAL CONNECTOR

KEYPAD

AIR

RECEIVER

AIR

TRANSMITTER

J203

J204

J205

200

BOTTOM BOARD

J207

J206

AUDIBLE BEEPER

PRESSURE SENSOR, AIR SENSOR

PROXIMAL

PRESSURE

DISTAL

PRESSURE

J201

J202

04K02002

Figure 4-2. Board Connector References

Technical Service Manual 4 - 3 430-600203-003 (Rev. 07/05)

SECTION 4 THEORY OF OPERATION

4.1.1.2

MEMORY

The operating program is stored in a 512K x 8 flash ROM (U7) that can be reprogrammed
with software updates.

 Note: The program cannot be modified without special tools and protocols.

A 32K x 8 low-power static RAM (U8) is used to store the following data:

- Specific patient delivery protocols

-User options

- History records

- Operating program during Flash ROM programming

When the infuser is powered off, an on-board lithium battery provides power
to the RAM chip.

4.1.1.3

FPGA

The FPGA (U9) is a specially programmed IC that incorporates auxiliary logic for the
infuser. The FPGA provides the following:

-Input/output mapping

- Keypad interface

- Buffering and control of interrupt signals

- Additional logic interfaces for the infuser

- Motor encoder logic

The FPGA interfaces to the CPU through the address and data bus.

4.1.2

CPU SUPERVISORY FUNCTIONS

A MAX793R supervisory IC (U1) provides a secondary check for proper CPU functioning
and monitors the following:

- Primary power source (V

- 3.3 volt power supply (V

- Battery backup switch over

- Power-on and brownout reset

4.1.2.1

SUPPLY MONITORING

PWR

CC

)

)

Whenever the 3.3 V power supply (VCC) drops below a safe system operating voltage
of 2.6 V
watchdog circuitry to sound an alarm. U1 also monitors the primary power (V
provides early detection of loss of primary power to the infuser. If V
power fail input (PFI) voltage of approximately 1.3 V
be expected. When this happens, U1 interrupts program execution with a non-maskable
interrupt via signal /PFO. This interrupt signals the microprocessor to execute
a power-down routine that gracefully stops the motor, saves current data, and powers off
the infuser.

430-600203-003 (Rev. 07/05) 4 - 4 GemStar

, U1 generates a system reset (/RST) that stops the computer and forces the

DC

drops below the

, imminent loss of 3.3 VCC power can

DC

PWR

PWR

) and

®

4.1 ELECTRO-MECHANICAL SYSTEMS

4.1.2.2

POWER-ON RESET

During power-on or other reset conditions, the supervisory circuit holds the system in
reset for 140 ms after V
starting normal operation. During reset conditions, the reset signal interfaces with all
circuitry to assure conditions are held in a safe operational state (e.g., motor stopped).

4.1.2.3

reaches 2.6 VDC to assure the system has stable power prior to

CC

MEMORY AND TIME RETENTION

Whenever all power sources are disconnected from the infuser, an internal 3.0 V lithium
battery (BT201) provides power to retain memory and real-time clock operation.
The lithium battery provides approximately three years of backup power from the time
of infuser assembly. U1 monitors power, and whenever the supervisory circuit detects that
the logic power is low (approximately 2.6 V
appropriate circuits. A series 100 Ω resistor (R227) is used to measure the lithium current
during off conditions. Voltage across R227 is normally less than 0.6 V

4.1.2.4

), it switches the lithium battery power to the

DC

(6 µA).

DC

WATCHDOG FUNCTION

U1 has a built-in secondary watchdog detection circuit (WDT) that provides a secondary
check for proper CPU operation. The primary watchdog circuit is implemented using two
programmable integrated circuit (PIC) microcontrollers on the bottom board

(see Section 4.1.2.6, WDT PIC/Beeper PIC/Beeper Driver).

During normal operation, the CPU provides a one-second timing signal (WDTRIG) to the
supervisory circuit indicating proper operation. If the WDTRIG signal is greater than
approximately 1.6 seconds, the supervisory circuit will generate a system reset and stop
all infuser operations.

Each of the following signals are driven low during system reset:

- Motor on (MOTORON)

- Motor drive enable (MOTDRVEN)

- Motor speed control (MOTSPCTL)

4.1.2.5

CPU ERROR CHECKING/WATCHDOG CIRCUITRY

The CPU is the primary error detection and checking component. When error conditions
exist, the CPU generates an alarm, warning, or other action appropriate to the conditions.
For example, it stops delivery when out-of-tolerance conditions are sensed.

The watchdog (U202) PIC has been designed to monitor the CPU for error-free operation.
The CPU toggles the logic state of the watchdog trigger (WDTRIG). If the CPU becomes
unstable, this signal will either not be generated or will have incorrect timing. The PIC
processors monitor the WDTRIG signal for the correct timing. Whenever this signal is out
of tolerance (1 sec ± 25%), U202 stops the motor (using the WDFLT signal) and sounds
an alarm independent of the CPU.

Technical Service Manual 4 - 5 430-600203-003 (Rev. 07/05)

SECTION 4 THEORY OF OPERATION

4.1.2.6

WDT PIC/BEEPER PIC/BEEPER DRIVER

The watchdog WDT PIC (U202) is clocked from an external 32 kHz oscillator and crystal
Y201 independent of the CPU clock. It monitors the WDTRIG signal for correct timing
(change of state once a second). If either clock is in error or if the WDTRIG from the CPU
is incorrect, the watchdog fault signal (WDFLT) goes low. This causes the beeper PIC (U201)
to generate an audible alarm and the motor servo switching current source (U102) to stop
the motor. When the infuser is turned off during normal power-down, the power-on
(POWERON) signal from the CPU inhibits a WDTRIG fault while the power supply supercap
discharges.

The beeper PIC (U201) can sound the beeper from the following two independent sources:

- Watchdog fault (WDFLT) signal from the WDT PIC (U202)

- Beeper control signal (BEEPCTL) from the CPU (U2)

When there is a watchdog fault, the WDFLT signal is activated and has the highest priority.
When this happens, the motor turns off and the infuser stops. This causes the beeper PIC
to produce an audible tone every five seconds.

The beeper PIC uses an internal 4 MHz oscillator and generates a predefined frequency
and duty cycle for WDFLT faults. The CPU sends the BEEPCTL signal to generate audio
output, such as audible operator alarms or keypad feedback. The beeper PIC passes the
BEEPCTL signal frequency and duty cycle to the beeper. This allows different tones,
duration, and volumes.

If the 3.3 V
CPUs are reset. R201, R202, R203, D204, and Q203 (brownout detector) provide
a reset-generator, which nominally trips at 2.1 V

When power losses occur, such as an accidental disconnection of the AC adapter with no
battery backup, two .047 F capacitors (supercaps) maintain the 3.3 V supply for
approximately 10 seconds. This allows the CPU to execute an orderly shutdown, and
provides enough power to the watchdog circuit to sound an audible alarm every five
seconds after power loss (at least three audible beeps).

supply drops below the minimum PIC operating level of 2.5 VDC, the PIC

CC

.

DC

4.1.3

DISPLAY MODULE/BACKLIGHT

The display module is a 64-by-128 dot matrix LCD array with control and memory
circuitry. The CPU and FPGA generate the display control signals. Since the display
consumes only 1 mA, it is powered from a logic gate (U4A) that goes low when powered
off. This allows the display to clear within seconds after power-off.

 Note: Display contrast can be factory adjusted.

An electroluminescent (EL) backlight illuminates the display. The CPU turns on the
backlight drive circuit (U10) when a key is pressed or when AC mains power is applied.

430-600203-003 (Rev. 07/05) 4 - 6 GemStar

®

4.1 ELECTRO-MECHANICAL SYSTEMS

4.1.4

KEYPAD/LEDS

A 23-key keypad receives operator input. One of these keys is used for power on/off

(see Section 4.1.9, Infuser On/Off Control). Each of the other keys is at a distinct junction

of an array of four columns and six rows, strobed by the FPGA approximately every 30
milliseconds. Pressing a key connects a row to a column. As the FPGA energizes each row,
the columns are monitored and the FPGA determines which key has been pressed.
A software routine eliminates noise (debounce) when the keys are pressed.

Two signal LEDs are mounted on the keypad and driven under software control, via FPGA
outputs. The yellow LED illuminates when AC mains power is connected to the infuser.
The red LED illuminates during an alarm condition, and is accompanied by an audible
alarm and a display message, when applicable.

4.1.5

BOLUS SWITCHES

Patients can request a bolus dose for pain management and variable time protocols.
The bolus switch (SW101) is located on the top of the infuser and is protected by a rubber
end cap. The bolus switch signal (logic low) is buffered, inverted (U4C), and passed to the
FPGA (U9-11) as the bolus request (BOLUSREQ) signal. The bolus request is latched by
the FPGA and passed to the CPU as an interrupt.

An external (remote) bolus pendant can be connected to the bolus connector on the bottom
of the infuser. The remote bolus pendant is wired in parallel with SW101. There is no
distinction between the infuser bolus switch and the remote bolus switch. The buffering
provided for the bolus request signal (U4C) allows for electrostatic discharge (ESD)
rejection.

4.1.6

TIME-OF-DAY CLOCK

The infuser has a separate time-of-day clock (U3). The time is displayed at power-on
and can be reset by the operator. This clock is used to provide the following:

- Schedule deliveries

- Record infuser history and event timing

- Generate a precise one-second CPU interrupt for timing functions

The internal lithium battery (BT201) powers the clock when no other power source
is present.

Technical Service Manual 4 - 7 430-600203-003 (Rev. 07/05)

SECTION 4 THEORY OF OPERATION

4.1.7

POWER INPUT SENSING/SELECTION CIRCUITRY

The infuser can be powered by two internal disposable AA batteries, or an external power
source connected to the 3.3 V connector on the bottom of the infuser (see Figure 4-3,

Power Input). Power is applied to the internal voltage-power (V

or disconnected when the infuser is powered on or off (see Section 4.1.9).

) line, which is connected

PWR

Battery power connects to V

through a fuse (F101) and a field effect transistor (FET)

PWR

switch (Q110 A and B) controlled by comparator U110. The FET switch has an intrinsic
forward diode, which allows sufficient battery current for the infuser to power-on when
only batteries are present.

External power (EXTPWR) connects to V

through an isolation diode D106. Comparator

PWR

U110 senses the external voltage and automatically switches to external power when the
external voltage (EXTPWR) is greater than approximately 1.8 V. When this happens,
transistors Q106 and Q104 turn off the FET switch (Q110 A and B) to disconnect the
internal batteries. The MAX965 (U110) has its own internal reference voltage at U110-6
of 1.235 V, which it uses to measure the switching point.

The external supply source may be from a DC supply connected to AC mains power or from
an external battery. If the source is derived from AC mains power, a separate signal line
is pulled high (to 3 volts). On external battery power, the signal line is low. The CPU
monitors this signal line through the multiplexer (U106-4) and the A/D converter.
The CPU uses this information when monitoring the external voltage to display
appropriate messages (e.g., ON BATTERIES; LOW BATTERIES) or to turn on the power
LED. The CPU monitors power source voltages. The internal (battery) and external voltages
are connected to the CPU A/D input port through the multiplexer, MUX U106 (U106-13
and U106-15).

430-600203-003 (Rev. 07/05) 4 - 8 GemStar

®

EXT PWR IN

ALK

F101

4.1 ELECTRO-MECHANICAL SYSTEMS

D106

VPWR

Q110A Q110B

Vcc

EXT PWR IN

ALK

3.3V

100K

R152

Vcc

47.5K
Q106

R115
100K

U110

VREF (1.2V)

INPUT SOURCE POWER SWITCHING

R156

499K

R155

4.99K

R157

4.99K

SOURCES FOR SUPPLYING Vcc TO U110

Figure 4-3. Power Input

Q104

499K

47.5K

-5V

D108B

VPWR

D107B

D108A

02K02009

Technical Service Manual 4 - 9 430-600203-003 (Rev. 07/05)

SECTION 4 THEORY OF OPERATION

4.1.8

INTERNAL POWER SUPPLIES

The input power at V

is converted to three operating voltages: +3.3 V, +5 V, and –5 V.

PWR

The 3.3 V supply is U109, a ML4875-3 outputting 3.3 V on pin 5. This switch-mode
regulator has internal FETs that ground inductor L103 and direct flyback current to the
output capacitor (C140). The value of coil L103 is chosen to optimize input power to achieve

3.3 V

output power during high loads, such as high motor torque, sensors on,

CC

or backlight activated.

The +5 V supply is U105, a ML4875-5. This circuit is similar to the 3.3 V regulator, except
for the output voltage. Both regulators have a tolerance of ± 3%.

The –5 V supply is U108, a MAX828 switched capacitor, +5 V to –5 V supply for high
efficiency at low currents. The –5 V is required at various points to allow FETs to turn on
with minimum resistance, which results in high efficiency and maximum battery life.
A separate –5 V supply is used in the motor drive servo amplifier circuitry. U101, a second
MAX828, provides –5 V to U103 A and B, and Q101.

The display backlight is an electroluminescent (EL) lamp that requires a symmetric,

®

low-frequency alternating voltage. This voltage is generated by U10, a Durel

D353 lamp

driver IC. This IC uses inductor L1 in switch mode inverter circuit to drive the EL lamp.

4.1.9

INFUSER ON/OFF CONTROL

Electronic hardware and software, in conjunction with a dedicated ON/OFF button on the
keypad, power the infuser on and off (see Figure 4-4, Power On/Off Circuitry). Flip-flop
U107A, and the 3.3 V and 5 V supplies (U109 and U105), form the core of the electronic
hardware. Pressing the keypad ON/OFF button grounds the on/off signal going to the
on-off control circuit. The following two other control lines are also used:

- Shutdown signal (SHUTDOWN): a signal from the ON/OFF hardware to the CPU

- Power switch off signal (PWRSWOFF): a signal from the CPU to the ON/OFF circuit

These signals allow power to be turned on and off while preserving all data and assuring
voltages are changed without damaging circuitry.

430-600203-003 (Rev. 07/05) 4 - 10 GemStar

®

VPWR

4.1 ELECTRO-MECHANICAL SYSTEMS

ON

OFF

R123

47.5K

R122

47.5K

R136

47.5K

FROM

CPU

TO

CPU

U109

2

SHDN

4

DET RESET

PWRSWOFF

SHUTDOWN

U105

2

SHDN

4

DET

RESET

5V OUT

3.3V OUT

Q109

Vcc

5

D

3

CLK

1

Q

2

Q

POWER OFF

POWER ON

U107A

R137

47.5K

02G02011

Figure 4-4. Power On/Off Circuitry

Technical Service Manual 4 - 11 430-600203-003 (Rev. 07/05)

SECTION 4 THEORY OF OPERATION

4.1.9.1

POWER ON

When power is first applied to the infuser, there is a voltage at V
and 5 V supplies are held in a shutdown mode. The voltage at V

. However, the 3.3 V

PWR

is applied through

PWR

resistor R136 to the shutdown inputs (U105-2 and U109-2). Meanwhile, the voltage at
pin 4 of U105 and U109 (ON/OFF) is held at one-half V

by resistor-divider R122 and

PWR

R123. When the ON/OFF key is pressed, the on/off signal line is pulled low, which causes
a comparator in U105-7 to go low and removes the shutdown signal on U105-4 and
U109-4. These switching regulators rapidly change their outputs (VOUT on pin 5) to 5 V
and 3.3 V respectively. This supplies power to flip-flop U107A where the clock is held low
by the reset output of U109-7. When the ON/OFF switch is released, the ON/OFF line
returns to one-half V

and the reset lines on U105-7 and U109-7 return high. This clock

PWR

flip-flops U107A. The Q-Bar output (U107-2) toggles high, switching the signal line
power-on (POWERON) high. It also turns on transistor Q109, which removes the shutdown
signal from power supplies U105-2 and U109-2. Simultaneously, the Q output (U107-1)
toggles low, switching POWEROFF low. As a result, power is established and maintained.

4.1.9.2

POWER OFF

Power is removed from the infuser under CPU control. When the ON/OFF switch is
pressed, it pulls pin 4 of the 3.3 V supply (U109-4) to ground. This causes the reset pin
(U109-7) to pull low and puts a low on the signal line SHUTDOWN\ to the CPU. When this
signal is received, the CPU begins its power-down sequence. First, it assures that
power-down is a viable choice. For example, if the infuser is in the delivery (RUN) mode,
the device will not power-off and a warning message will display. If power-down is a viable
choice, the CPU gracefully shuts down by saving data, history, and other required
housekeeping. When this is complete, the CPU changes the PWRSWOFF signal high. The
ON/O F F swi t ch mu s t be p r esse d and h e ld du r ing t h is pr o cess , whic h may t a ke up t o thr e e
seconds. After the PWRSWOFF signal is switched high, releasing the power switch will
change the signal ON/OFF and U109-4 back to one-half V
U109-7 and at the clock input of U107-A-3. The high on PWRSWOFF at the flip-flop data
input U107A-5 will be clocked to the Q output, and the Q output will go high. At the same
time, Q-bar (U107-2) will go low and Q109 will shut down both U109 and U105. This
removes power from the circuits.

. This will raise the signal at

PWR

4.1.10

MOTOR DRIVE CIRCUITS

A high efficiency moving coil permanent magnet DC motor operates a plunger to deliver
fluid. The motor includes a 27:1 speed reduction transmission and an integral,
dual-channel, quadrature-encoded tachometer. The speed of the motor is set by the CPU.
A hardware servo control circuit maintains the selected speed while compensating
for variations in load torque, motor losses, and power source voltage. The CPU monitors
the servo circuit by reading the motor voltage, motor current, and motor turns
(encoder counts). The CPU also monitors the activation of the cassette (via output shaft
encoder) to verify that motor turns are correctly converted into fluid delivery actions.
See Figure 4-5, Motor Control Circuit, and Figure 4-6, Detail of Motor Circuit.

430-600203-003 (Rev. 07/05) 4 - 12 GemStar

®

MOTCNTRL

R106
100K

1.24V

REFERENCE

Figure 4-5. Motor Control Circuit

R105
301K

+

AMPLIFIER

-

4.1 ELECTRO-MECHANICAL SYSTEMS

U102, Q101, Q102

Q103, Q108, D101

MOT+

02K02013

MOT DREN

MOT+

MOTOR

R125

1

W

MOT SPCTL

R105

R121

57.6K

R120

1M

+

-

+5

-5

R112
150K

R111

U103A

-5V

+

-

R114

R110

200K

U103B

R106

TO U102-3

02K02005

Figure 4-6. Detail of Motor Circuit

Technical Service Manual 4 - 13 430-600203-003 (Rev. 07/05)

SECTION 4 THEORY OF OPERATION

4.1.10.1

SPEED CONTROL

The CPU sets a desired speed. A summing amplifier (U103B) combines this speed setting,
the motor speed (voltage across the motor), and the motor load (current through the motor)
to establish a motor drive set point. This is converted into a drive voltage using a step-up
DC-DC controller (U102). The CPU sets the motor speed as a pulse-width (duty-cycle)
modulated signal (MOTSPCTL). Zero pulse width indicates a speed of zero, while full pulse
width (100% duty cycle) is maximum speed resulting in approximately 1150 mL/hr
delivery rate. A two pole RC filter (R117, C119, R118, C120) converts the duty cycle into
a DC voltage (MSPEED). This voltage is fed to the summing amplifier U103B. Other inputs
to this amplifier represent motor current and an offset reference current to assure the
motor is off when the CPU sets a zero speed.

The motor current is sensed as the voltage across R125, amplified by U103A
(gain approximately 18.4), and input to U103B via resistor R111. The motor current
is sensed by the CPU A/D converter by monitoring the voltage at the output of U103A
through R119 (MOTCUR).

The motor voltage and current range from approximately 1.5 V to 6.0 V, and 15 mA
to 150 mA depending upon speed and load torque. This wide range of power must be
delivered over the full range of input voltage (V
the motor servo output is a switch-mode up/down (buck/boost) voltage regulator (U102;
Q108B; Q102 A and B; L102; D101; and D102). It receives a DC signal (MOTCNTRL) from
the summing amplifier U103B and converts this to the required rate of current pulses to
equal the necessary output power to the motor.

) of 1.3 V to 3.2 V. To accomplish this,

PWR

U102 is a step-up DC-DC controller that adjusts the output pulses at pin 1 to maintain
a constant voltage of 1.24 V at the feedback pin 3. IC U102 and its associated switching
circuitry may be considered part of high gain op-amp circuit with input resistor R106 and
feedback resistor R105. The junction of R105 and R106, and U102-3 is a current summing
point maintained by U102. The ratio of R105 to R106 sets the gain at –3. As the motor
control signal (MOTCNTRL) at U103B-7 ranges from 1.65 V to –1.24 V, the motor voltage,
MOT+, will range from zero to 8.68 V. If the voltage MOT+ at the right side of R105 begins
to dip, U102-3 will dip, causing the output, U102-1, to output more control pulses. These
are amplified, and become higher output DC after filtering. Individual components have
been selected to make the servo circuit operate properly. U102 does not provide enough
current, or the required negative voltage, to drive Q108B efficiently, so Q103 and Q101
are used in the classic complementary CMOS output configuration. The low side of this
totem pole combination is tied to minus 5 V (MD-5V). This reduces the switching time of
the FETs and hence minimizes current consumption. L101 has been selected to deliver
approximately 1 V at the maximum frequency of output pulses from U102.

Peak current in L101 (22 _H) must be limited, or coil saturation may adversely affect
efficiency. Based on the voltage drop across R103 (0.05 Ω), U102 automatically terminates
the coil charging ramps at 1.6 amperes.

430-600203-003 (Rev. 07/05) 4 - 14 GemStar

®

4.1 ELECTRO-MECHANICAL SYSTEMS

4.1.10.2

POWER CONSERVATION

To conserve power, the 5 V supply is disconnected when the motor circuit is not operating.
To activate the motor circuitry, the CPU switches the motor drive on signal (MOTDRVON)
high. This is inverted by U104A, turns transistor Q105A on, and connects 5 V to the motor
drive 5 V line (MD5V). When positive 5 V is available on MD5V, U101, a MAX828 voltage
inverter, generates a -5 V (MD5V) for the negative rail of the op-amps and for FET switching.

4.1.10.3

MOTOR

The drive motor is a combined gear motor with integral quadrature tachometer.
The gearbox following the motor divides the motor speed by 27.0. The motor speed
constant is chosen such that with the maximum voltage available from the servo, the motor
output shaft will turn at a speed sufficient to provide approximately 1000 mL/hr.
The motor speed constant is 0.75 V
revolutions to in-out strokes for the cassette. One revolution equals one stroke to cassette.

The motor resistance is 15 Ω +/- 8% (16.2 Ω maximum). At 120 mA, the motor voltage loss
may be as high as 15.1 x 0.12 = 1.81 V
adjusted for by the servo to keep the motor speed constant. The servo adds this lost voltage
to the applied voltage to the motor. A 1 Ω resistor in series with the low side of the motor
provides for the required motor current sensing.

per 1000 RPM. The mechanism converts rotary

DC

. This internal motor drop is automatically

DC

To get 1000 mL/hr requires 220 RPM at the output shaft. With a 27:1 gearbox, the motor
is turning 6000 RPM. At 0.75 V/1000 RPM, the basic drive voltage is 4.5 V. The total
maximum required drive voltage is then: 4.50 + 1.81 + 0.12 = 6.43 V.

4.1.10.4

TACHOMETER

A digital tachometer keeps precise track of motor rotations. The tachometer is integrally
mounted on the motor, and has a two-channel output (PHASE A, PHASE B). Each channel
uses a Hall-effect sensor to generate a digital square wave of 16 pulses for each revolution.
The pulses on one channel follow the other by a one-fourth pulse. This quadrature phase
shift allows the direction of motor movement to be detected. Counting the pulses is an
indication of motor movement and is converted into volume delivered. Play in the
mechanism may result in backward motor movement. The tachometer allows the CPU to
keep track of this and correct for reverse motion.

4.1.10.5

REDUNDANT MOTOR CONTROL

Note that when the microcontroller detects an error or out of tolerance condition, it can
inhibit motor motion with any one of three commands. A logic low on MOTORON,
MOTDRVEN, or MOTSPCTL will stop the motor. All three being a logic low adds triple
redundancy for overdelivery protection.

Technical Service Manual 4 - 15 430-600203-003 (Rev. 07/05)

SECTION 4 THEORY OF OPERATION

4.1.11

MOTOR TACHOMETER POWER CONSERVATION

The motor tachometer is used to monitor motor speed. To minimize power consumption,
the motor tachometer (encoder) is turned off whenever the motor is not running.
In addition, when the motor is running, the tachometer is strobed. This means that at
fixed intervals, the tachometer output is read into the computer. When it is not being read,
it uses less power.

The tachometer is turned on just before the motor is turned on and remains on a short
time after the motor turns off. It is switched on by the motor enable control signal
(MOTENCON) from the CPU which turns on transistor Q108A to supply power to the
tachometer on the motor (TACHVCC). The tachometer uses Hall-effect devices that switch
on rapidly. A second line from the CPU, motor enable strobe (MOTENSTB), is buffered by
U104E to become the tachometer strobe signal (STRB). This enables the Hall-effect devices
to output the PHASE A and PHASE B signals. The strobe sampling rate is 31.25 kHz.
This is fast enough to assure that no tachometer signals are missed, yet slow enough to
conserve power. There are 16 tachometer pulses generated on each channel when the
motor makes one revolution. The motor gear box has a gear ratio of twenty seven to one
(27:1). This makes the output shaft turn once for every 27 motor turns. The drive shaft
operates the pumping plunger once per revolution. As a result, there are 432 (16 x 27)
tachometer pulses per pumping stroke.

The tach operates at 5 V (TACHVCC). To reduce the output signals to the 3.3 V levels
required by the CPU system, resistors R145, R146, R107, and R108 divide the PHASE A
and PHASE B signals.

4.1.12

OUTPUT SHAFT ENCODER

The motor output shaft turns the drive mechanism which drives the pumping plunger.
A flag is attached to the end of the drive mechanism. Monitoring this flag allows the three
following functions:

- A positive indication that the mechanism is operating when the motor is operating

- An indicator when the pumping plunger is in the home (fully retracted) position

- An indication of pumping speed

The flag is monitored using a reflective optical encoder (U208). The encoder LED emits an
infrared beam of light. When the encoder flag enters the beam, it reflects light back to a
photo detector which generates an output signal (SHFTSIGNAL). This signal is squared
up by two inverters (U4D and E) before being input to the FPGA (U9-57) as shaft encoder
check (SHFTENCH).

When the signal transitions low to high, this event is latched by the FPGA, which presents
it to the CPU as an interrupt. In responding to this interrupt, the CPU polls
a memory-mapped location in the FPGA to determine which external event caused the
interrupt.

To assure correct motor operation, the shaft encoder looks for the flag every 8.2 ms
whenever the infuser is on. This assures that the motor is only running when it should
be. Any unauthorized motor movement or missing motor movement will be detected.
To minimize power consumption, the shaft encoder is enabled for only 140 µs for a 2 %
duty cycle. The shaft-on (SHFT-ON) control signal is generated at the FPGA (U9-30), passes
through connectors J3, J103, J105, and J205 to R224 and U208.

430-600203-003 (Rev. 07/05) 4 - 16 GemStar

®

4.1 ELECTRO-MECHANICAL SYSTEMS

4.1.13

AIR-IN-LINE SENSING

The GemStar® uses an ultrasonic air detection system. The mechanism holds a pulse
generator on one side of the IV tubing and a receiver on the opposite side. If there is fluid
inside the tubing, the sound pulse is conducted to the receiver and a strong signal results.
Air in the tubing gives only a weak signal. The pulse generator (transmitter) and the receiver
are made of piezo-electric crystals. These convert electrical energy into mechanical motion
or mechanical motion into an electric signal. Sending an electrical pulse to a transmitting
crystal generates an ultrasonic pulse. When the pulse is transmitted to the receiving
crystal, the pulse energy acting on the crystal generates an electrical output signal. This
signal is amplified, filtered, and converted into a digital signal for processing by the CPU.

When the cassette is inserted into the infuser, the transmit and receive crystals are
clamped to opposite sides of the IV tubing. The transmit crystal is driven by U207 and
connected to J204. The receive crystal is connected to amplifier U206 through J203. To
check for air, the CPU first applies power to the ultrasonic circuits (AIRON) by turning
Q204 on. This activates power to the ultrasonic transmitter and receiver. After the U5V
supply is stable (about 10 µs), and before transmitting, the CPU measures the receive
signal to establish background noise levels. Next, a signal is transmitted. The signal toggle
air (TOGLAIR) switches from low to high. This is buffered by U207D and causes one side
of the transmit piezo to receive an out-of-phase signal from the other. The piezo deflects,
and rings slightly to generate approximately a 700 kHz burst. Approximately 12 ms later,
TOGLAIR returns to low. This causes the crystal to transmit a second signal. The CPU
measures the AIR reading immediately after this transmitted pulse.

The receiver is a differential amplifier, U206, which rejects low frequency interference,
such as 50-60 Hz, and triples the received signal. Inter-stage capacitor C219 is a high-pass
filter that rejects frequencies up to approximately 100 kHz. The second-stage amplifier is
Q205 with an AC gain of approximately 14. L20 and C215 tune the amplifier frequency
response to optimize only the range of piezo ringing frequencies. Total AC gain is
approximately 45. The amplified output is rectified and filtered by D201 and C206 and
converted to a digital value by the CPU’s A/D. The CPU records the signal value and the
baseline values to determine whether air is present.

4.1.14

PROXIMAL PRESSURE MEASUREMENT

Proximal and distal pressures in the set are obtained by using strain gauges to measure
forces on pins that contact the cassette diaphragm. The proximal pressure sensor pin
contacts the cassette diaphragm at the inlet chamber. When proximal pressure decreases,
the chamber deflates slightly and as a result, the pressure pin moves with the chamber
wall. A resistive strain gauge connected to the pin deflects and changes its electrical output
in proportion to the applied pressure. The signal from the strain gauge (J202) is filtered
(R240; R241; C226; C227; C228) and then amplified by instrumentation amplifier U204
with a gain of 1000. Gain is established via gain resistor R211. The resultant signal,
proximal pressure (PROXPRES), is converted to a digital signal by the analog-to-digital
converter in the CPU (U2-48). The result is a signal with a range of 0 to 255. The normal
proximal pressure range is from 2 psi to –8 psi. This pressure range results in a strain
gauge signal change of approximately 1.75 mV
has full range reference voltage of 3.3 V (i.e., 3.3 V = 255 counts). As a result, the proximal
pressure gauge has a range change of 135 counts (1.75 mV x 1000 x 255 counts/3.3 V).

. The gain of U204 is 1000 and the ADC

DC

Initial offset voltages of the strain gauge circuit are adjusted to zero during production test
and calibration. During calibration, the CPU adjusts a digital potentiometer (U203)
to cancel the offset voltage. The setting is stored as calibration data in the
battery-backed-up RAM. The offset adjustment can be 6.75 mV.

Technical Service Manual 4 - 17 430-600203-003 (Rev. 07/05)

SECTION 4 THEORY OF OPERATION

4.1.15

DISTAL PRESSURE MEASUREMENT

The distal pressure measurement is very similar to the proximal. Rather than the pressure
pin contacting the diaphragm directly, however, it contacts the cassette at the flow stop.
The flow stop makes direct contact with the diaphragm. The opposite end of the pin
contacts the strain gauge. The strain gauge connects at jack J201 and is filtered and
amplified by U204 and the associated circuitry. Distal pressures are higher than proximal
pressures (-5 to 40 psi). As a result, output voltages are larger (up to 6.75 mV) so the
amplifier gain (U205) is smaller. Gain is set at 301 via gain resistor R212. The distal
pressure gauge has a range change of 157 ADC counts (6.75 mV x 301 x 255 counts/3.3 V).

The distal pressure amplifier uses the same offset potentiometer that is used for proximal
measurements. The CPU selects the appropriate value before taking a pressure reading.
Because they share the same offset resistor, distal and proximal pressures cannot be
measured at the same time.

To conserve power, the pressure measurement circuits are turned off between readings.
The control signal from the CPU is called pressure sense on (PRSENSON). Transistors
Q201 and Q202 connect + 5 V (5V-B) to the sensors (P5V) while transistors Q207 and
Q208 connect - 5 V (-5 V-B) to the sensors (P-5V).

4.1.16

RS-232 INTERFACE SYSTEM

The infuser has an RS-232 interface to allow connection to a multiple of RS-232 devices.
This allows printing reports, downloading new software, remote monitoring, and modem
interfacing. The circuitry uses an RS-232 transceiver/receiver (U5) to buffer the signals.
To input data, U5 receives the RS-232 logic level signals, serial data in [SDATIN] and serial
control in [SCTLIN], converts them to 3.3 V
UART serial port. For output, U5 receives 3.3 V
serial data out (SDATOUT), and serial data control out (SCTLOUT) and converts them to
RS-232 logic levels for external transmission from the infuser at J109.

U5 provides ohmic isolation between the infuser circuitry, and the RS-232 inputs and
outputs. This isolation is good to several thousand volts, giving the infuser the ability to
withstand electrostatic discharges on th e seri a l por t pins . When t he se r ial p o rt is n ot be i n g
used, the IC is switched to a low-power mode. The logic line serial-on (SERIALON) (U9-29)
connects to U5-13, disables the charge pump, and switches the outputs to high-impedance
output states.

logic level signals, and connects to the CPU

DC

logic level signals from the CPU UART

DC

4.2

CASSETTE SYSTEM

The GemStar® cassette is a small, low cost, sterile pumping chamber that snaps into the
infuser to deliver fluid to the patient. The cassette snaps and locks into the infuser without
the need for a separate door. When the cassette release button on the top of the infuser
is depressed, the cassette is released. When released, the cassette is automatically
protected against fluid free-flow. By opening the flow stop rocker, the cassette may be
gravity primed. The cassette has an infusion range from 0.1 mL/hr to 1000 mL/hr. Air is
ultrasonically detected by the infuser in the tubing as fluid exits from the cassette.

430-600203-003 (Rev. 07/05) 4 - 18 GemStar

®

4.2 CASSETTE SYSTEM

A pumping chamber forms the heart of the cassette. It interfaces to a plunger in the infuser.
When the plunger is depressed, fluid in the chamber is exhausted through a one-way
outlet valve to a small outlet chamber. When the plunger is retracted, the outlet valve
closes and a one-way inlet valve opens to let fluid in from a small inlet chamber. The volume
pumped for each pumping cycle is approximately 75 microliters (about 13 strokes per mL).
The inlet and outlet chambers connect to strain gauges in the infuser to monitor proximal
and distal tubing pressures. A latching flow stop contacts the outlet chamber. When it is
latched open, the outlet valve is free to open and close. When latched closed, it causes the
outlet valve to remain in the closed position, preventing fluid flow when the cassette is
outside of the infuser.

The cassette consists of four parts: body, top, diaphragm, and flow stop.

4.2.1

BODY AND TOP

The body and top enclose the silicone diaphragm to form the inlet, pumping, and outlet
chambers. The flexible diaphragm mates to the body to enclose the chambers and form
the one-way valves. The pump plunger presses on the diaphragm to empty the pumping
chamber and when the plunger retracts, the spring force of the diaphragm refills the
pumping chamber.

4.2.2

DIAPHRAGM

Fluid enters the cassette at the inlet port to fill the inlet chamber. The top of this chamber
is part of the diaphragm. A pin from the infuser contacts the top of this chamber to detect
any deflection. If pressure drops in this chamber (evidence of a proximal occlusion), the top
of the chamber will deflect, which the infuser can sense. The infuser analyzes this
deflection to determine if there is a proximal occlusion.

When the pump plunger retracts, fluid is drawn from the inlet chamber to the pumping
chamber through the one-way flapper valve. When the plunger completes the retracting
stroke, it reverses direction. The flapper valve to the inlet chamber closes. As the plunger
advances, pressure builds in the pumping chamber and opens the outlet valve. Fluid
moves to the outlet chamber and the outlet port to the patient.

Like the inlet chamber, the outlet chamber top is part of the flexible diaphragm. The flow
stop contacts the diaphragm and a pin from the infuser contacts the flow stop. If pressure
builds up in the outlet chamber (evidence of a distal occlusion), the top of the chamber
will deflect, which the infuser can sense. The infuser analyzes this deflection to determine
if there is a distal occlusion.

4.2.3

FLOW STOP

The flow stop is a rocker that latches either open or closed. When closed, it will deflect the
top of the outlet chamber to press the outlet valve closed. The flow stop pressure is
sufficient to prevent free-flow to about a nine-foot head height. After priming, a caregiver
should close the flow stop prior to installing the cassette in the infuser. However, when
the cassette is installed into the infuser, the flow stop is switched to the closed position
automatically. As the plunger engages the chamber, it relaxes the outlet valve and reduces
the valve cracking pressure. When the cassette is removed from the infuser, the flow stop
remains in the closed position and requires manual opening for priming.

Technical Service Manual 4 - 19 430-600203-003 (Rev. 07/05)

SECTION 4 THEORY OF OPERATION

This page intentionally left blank.

430-600203-003 (Rev. 07/05) 4 - 20 GemStar

®

Section 5

MAINTENANCE AND SERVICE TESTS

A complete maintenance program promotes longevity and trouble-free instrument
operation. Such a program should include routine maintenance, operation testing,
and periodic maintenance inspection.

This section details routine maintenance procedures and the operation test.

 Note: Store the infuser in a cool, dry place. Remove the disposable batteries or optional

battery pack before storing the infuser.

 Note: Program and Event History are protected in memory for at least one year when

power is removed from the infuser.

5.1

ROUTINE MAINTENANCE

Routine maintenance consists of basic inspection and cleaning procedures. As a minimum
requirement, inspect and clean the infuser after each use. In addition, establish a regular
cleaning schedule for the device.

5.1.1

CLEANING

Accumulation of dust or spilled fluids on the cassette door and housing can affect proper
operation. The following cleaning procedures are designed to sustain longevity and
promote trouble-free operation.

Follow hospital protocol for establishing the infuser cleaning schedule.

WARNING: DISCONNECT THE INFUSER FROM AC POWER AND REMOVE THE

BATTERIES OR BATTERY PACK PRIOR TO CLEANING. FAILURE
TO COMPLY WITH THIS WARNING COULD RESULT IN ELECTRICAL
SHOCK.

CAUTION: Do not immerse the infuser in liquids. Immersion could damage the
device. Do not allow liquids to enter the electronics compartment. Do not spray
cleaning solutions toward any openings in the device.

Technical Service Manual 5 - 1 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

CAUTION: Certain cleaning and sanitizing compounds may slowly degrade
components made from some plastic materials. Using abrasive cleaners or cleaning
solutions not recommended by Hospira may result in product damage and,
potentially, void the product warranty. Do not use compounds containing
combinations of isopropyl alcohol and dimethyl benzyl ammonium chloride.

CAUTION: Clean the exposed surfaces of the infuser with a soft, lint-free cloth
dampened with one of the cleaning solutions listed in Table 5-1, or a mild solution of
soapy water. Remove soap residue with clear water. Do not use solvents that are
harmful to plastic. Do not use abrasive cleaners.

CAUTION: To avoid damage to the device, cleaning solutions should be used only
as directed in Table 5-1. The disinfecting properties of cleaning solutions vary;
consult the manufacturer for specific information.

Table 5-1. Cleaning Solutions

Cleaning Solution Manufacturer Preparation

Coverage

TM

HB Steris Corporation Per manufacturer's

recommendation

Dispatch

TM

Caltech Industries Per manufacturer's

recommendation

Manu-Klenz

®

Steris Corporation Per manufacturer's

recommendation

Precise

TM

Caltech Industries Per manufacturer's

recommendation

Sporicidin

®

Sporicidin International Per manufacturer’s

recommendation

Household bleach Various Per hospital procedures;

do not exceed one part
bleach in ten parts water

5.1.1.1

SANITIZING

Sanitize the external surfaces of the infuser using a cleaning solution listed in Table 5-1.

 Note: Not all cleaning solutions are sanitizers. Check product labeling.

CAUTION: Do not sterilize the infuser using heat, steam, ethylene oxide (ETO),
or radiation. These methods may cause the instrument to malfunction.

430-600203-003 (Rev. 07/05) 5 - 2 GemStar

®

5.1 ROUTINE MAINTENANCE

5.1.1.2

CLEANING THE CASSETTE POCKET AND TUBING CHANNEL

Clean the cassette pocket and the tubing channel on a regular basis. The ultrasonic
sensors are located in the cassette pocket.

CAUTION: Do not damage the silicone seals around the sensor bodies.

See Figure 5-1, Cassette Pocket and Tubing Channel, and complete the following steps:

1. Remove the cassette.

2. Using a cotton swab moistened with a recommended cleaning solution, clean the
sensor faces (A), tubing channel (B), plunger tip (C), and sensor pins (D).

3. Dry the sensor faces and tubing channel and confirm that the sensor faces are free
of detergent film and/or debris.

 Note: Removing excess cleaning solution from the infuser helps prevent detergent

buildup, which could adversely affect performance.

A

D

C

B

02G02003

Figure 5-1. Cassette Pocket and Tubing Channel

Technical Service Manual 5 - 3 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.1.2

INSPECTION

Inspect the infuser periodically for signs of defects, such as worn accessories or damaged
cables. Also, inspect the infuser after repair or during cleaning. Replace any damaged
or defective external parts.

The following sections detail infuser inspection procedures.

5.1.2.1

MATERIALS REQUIRED

Infuser inspection requires the following materials:

-Cotton swab

- Cleaning solution

- Infuser administration set

- Small flashlight

- Two fresh AA disposable batteries

-3 V

- Digital multimeter (DMM) (Optional)

AC adaptor (optional)

DC

5.1.2.2

LABEL INSPECTION

See Figure 5-2, Label Inspection, and verify the following labels are present and
in good condition:

1 Hospira void label

2 Configuration letter label

3 System kit label

4 Serial number label

5 GemStar

6 Operating instructions label

7 Battery door void label

8 3 V

9 Battery insertion label (not shown; located inside the battery compartment)

®

logo void label

/printer/bolus connector label

DC

430-600203-003 (Rev. 07/05) 5 - 4 GemStar

®

5.1 ROUTINE MAINTENANCE

4

1

2

7 8

3

4

5

6

02G0201

Figure 5-2. Label Inspection

Technical Service Manual 5 - 5 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.1.2.3

LATCH MECHANISM INSPECTION

See Figure 5-3, Cassette Retention and Ejection, and complete the following steps:

1. Verify the four cassette latches are present.

2. Load a cassette into the chassis pocket and push the cassette until all four cassette
latches securely hold the cassette in place.

3. Gently pull on the distal and proximal tubing to verify that the latches secure the
cassette.

4. Push the cassette release button until the cassette snaps free from the service
position.

5. Gently pull on the distal or proximal tubing to verify the cassette can be removed
from the chassis with minimum resistance.

1

1

02K02021

Figure 5-3. Cassette Retention and Ejection

430-600203-003 (Rev. 07/05) 5 - 6 GemStar

®

5.1 ROUTINE MAINTENANCE

5.1.2.4

AIR SENSOR INSPECTION

See Figure 5-4, Air Sensor Inspection, and complete the following steps:

1. Verify the two air sensor anvils are present and in good condition.

2. Apply gentle pressure to each anvil face with a cotton swab to verify the sensors
retract and re-position.

3. Load the set into the chassis, nest the tubing between the air sensor anvils,
and verify that both anvils engage the distal set tubing.

4. Verify the two sensor seals are present and in good condition. Each seal should be
free of tears and nest snugly around the sensor. The seals should not interfere with
contact between the anvil face and the set tubing.

5. Verify the sensor seal pockets and sensor anvils are free of debris and
contamination.

2

5

1

3

4

02K02022

Figure 5-4. Air Sensor Inspection

Technical Service Manual 5 - 7 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.1.2.5

PLUNGER AND PRESSURE SENSOR INSPECTION

CAUTION: DO NOT apply excessive force to pressure sensor pins. Excessive force
may damage sensor pins or internal beams.

See Figure 5-5, Plunger and Pressure Sensor Inspection, and complete the following steps:

1. Verify the plunger seal is present and in good condition.

2. Apply gentle pressure to the plunger to verify transmission compliance.
There should be no significant free-play or reversing of the plunger position.

3. Verify the two pressure sensor pins are present and in good condition.

4. Using one finger, apply gentle pressure to each pressure sensor pin to verify proper
beam deflection. The pin should retract slightly then re-position after pressure
is removed.

1

3

Figure 5-5. Plunger and Pressure Sensor Inspection

2

4

02K02023

430-600203-003 (Rev. 07/05) 5 - 8 GemStar

®

5.1 ROUTINE MAINTENANCE

5.1.2.6

TOP CAP INSPECTION

See Figure 5-6, Top Cap Inspection, and complete the following steps:

1. Verify the top cap is free of cracks, holes, and evidence of fluid ingress.

2. Verify the seal between the top cap and the bezel/extrusion is present and in good
condition.

3. Verify the condition of the pole clamp retainer.

2

1

3

2

Figure 5-6. Top Cap Inspection

02K02024

Technical Service Manual 5 - 9 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.1.2.7

BOTTOM CAP INSPECTION

See Figure 5-7, Bottom Cap Inspection, and complete the following steps:

1. Verify the bottom cap is flush with the extrusion and bezel.

2. Verify the bottom cap is free of cracks and holes.

3. Verify all three hole plugs are present.

 Note: Steps 4 through 6 apply to the GemStar

component interface.

4. Verify each port is free of foreign material and contamination.

5. Verify that each port retention and keying features are free from damage.

6. Verify that each gold contact is clearly visible, intact, and free of contamination.

®

with the optional system

PURGE

0

OPTIONS

NOHELP

YES

ENTER

1

1

3

Figure 5-7. Bottom Cap Inspection

2

02K02025

430-600203-003 (Rev. 07/05) 5 - 10 GemStar

®

5.1 ROUTINE MAINTENANCE

5.1.2.8

BEZEL, GRIP, AND KEYPAD INSPECTION

See Figure 5-8, Bezel, Grip, and Keypad Inspection, and complete the following steps:

1. Verify the bezel face is in good condition.

2. Verify the seal of the bezel face to the grip.

3. Verify the bezel tail is in good condition.

4. Verify the seal of the bezel tail to the grip.

5. Verify the seal of the bezel face edge to extrusion.

6. Verify the keypad is free of damage and that each key provides tactile feedback
when pressed.

1 3

4

7

2 6

5

5

02G02026

Figure 5-8. Bezel, Grip, and Keypad Inspection

Technical Service Manual 5 - 11 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.1.2.9

BATTERY DOOR AND COMPARTMENT INSPECTION

The following sections describe battery door and battery compartment inspection.

5.1.2.9.1

Battery Door Engagement

See Figure 5-9, Battery Door Engagement, and complete the following steps:

1. Flip the door latch to the open position, then to the closed position, then to the open
position again. The door latch should snap positively in both positions with
no free-play.

2. Verify the door retainer is present and in good condition.

3. Gently rotate the battery door latch counterclockwise to the open position, then
clockwise to the closed position to verify proper engagement. The door is properly
engaged when the door is secured by the door retainer.

2

1

Figure 5-9. Battery Door Engagement

3

04K02027

430-600203-003 (Rev. 07/05) 5 - 12 GemStar

®

5.1 ROUTINE MAINTENANCE

5.1.2.9.2

Battery Door Inspection

See Figure 5-10, Battery Door Inspection, and complete the following steps:

1. Remove the battery door from the infuser.

2. Verify the o-ring is present and in good condition.

3. Verify the door latch and plunger hinges are free of fractures.

4. Verify the spring is secure with no wobble or excessive collapse.

5. Verify the wiper contact is free of contamination, corrosion, and excessive
deformation.

2

4

5

3

02G02028

Figure 5-10. Battery Door Inspection

Technical Service Manual 5 - 13 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.1.2.9.3

Battery Compartment Inspection

See Figure 5-11, Battery Compartment Inspection, and complete the following steps:

1. Remove the battery door.

2. Verify the circuit board wiper contact is present and free of contamination,
corrosion, and excessive deformation.

3. Verify the battery cap is present and free of contamination and corrosion.

2

3

02G02029

Figure 5-11. Battery Compartment Inspection

430-600203-003 (Rev. 07/05) 5 - 14 GemStar

®

5.1 ROUTINE MAINTENANCE

POWER

BACK-UP

CHANGE

OPTIONS

YES

ENTER

ON/OFF

5.1.2.10

POWER-ON TEST

See Figure 5-12, Power-On Test, and complete the following steps:

1. Install two fresh, disposable AA batteries in the infuser.

2. Press [ON/OFF]. Verify the infuser powers on and UNIT SELF-TEST displays, along
with the time and date.

3. Verify the audible alarm sounds at power-on.

4. Verify USING BATTERIES displays, and press [YES/ENTER].

5. Connect the AC adaptor to the 3 volt connector on the bottom of the infuser,
and verify the green power LED illuminates.

6. Disconnect the AC adaptor, and verify the green power LED is not illuminated.

7. Remove the battery door. Verify the red LED illuminates, the beeper sounds,
and POWER LOSS displays.

7

5

6

SILENCE

1

4
7

STOP

2
5
89
0

1

PURGE

START

3
6

NOHELP

POWER

ON/OFF

BACK-UP

CHANGE

OPTIONS

YES

ENTER

2

3

4

04K02030

Figure 5-12. Power-On Test

Technical Service Manual 5 - 15 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.1.2.11

RECHARGEABLE BATTERY PACK (OPTIONAL)

See Figure 5-13, Rechargeable Battery Pack, and complete the following steps:

1. Verify the 3 V

/printer/bolus port connector contacts are present and in good

DC

condition.

2. Verify the 3 V

/printer/bolus pass-through port connector contacts are present

DC

and in good condition.

CAUTION: Do not touch exposed connectors on the bottom of the infuser.
Exposed connectors are susceptible to electrostatic discharge (ESD) damage.

3. Connect the infuser, without batteries, to the battery pack, and verify the battery
pack slides into place and locks firmly.

4. Press [ON/OFF], and verify the infuser powers on and the green LED on the infuser
flashes slowly.

5. Press the release buttons, and verify the latch mechanism releases.

6. Connect the battery pack to the battery pack charger, and verify the battery pack
LED illuminates.

1

TOP VIEW

2

BOTTOM VIEW

5

6

FRONT VIEW

05K02031

Figure 5-13. Rechargeable Battery Pack

430-600203-003 (Rev. 07/05) 5 - 16 GemStar

®

5.1 ROUTINE MAINTENANCE

5.1.2.12

DOCKING STATION (OPTIONAL)

See Figure 5-14, Docking Station, and complete the following steps:

1. Verify the dovetail is in good condition.

2. Press the release button, and verify the detent retracts.

3. Verify the 3 V
condition.

CAUTION: Do not touch exposed connectors on the bottom of the infuser.
Exposed connectors are susceptible to electrostatic discharge (ESD) damage.

4. Remove the connector cap and verify the bolus and printer pass-through port
connector contacts are present and in good condition.

5. Verify the pole clamp is securely attached to the docking station body.

6. Verify the docking station is free of contamination, cracks, and other physical
damage.

7. Verify the AC mains power cord lanyard and retention features are present.

8. Verify the AC mains power cord, plug, and prongs are in good condition.

9. Connect the docking station to AC mains power, and verify the docking station
LED illuminates.

10. Slide the infuser, without batteries, into the docking station, and verify the device
locks firmly into place.

11. Press [ON/OFF], and verify the infuser powers on and initiates the self test.

12. Remove the infuser, disconnect power, and perform a continuity test between the
corresponding top and bottom pins to verify bolus pass-through functionality.

/printer/bolus port connector contacts are present and in good

DC

Technical Service Manual 5 - 17 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

2

7

1

8

FRONT VIEW

5

9

6

4

12

12

3

BACK VIEW TOP VIEW

02G02015

Figure 5-14. Docking Station

430-600203-003 (Rev. 07/05) 5 - 18 GemStar

®

5.1 ROUTINE MAINTENANCE

5.1.2.13

AC ADAPTOR (OPTIONAL)

CAUTION: Do not use the AC adaptor if the cord is frayed or torn insulation is found,
or if any prong is missing from the plug.

See Figure 5-15, AC Adaptor, and complete the following steps:

1. Using a multimeter and probes, verify the AC adaptor output is 3 V

2. Verify the cord is in good condition.

3. Verify the transformer and 3-prong plug are in good condition.

4. Verify the infuser plug adaptor pins are present and in good condition.

5. Connect the AC adaptor to the adaptor port on the bottom of the infuser.
Verify the AC plug is properly engaged/retained.

6. Remove the batteries.

7. Press [ON/OFF], and verify the infuser powers on.

± 5 %.

DC

3

12

1

3

4

2

4

02K02032

Figure 5-15. AC Adaptor

Technical Service Manual 5 - 19 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.1.2.14

REMOTE BOLUS CORD AND SWITCH (OPTIONAL)

See Figure 5-16, Remote Bolus Cord and Switch, and complete the following steps:

1. Verify the bolus cord is free from fraying and torn insulation.

2. Verify the switch body is free of damage and evidence of fluid ingress.

3. Verify the bolus port connector pins are present and in good condition.

4. Press the bolus switch, and verify the bolus continuity across pins 1 and 2.

5. Connect the bolus cord to the bolus port on the bottom of the infuser.
Verify the bolus cord plug is properly engaged/retained.

2

3

1

Figure 5-16. Remote Bolus Cord and Switch

4

1

2

3

02K02033

430-600203-003 (Rev. 07/05) 5 - 20 GemStar

®

5.2 OPERATION TEST

5.2

OPERATION TEST

The operation test is designed to assure the infuser is operating properly.
Hospira recommends performing this test a minimum of once every 12 months.
Refer to facility requirements to determine additional testing needs.

The test can be performed when the infuser is in the STOP mode and requires
approximately 15 minutes to complete. Each section of the test must be run in sequence.
The infuser automatically sets the delivery rate when required during the operation test.

 Note: This test is available only when the infuser is UNLOCKED.

WARNING: A PATIENT SHOULD NEVER BE CONNECTED TO THE INFUSER

DURING TESTING.

5.2.1

EQUIPMENT REQUIRED

The operation test requires the following equipment, or equivalents:

-GemStar

- Reservoir, with at least 50 mL of water

- Graduated cylinder, 25 mL or larger, graduated in 0.1 mL

- Two fresh, disposable AA batteries

- Hospira-approved AC adaptor

- Serial printer cable, List Number 13078-01

®

non-filter, straight ambulatory set, List Number 13273-01

5.2.2

TEST SETUP

1. Connect the external power source and install two fresh, disposable AA batteries.

2. Power on the infuser, and press [OPTIONS].

3. Select HISTORIES from the Options menu.

4. Select OPERATION TEST from the Histories menu, and follow the instructions
on the display.

5.2.3

PERFORMING THE OPERATION TEST

The infuser display provides step-by-step guidance through each section of the test.

 Note: The infuser clears any program and shift totals stored in memory before

starting the operation test.

Use the checklist provided in Section 5.2.5 to record test results (see Table 5-2, GemStar

Operation Test Checklist).

Technical Service Manual 5 - 21 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.2.3.1

POWER TEST

1. The display indicates an external power source and batteries are connected

(see Figure 5-12).

2. Remove the disposable AA batteries and press [
external power is connected. Press [

3. Install the batteries.

4. Disconnect the external power source and press [

5. The display indicates that only batteries are connected and displays the test results.
Press [

6. If the test fails, reconnect the external power source and press [
test, or press [YES/ENTER] to confirm failure.

5.2.3.2

].

].

]. The display indicates that only

].

] to rerun the

KEYPAD TEST

1. Press each key, including the bolus button. Press [YES/ENTER] last.

2. Enter one of the following results:

- If each key makes an audible tone, press [YES/ENTER].

- If any key does not make an audible tone, press [NO].

5.2.3.3

DISPLAY TEST

1. Press [YES/ENTER] when prompted. The display fills with solid boxes for
approximately ten seconds. To view the solid boxes for another ten seconds after
the display times out, press [

2. Enter one of the following results:

- If the display fills with solid boxes, press [YES/ENTER].

- If the display does not fill with solid boxes, press [NO].

5.2.3.4

].

LED TEST

1. Verify the green power LED and red alarm LED illuminate (see Figure 5-12).

2. Enter one of the following results:

- If both LEDs illuminate, press [YES/ENTER].

- If either of the LEDs does not illuminate, press [NO].

430-600203-003 (Rev. 07/05) 5 - 22 GemStar

®

5.2 OPERATION TEST

5.2.3.5

VOLUME ACCURACY TEST

To pass the volume accuracy test, the infuser must deliver between 19 and 21 mL within
approximately three minutes.

1. Load a primed infuser set into the device, and press [

2. Place the proximal end in the reservoir of water, and press [

3. Place the distal end in a 20 mL graduated cylinder, and press [

4. Press [START].

5. Enter one of the following results:

- If the infuser delivers between 19 and 21 mL, press [YES/ENTER].

- If the infuser does not deliver between 19 and 21 mL, press [NO].

5.2.3.6

].

].

].

DISTAL OCCLUSION TEST

To pass the distal occlusion test, the occlusion must occur within approximately
30 seconds.

1. Clamp the set 10 to 12 inches (25.4 to 30.5 cm) below the cassette.

2. Press [START].

3. One of the following test results displays. Release the clamp and press [

- If the test has passed, the infuser advances to the next test.

- If the test has failed, clean the sensors and press [
[YES/ENTER] to confirm failure.

] to rerun the test, or press

].

5.2.3.7

PROXIMAL OCCLUSION TEST

To pass the proximal occlusion test, the occlusion must occur within approximately
30 seconds.

1. Clamp the infuser set above the cassette.

2. Press [START].

3. One of the following test results displays. Release the clamp and press [

- If the test has passed, the infuser advances to the next test.

- If the test has failed, clean the sensors and press [
[YES/ENTER] to confirm failure.

] to rerun the test, or press

].

 Note: Clean the sensor pins before repeating the proximal occlusion test

(see Section 5.1.1.2).

Technical Service Manual 5 - 23 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.2.3.8

AIR-IN-LINE TEST

To pass the air-in-line test, the alarm must occur within approximately one minute.

1. Release the clamp.

2. Remove the proximal end of the set from the reservoir, and press [

3. Press [START].

4. One of the following test results displays. Press [

- If the test has passed, the infuser advances to the next test.

- If the test has failed, clean the sensors and press [
[YES/ENTER] to confirm the failure.

].

] to rerun the test, or press

].

5.2.4

PRINTING THE TEST RESULTS

When the test is complete, the infuser displays an option to print the test results.
Follow Steps 1 through 3 to print the test results (see Figure 5-17, Sample Test Results

Printout).

 Note: For maximum battery life, the infuser should be operated on AC mains power

when connected to a printer or computer.

1. Connect the serial printer cable to the infuser. Refer to the system operating manual
for more information.

2. Press [YES/ENTER] to print the test results.

3. After the results have been transmitted to the printer, or if [NO] is pressed,
the infuser automatically proceeds to the main programming menu.

430-600203-003 (Rev. 07/05) 5 - 24 GemStar

®

5.2 OPERATION TEST

******************************************
*

*

*

GemStar

OPERATION TEST

RESULTS

*

*

*

******************************************

PUMP SERIAL NUMBER: XXXXXXXXX

10:54AM JAN 4, 05

VERSION n.n.n

1. Case Inspection PASS

2. Cassette Pocket & Latch PASS

3. Power Check PASS

4. Keypad Test PASS

5. Display Test FAIL

6. LED Test PASS

7. Volume PASS

8. Distal Occlusion Test PASS

9. Proximal Occlusion Test PASS

10. Air-in-line Test PASS

******************************************

**

VERIFIED BY:

******************************************

******************************************

*

*

*

******************************************

1234567890123456789012345678901234567890

END OF

OPERATION TEST

RESULTS

*

*

*

04K02039

Figure 5-17. Sample Test Result Printout

Technical Service Manual 5 - 25 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.2.5

OPERATION TEST CHECKLIST

Use the checklist provided in Table 5-2 to record operation test results.

Table 5-2. GemStar Operation Test Checklist

Pass Fail

Power Test ❏❏

Keypad Test ❏❏

Display Test ❏❏

LED Test ❏❏

Volume Accuracy Test ❏❏

Distal Occlusion Test ❏❏

Proximal Occlusion Test ❏❏

Air-in-Line Test ❏❏

Printed Test Results ❏❏

Restoring the Infuser for Use ❏❏

Serial Number:

Verified By: Date:

430-600203-003 (Rev. 07/05) 5 - 26 GemStar

®

5.3 PERIODIC MAINTENANCE INSPECTION

5.2.6

RESTORING THE INFUSER FOR USE

Before returning the infuser for use, it must be initialized. Initializing the infuser
automatically performs the following functions:

- Resets the configuration registers

- Performs a power-on test

- Clears the error log

- Resets RAM variables

- Sets the default beeper level

- Clears user history

To initialize the infuser for use, complete the following steps:

1. Power on the infuser with a 3.0 V

2. At the power status display, press and hold [OPTIONS] until ENTER ACCESS CODE
displays. Ignore the stuck key alarm that will sound while [OPTIONS] is pressed.

3. Enter access code 72255. Asterisks display as the numbers are entered.

AC adaptor only (no internal batteries).

DC

 Note: Press [CHANGE} to clear an entry and enter a new code. An invalid code causes

the infuser to return to the power-on self test.

4. Press [0][2] to select INT PUMP.

5. Turn off the infuser when initialization is complete.

5.3

PERIODIC MAINTENANCE INSPECTION

Periodic maintenance inspections should be performed per hospital procedures for
compliance to accreditation requirements. It is recommended that JCAHO and/or hospital
protocol be followed for establishing a periodic maintenance inspection schedule.
Product specifications for this inspection are listed in Section 8, Specifications.

To perform the periodic maintenance inspection, complete the operation test in Section 5.2.

Technical Service Manual 5 - 27 430-600203-003 (Rev. 07/05)

SECTION 5 MAINTENANCE AND SERVICE TESTS

This page intentionally left blank.

430-600203-003 (Rev. 07/05) 5 - 28 GemStar

®

Section 6

TROUBLESHOOTING

This section contains information on technical assistance, troubleshooting references,
service alarms, and operational alarms for the GemStar

®

infuser.

6.1

TECHNICAL ASSISTANCE

For technical assistance and product return authorization, and to order parts, accessories,
or manuals within the United States, contact Hospira Technical Support Operations.

1-800-241-4002

For additional technical assistance, technical training, and product information,
visit the website at www.hospira.com.

Send all authorized, prepaid returns within the United States to the following address:

Hospira, Inc.

Technical Support Operations

755 Jarvis Drive

Morgan Hill, California 95037

For technical assistance, product return authorization, and to order parts, accessories,
or manuals from outside the United States, contact the nearest Hospira sales office.

6.2

TROUBLESHOOTING REFERENCES

The following information is provided to assist in troubleshooting the GemStar®.

Under most alarm conditions, the infuser ceases normal operation, generates an audible
alarm, and displays an alarm message or error code on the LCD screen.

Troubleshooting should always start with a basic infuser inspection to isolate and
eliminate common infuser/cassette interface problems and user errors. Most problems
can be easily resolved through non-invasive recovery procedures.

Technical Service Manual 6 - 1 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

6.2.1

TROUBLESHOOTING TOOLS

Table 6-1, Troubleshooting Tools, describes the tools available to help isolate and resolve

many infuser problems.

Table 6-1. Troubleshooting Tools

Section Description Purpose

6.2.2 Alert/alarm message

6.2.3 Printing device history Provides significant events, in chronological

5.1.2 Inspection Provides information for inspecting the physical

5.2 Operation test Verifies infuser operation, including

index Provides the appropriate reference for a specific

error type

order, such as programming and infuser
performance history

and functional parameters of the infuser to
assure optimal performance

programmability, pressure and air sensitivity,
and volume accuracy

6.2.2

ALERT/ALARM MESSAGE INDEX

Table 6-2, Alert/Alarm Message Index, describes error types, display messages,

descriptions, and references.

Table 6-2. Alert/Alarm Message Index

Error Type Display/Description Reference

Alert message ALMOST EMPTY

CHECK PRINTER

EMPTY CONTAINER

FLASHING DISPLAY

PROGRAM INCOMPLETE

START

Sensor alarm AIR-IN-LINE

DISTAL OCCLUSION

PROXIMAL OCCLUSION

Alarm message CHANGE BATTERIES

CHECK CASSETTE

LOW BATTERIES

POWER LOSS

USING BATTERIES

430-600203-003 (Rev. 07/05) 6 - 2 GemStar

System operating manual

®

6.2 TROUBLESHOOTING REFERENCES

Table 6-2. Alert/Alarm Message Index

Error Type Display/Description Reference

Service alarm CALL 1-800-241-4002

CODE: NN/MMM/TTT

Section 6.1, Technical Assistance

Section 6.3, Service Alarm Codes

Other display messages KEYPAD LOCKED System operating manual

NOT ALLOWED DURING
INFUSION PROCESS

PRESS STOP TO
HALT DELIVERY

ROUNDING

DOSE IN PROGRESS

NEW CONTAINER
NOT ALLOWED

CANNOT CHANGE
CLOCK WHILE THE
BASE DELIVERY
IS IN PROGRESS

PROGRAM EXCEEDS
MAX CONTAINER SIZE

CHANGE PROGRAM
VALUES

THIS OPTION IS
NOT AVAILABLE
WHILE PROGRAMMING
THE PUMP

No display No power or sign

of functionality

Locked up Infuser is powered on

but is not responding

Section 6.1

Section 5.2.6

Technical Service Manual 6 - 3 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

6.2.3

PRINTING DEVICE HISTORY

1. Power on the infuser.

2. Wait for the self test to complete, then press [YES/ENTER].

3. Connect the printer to the infuser.

4. Press [OPTIONS].

5. Select HISTORIES from the Options Menu.

6. Select HISTORY from the Histories menu to begin printing.

 Note: Refer to the system operating manual for additional printing instructions and

configuration settings.

6.3

SERVICE ALARM CODES

Service alarms indicate maintenance or repair of the infuser is required to restore proper
infuser performance. Service alarm codes are displayed in the following format:

Primary Supplemental Type

NN MMM TTT

The following sections provide an explanation of service alarm codes, quick references,
and service alarm code details.

6.3.1

SERVICE ALARM CODES - QUICK REFERENCE

Table 6-3, Service Alarm Codes - Quick Reference, lists error codes and descriptions.

Table 6-3. Service Alarm Codes - Quick Reference

Error Description

01/000 CONFIG register contents are not what is expected

02/000 Stack error

03/000 Invalid interrupt

03/001 Interrupt overlap

03/002 Invalid IRQ interrupt

04/000 RAM Test error

05/000 EEPROM write error – data read back does not match data written

05/001 EEPROM write error – invalid EEPROM address

06/000 Pump configuration CRC error

430-600203-003 (Rev. 07/05) 6 - 4 GemStar

®

Table 6-3. Service Alarm Codes - Quick Reference

Error Description

06/001 Infusion data CRC error

06/002 Pump data CRC error

06/003 Program data CRC error

06/004 Speed protocol CRC error

06/005 ROM CRC error

06/006 Protected variable error

06/007 Dose data CRC error

06/008 Air calibration CRC error

06/009 Pressure calibration CRC error

06/010 Motor calibration CRC error

06/011 Settings CRC error

6.3 SERVICE ALARM CODES

07/000 High air sensor value

07/001 Negative volume sampled

07/002 Bad air sensor state

07/003 Bad air sensor event

07/004 Air sensor not calibrated

07/005 Excessive volume sampled

08/005 Bad pressure sensor event

08/006 Bad pressure sensor state

08/007 Distal pressure is out of range

08/008 Proximal pressure is out of range

09/000 Short term overdelivery

09/001 Backward motor movement

09/002 Motor not calibrated

09/006 Power on motor test

09/007 Motor not turning when it should be turning

09/008 Bad motor state

09/009 Bad motor event

09/010 Bad motor rate

09/011 Motor stack error

09/012 Motor step overlap

09/013 Motor control error

Technical Service Manual 6 - 5 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-3. Service Alarm Codes - Quick Reference

Error Description

09/014 Bad motor step number

09/015 Motor overshot IPRF step

09/016 Motor encoder overflow

09/017 Bad restart command

09/018 Motor overdelivery

09/019 Motor underdelivery

09/020 Motor runaway

10/000 Beeper error

11/000 More than 5.5 volts measured on the 5 V line

11/001 Less than 4.5 volts measured on the 5 V line

11/002 More than 3.2 volts measured on the AA battery voltage input

11/003 More than 3.6 volts measured on the external voltage input

11/004 Less than 2.0 volts measured on the lithium battery input

12/000 Stuck key

13/000 IRQ test of oscillator – timing error

13/001 RTI test of one second interrupt – timing error

14/001 Watchdog timeout – motor was turning when it should not be turning

14/003 Watchdog error – task not responding

15/000 Power down error

16/001 Air-in-line was active when it should not be active

16/002 Key event timeout

16/003 Invalid alarm semaphore

16/004 Invalid alarm message

16/005 Invalid alarm type

16/006 Invalid alarm callback

16/007 Invalid sound type

16/008 IQUEUE full

16/009 Infusion safety task received an invalid message type

16/010 Infusion safety task received a null message type

16/011 Infusion safety task received an invalid pressure message

16/012 Infusion safety task did not receive the expected queue information

16/013 Infusion safety task received an invalid semaphore value

430-600203-003 (Rev. 07/05) 6 - 6 GemStar

®

6.3 SERVICE ALARM CODES

Table 6-3. Service Alarm Codes - Quick Reference

Error Description

16/014 Infusion safety task received an invalid air message

16/015 Infusion safety task received an invalid check cassette message

16/016 Infusion safety task received a resume without an initial start

16/017 Infusion safety task detects a rate mismatch

16/018 Infusion safety task detects a mode mismatch

16/019 IED has message conflict

16/020 Remote queue out full

16/021 Remote queue out empty

16/022 Remote queue out bad state

16/023 ISA bad rate

18/000 History pointer error while inserting a new record into the history log

18/001 History pointer error while traversing to bottom of history

18/002 History pointer error while traversing to top of history

21/000 Remote communication input buffer error

21/001 Keypad queue error

21/002 Remote communication input message error

Technical Service Manual 6 - 7 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

6.3.2

SERVICE ALARM CODES - DETAILS

Table 6-4, Service Alarm Codes - Details, lists primary errors, supplemental errors, types,

error detection methods, error descriptions, and possible causes.

Table 6-4. Service Alarm Codes - Details

Error

Primary

Error

(NN)

01

CPU_ERROR

02

STACK_

ERROR

03

INTERRUPT_

ERROR

Supplemental

Error

(MMM)

000

CONFIG_REG

000 Stack #

000

INVALID_

INTERRUPT

Error

Typ e

(TTT)

CONFIG register contents At power on, the

0 = RTXC stack
1 = SCI_INPUT stack
2 = SCI_OUTPUT stack
3 = IED stack
4 = UI stack
5 = DISPMGR stack
6 = INFUSION stack
7 = ISAFETY stack
8 = ALARM stack

9 = NISAFETY stack
10 = HISTORY stack
11 = REMOTE OUT stack
12 = STACKMAX

Interrupt #

1 = SPI_INTERRUPT

2 = PAIE_INTERRUPT
11 = TIC2_INTERRUPT
12 = TIC1_INTERRUPT
18 = NOCOP_

INTERRUPT

19 = CME_INTERRUPT

Detection

Method

contents of the
CONFIG register
is tested for the
expected value.

If the contents are
invalid, a service
alarm occurs.

Each stack is
initialized during
power on.

Once per second,
these values are
checked for
corruption.

If a guard byte has
been overwritten,
a service alarm
occurs.

All unsupported
ISRs, when called,
are trapped in
a service alarm

Description

and

Possible Cause

The CONFIG
register does
not contain the
expected value
due to:

CPU failure
EEPROM failure

Stack overflowed
due to:

CPU failure
Flash RAM

failure
RAM chip

failure
Bus failure

An unsupported
interrupt has been
called due to:

Flash RAM
failure

Bus failure
CPU failure
RAM chip

failure

430-600203-003 (Rev. 07/05) 6 - 8 GemStar

®

Primary

Error

(NN)

03

INTERRUPT_

ERROR

04

RAM_ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

001

INTERRUPT_

OVERLAP

002

INVALID_IRQ_

INTERRUPT

000

INTERNAL_

TEST

6.3 SERVICE ALARM CODES

Error

Typ e

(TTT)

Interrupt #

0 = SCI_INTERRUPT
serial port

3 = PAO_INTERRUPT
motor forward
counts = 256

4 = TO_INTERRUPT
timer overflow;
general purpose timing

5 = TOC5_INTERRUPT
air monitoring

6 = TOC4_INTERRUPT
keypad scanning

7 = TOC3_INTERRUPT
pressure monitoring

8 = TOC2_INTERRUPT
motor control

9 = TOC1_INTERRUPT
output shaft sensor
scanning

10 = TIC3_INTERRUPT
motor backward ticks

13 = RTI_INTERRUPT
system clock;
watchdog servicing;
stack checking)

14 = IRQ_INTERRUPT
real-time clock
chip interrupt

15 = XIRQ_INTERRUPT
power loss

IRQ status byte Upon entry into the

Test #

0 = Power on test
1 = Background test

Detection

Method

Each interrupt
service routine has
a unique activity
flag associated
with it.

The flag is set upon
entry into the ISR
and cleared upon
exit.

If, on entry, the
flag is already set,
a service alarm
occurs.

ISR, a processing
flag is set to
FAILURE.

As the individual
bits are processed,
the flag is set
to SUCCESS.

If no flags are
processed,
a service alarm
occurs.

At power on and
continuously
during operation,
all RAM locations
are tested by
writing patterns
of 0XAA and 0X55
and by address
count up.

Error

Description

and

Possible Cause

An interrupt was
called again before
the last execution
completed due to:

Flash RAM
failure

Bus failure
CPU overload

The IRQ interrupt
was called but no
interrupts were
processed due to:

CPU failure
FPGA failure
timer chip failure
output shaft

sensor failure

Read/write test to
internal RAM failed
due to:

CPU failure

Technical Service Manual 6 - 9 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

05

EEPROM_

WR_ERROR

06

CRC_

CHKSUM_

ERROR

Supplemental

Error

(MMM)

000 N/A All writes to CPU

001 N/A All writes to CPU

000

PUMP_

CONFIG_CRC

Error

Typ e

(TTT)

N/A The configuration

Detection

Method

EEPROM are
processed via
a common function
which reads back
the EEPROM
contents following
a write.

If the data read
back following the
write does not
match the data
written, a service
alarm occurs.

EEPROM are
processed via
a common
function.

If the function
receives an invalid
EEPROM address,
a service alarm
occurs.

data integrity
is verified:

before viewing
before printing
before using

in rate-lock
change
function

before using in
menu function

at power on
whenever any

dose is started
or restarted

If the CRC
stored with the
configuration data
does not match the
calculated value,
a service alarm
occurs.

Error

Description

and

Possible Cause

Unable to write
to EEPROM in
the 68HC11 chip
due to:

CPU EEPROM
failure

CPU failure

Unable to write
to EEPROM in
the 68HC11 chip
due to:

RAM chip failure
Bus failure

The computed
configuration CRC
value does not
match the stored
value due to:

CPU EEPROM
failure

CRC calculation
error

430-600203-003 (Rev. 07/05) 6 - 10 GemStar

®

Primary

Error

(NN)

06

CRC_

CHKSUM_

ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

001

INFUSION_
DATA_CRC

002

PUMP_DATA_

CRC

003

PROGRAM_

CRC

6.3 SERVICE ALARM CODES

Error

Error

Typ e

(TTT)

N/A The infusion data

N/A The infuser data

N/A The infuser

Detection

Method

integrity is verified
at power on and
once per second
while the infusion
task is running.

If an invalid infusion
data pointer is
found or if the CRC
stored with the
infusion data does
not match the
calculated value,
a service alarm
occurs.

integrity is verified
at power on and
once per second
while the infusion
task is running.

If the CRC stored
with the infuser
data does not
match the
calculated value,
a service alarm
occurs.

program data
integrity
is verified:

entering stop
mode

entering run
mode

when a new
program is sent
to infusion

whenever any
dose starts
or restarts

If the CRC stored
with the infuser
program data does
not match the
calculated value,
a service alarm
occurs.

Description

and

Possible Cause

The computed
infusion data CRC
does not match the
stored value due to:

RAM chip failure
Bus failure
CRC calculation

error

The computed
infuser data CRC
does not match the
stored value due to:

RAM chip failure
Bus failure
CRC calculation

error

The computed
infuser program
CRC does not
match the stored
value due to:

RAM chip failure
Bus failure
CRC calculation

error

Technical Service Manual 6 - 11 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

06

CRC_

CHKSUM_

ERROR

Supplemental

Error

(MMM)

004

SPEED_

PROTOCOL_

CRC

005

ROM_CRC

006

PROTECTED_

VAR

Error

Typ e

(TTT)

Speed protocol # The speed protocol

N/A The Flash RAM

Variable type

003 = Air state
004 = Pressure state
006 = Distal pressure

threshold
007 = Proximal pressure

threshold

Detection

Method

data integrity
is verified:

before
printing
a speed
protocol

before
viewing
a speed
protocol

before
assigning
a speed
protocol

before
deleting
a speed
protocol

before
retrieving
a speed
protocol

If the CRC stored
with the speed
protocol data does
not match the
calculated value,
a service alarm
occurs.

data integrity is
verified at power on
and once every
hour.

If the checksum
stored in the Flash
RAM does not
match the
calculated value,
a service alarm
occurs.

Critical data used in
air and pressure
sensing is mirrored
in RAM when
written.

When read back,
the data and its
mirrored value is
compared to verify
data integrity.

If the data value
cannot be verified,
a service alarm
occurs.

Error

Description

and

Possible Cause

The computed
speed protocol
CRC does not
match the stored
value due to:

RAM chip failure
CRC calculation

error

The computed
FLASH RAM
checksum does not
match the stored
value

The protected
variable value is
corrupted due to:

RAM chip failure
Bus failure
CPU failure

430-600203-003 (Rev. 07/05) 6 - 12 GemStar

®

Primary

Error

(NN)

06

CRC_

CHKSUM_

ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

007

DOSE_DATA_

CRC

008

AIR_CAL_CRC

009

PRESS_CAL_

CRC

010

MOTOR_CAL_

CRC

6.3 SERVICE ALARM CODES

Error

Typ e

(TTT)

Dose type The dose data

N/A The air calibration

N/A The pressure

N/A The motor

Detection

Method

integrity is verified
at power on, once
every second and
at the start of a new
dose.

If the CRC stored
with the dose data
does not match the
calculated value,
a service alarm
occurs.

data integrity is
verified at power on
and in the
background.

If the CRC stored
with the air
calibration data
does not match the
calculated value,
a service alarm
occurs.

calibration data
integrity is verified
at power on and
in the background.

If the CRC stored
with the pressure
calibration data
does not match the
calculated value,
a service alarm
occurs.

calibration data
integrity is verified
at power on and
every time a start
delivery command
is sent to infusion
safety.

If the CRC stored
with the motor
calibration data
does not match the
calculated value,
a service alarm
occurs.

Error

Description

and

Possible Cause

The computed
dose data CRC
does not match the
stored value due to:

RAM chip failure
CRC calculation

error

The computed air
calibration data
CRC does not
match the stored
value due to:

CPU EEPROM
failure

CRC calculation
error

The computed
pressure
calibration data
CRC does not
match the stored
value due to:

CPU EEPROM
failure

CRC calculation
error

The computed
motor calibration
data CRC does not
match the stored
value due to:

CPU EEPROM
failure

CRC calculation
error

Technical Service Manual 6 - 13 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

06

CRC_

CHKSUM_

ERROR

07

AIR_

SENSOR_

ERROR

Supplemental

Error

(MMM)

011

SETTINGS_

CRC

000

HIGH_VALUE

001

AIR_NEGATIVE

_VOLUME

002

AIR_BAD_

STATE

003

AIR_BAD_

EVENT

004

AIR_NOT_

CALIBRATED

Error

Typ e

(TTT)

0 = Error when entering

a function that will alter the
infuser settings

1 = Error when entering
a function that displays the
current lock levels

Measured value When evaluating

N/A The volume

State # The state variable

Event # If an event code

0 The AIR MAX PRE

Detection

Method

Verifies the
settings data
is correct when:

displaying the
lock levels

entering Run
mode or Stop
mode

changing the
PM rate, PM
bolus dose,
or occlusion
setting

the air sensor state,
the measured
pre-trigger value
is compared with
the level set during
calibration.

If the measured
value is greater
than the calibration
value, a service
alarm occurs.

delivered between
checkpoints is
calculated each
checkpoint.

If the volume is
negative and more
than one stroke has
been delivered,
a service alarm
occurs.

was not one of the
recognized states
for the pressure
software.

is received that
is not one of the
recognized events
for the air software,
a service alarm
occurs.

LEVEL is checked
to see that it is not
zero at power on

If it is zero,
a service alarm
occurs.

Error

Description

and

Possible Cause

One of the
following is
corrupted:

lock level
occlusion setting
default occlusion

setting
PM rate lock

ranges

Air sensor
returning too high
a value due to:

calibration error
air sensor

receiver fault

Negative volume
sampled due to:

RAM chip failure
180 degree

miscalibration of
the output shaft
encoder

The air sensor was
in an invalid state
due to:

RAM chip failure

The air sensor
received an invalid
event due to:

RAM chip failure

The air sensor
calibration values
are not within the
expected ranges
due to:

calibration error
EEPROM failure

430-600203-003 (Rev. 07/05) 6 - 14 GemStar

®

Primary

Error

(NN)

07

AIR_

SENSOR_

ERROR

08

PRESSURE_

SENSOR_

ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

005

AIR_

EXCESSIVE_

VOLUME

005

PRESS_BAD_

EVENT

006

PRESS_BAD_

STATE

007

PRESS_
DISTAL_

RANGE

008

PRESS_

PROX_

RANGE

6.3 SERVICE ALARM CODES

Error

Typ e

(TTT)

N/A The volume

Bad event # Pressure sensor

State # If processing is not

N/A When delivery is

N/A When delivery

Detection

Method

delivered between
checkpoints is
calculated each
checkpoint.

If the volume
exceeds 100
a service alarm
occurs.

software checks
events it receives
against a list of
valid events.

If a received event
is not in the list,
a service alarm
occurs.

defined for a state
value, a service
alarm occurs.

started and after
the plunger passes
home, the distal
threshold is
recomputed.

If it is not in the
0–255 range,
a service alarm
occurs.

is started, the
proximal occlusion
threshold is
recomputed.

If it is not in the
0–255 range,
a service alarm
occurs.

µL,

Error

Description

and

Possible Cause

Excessive volume
sampled due to:

RAM chip failure
180 degree

miscalibration of
the output shaft
encoder

CPU overload

The pressure
sensor received
an invalid event
due to:

RAM chip failure
Bus failure

The pressure
sensor state
variable was invalid
due to:

RAM chip failure
Bus failure

The distal pressure
is out of range
due to:

corruption
of calibration
data used
to compute
pressure

computation
error in hardware
or software

RAM error

The proximal
pressure is out
of range due to:

corruption
of calibration
data used
to compute
pressure

computation
error in hardware
or software

RAM error

Technical Service Manual 6 - 15 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

09

MOTOR_

ERROR

Supplemental

Error

(MMM)

000

MOTOR_IPRF_

ENC_OS_SYNC

Typ e

(TTT)

Step where problem
occurred

Error

Detection

Method

IPRF steps,
in general,
are expected to
begin on the pump
side of the stroke.

If the
microprocessor
misses motor
encoder counts,
the plunger will
advance further
than it should,
resulting in a
short-term
overdelivery.

Before beginning
to deliver the next
step, the software
tests the output
shaft flag position
to detect that it is
still on the pump
side of the stroke.

There are several
exceptions:

Step 0 of any
delivery

Step 7 of an
8-step delivery

Steps 13, 14,
and 15 of
a 16-step
delivery

Error

Description

and

Possible Cause

Microprocessor
misses motor
encoder counts

This error will never
be reported for
single step IPRF
(30.1 mL/hr
to 125 mL/hr).

430-600203-003 (Rev. 07/05) 6 - 16 GemStar

®

Primary

Error

(NN)

09

MOTOR_

ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

000

MOTOR_IPRF_

ENC_OS_SYNC

Typ e

(TTT)

Step where problem
occurred

6.3 SERVICE ALARM CODES

Error

Detection

Method

The last step of
a stroke frequently
overshoots its
stopping position,
near full extension,
so Step 0 often
starts on the fill
side.

If the output shaft
has the maximum
positive offset
(+10), all other
steps can be
expected to start
on the output shaft
flag.

If the output shaft
has the maximum
negative offset
(-30), any step
beginning at
a position under
186 should be
expected to start
on the output shaft
flag.

The steps that may
not start on the flag
is this case are:

Step 7 of an
8-step delivery

Steps 13, 14,
and 15 of
a 16-step
delivery

Error

Description

and

Possible Cause

Microprocessor
misses motor
encoder counts

This error will never
be reported for
single step IPRF
(30.1 mL/hr
to 125 mL/hr).

Technical Service Manual 6 - 17 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

09

MOTOR_

ERROR

Supplemental

Error

(MMM)

001

MOTOR_

BACKWARD_

MOVEMENT

Typ e

(TTT)

Type 1:

single rollback greater
than 40 counts

number of backward
encoder counts

Type 2:

excessive
accumulation
of rollbacks greater
than 16 counts

accumulated backward
counts in excess of 16

Error log data, Type 1 only:

26/000/sss
26/fff/bbb
26/ppp/aaa

Where:

sss = iprf step number
fff = forward count register

(*PACNT)
bbb = total back ticks

this stroke
ppp = distal pressure

(ADC)
aaa = distal alarm flag

(1 = alarm)
For each rollback greater

than 16 counts, error log
contains:

29/ppp/rrr
29/ccc/nnn

Where:
ppp = distal pressure

(ADC)

rrr = rollback amount, ticks
ccc = count of large

rollbacks within this
16-stroke window

nnn = net position
(forward–back counts)
at start of this step

Error

Detection

Method

Type 1:
The motor encoder

backward count
accumulator tests
the number of
counts each time
a count is
accumulated.

If the backward
count exceeds the
limit (40), a service
alarm occurs.

Type 2:
Each time the

motor is started,
if the number of
backward counts
in the previous
rollback is greater
than 16, the
amount in excess
of 16 is
accumulated.

This accumulation
is cleared every 16
strokes.

If the accumulation
exceeds 40 counts,
a service alarm
occurs.

Error

Description

and

Possible Cause

Excessive motor
backward
movement
due to:

high distal
pressure

motor clutch
failure

motor gearbox
failure

430-600203-003 (Rev. 07/05) 6 - 18 GemStar

®

Primary

Error

(NN)

09

MOTOR_

ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

002

MOTOR_NOT_

CALIBRATED

006

NO_MOTOR_

CONTROL

Typ e

(TTT)

Error type

0 = Invalid PWM
1 = Stroke volume
2 = Motor slope
4 = Output shaft offset

Error type

1 = Shorted switch FET
2 = Backward movement
3 = Motor does not turn
4 = Motor runs too fast
5 = Motor runs backward

Error log data
for 09/006/003:

24/000/iii
24/fff/ppp

Where:

iii = motor current (ADC)
fff = forward count register

(*PACNT)
ppp = distal pressure

(ADC)

6.3 SERVICE ALARM CODES

Error

Detection

Method

The motor
calibration values
are tested at
power on to verify
they are within
expected ranges.

If a value is out
of range, a service
alarm occurs.

For each new rate,
a PWM is
calculated.

If the calculated
value is less than
the minimum set
during calibration,
a service alarm
occurs.

At power on,
a motor test is
performed to verify
that, with other
motor controls set,
the motor does not
turn when the
motor switch FET
is off and that the
motor does turn
when the motor
switch FET is on.

If a test fails,
a service alarm
occurs.

Error

Description

and

Possible Cause

The motor
calibration values
are not within the
expected ranges
due to:

calibration error
EEPROM failure

The power on
motor control
test failed

independent
motor switch
FET failed

motor wiring
error

motor encoder
strobe failure

motor encoder
failure

PIC became
active (003)

PIC failure (003)

Technical Service Manual 6 - 19 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

09

MOTOR_

ERROR

Supplemental

Error

(MMM)

007

MOTOR_NOT_

PUMPING

Typ e

(TTT)

State #; Event #
The type field is displayed

as xy, where x is the state
# and y is the event #.

No movement while:

016 = Homing
036 = Stepping
046 = Continuous
066 = Ramping up

Error log data:

25/fff/bbb
25/vvv/iii
25/sss/000
25/ppp/aaa
25/nnn/ttt
25/ooo/eee
25/ddd/ccc
25/aal/prx

Where:
fff = forward count register

(*PACNT)
bbb = mticks_

back_stroke

iii = motor current (ADC)
vvv = motor voltage (ADC)
sss = motor speed (pwm)
ppp = distal pressure

(ADC)
aaa = distal alarm

local flag (1= alarm)
nnn = motor encoder

enable (1 = on)
ttt = motor encoder

strobe (1 = on)
ooo = motor drive on

(1 = on)
eee = motor drive

enable (1 = on)
ddd = distal occlusion

alarm condition (1 = on)
ccc = check cassette

alarm condition (1 = on)
aal = air alarm condition

(1 = on)
prx = proximal occlusion

alarm condition (1 = on)

Error

Detection

Method

Motor movement is
tested during ramp
up, IPRF homing,
IPRF stepping,
and continuous
delivery.

If the PWM value to
the motor reaches
200 and no
movement is
detected, a service
alarm occurs.

Error

Description

and

Possible Cause

No encoder counts
detected when the
motor is supposed
to be running
due to:

motor drive
failure

motor encoder
strobe failure

motor encoder
failure

PIC became
active

The motor was off
when it should not
be due to:

independent
motor switch
FET fails off

V+ regulator
shorted to
ground

motor circuit
open

The motor has
stalled, due to:

motor drivetrain
failure
(high torque)

high
backpressure

430-600203-003 (Rev. 07/05) 6 - 20 GemStar

®

Primary

Error

(NN)

09

MOTOR_

ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

008

MOTOR_BAD_

STATE

009

MOTOR_BAD_

EVENT

010

MOTOR_BAD_

RATE

011

MOTOR_

STACK_

ERROR

012

MOTOR_

STEP_

OVERLAP

6.3 SERVICE ALARM CODES

Error

Typ e

(TTT)

State # If the motor state

State #; Event #
The type field is displayed

as xy, where x is the state
# and y is the event #.

Error #

000 = IPRF rate: 0.1 mL/hr
001 = Continuous rate:

1000 mL/hr

002 = Taper time is zero
003 = Taper dose is zero
004 = Taper starting rate:

400 mL/hr
005 = Taper ending up

rate: 400 mL/hr
006 = Taper down starting

rate is zero
007 = Taper down dose

cannot be delivered with
the given starting rate
and taper time

Error #

001 = Stack full
002 = Stack empty
003 = Invalid stack pointer

detected when pushing
onto the stack

004 = Invalid stack pointer
detected when popping
from the stack

State #; Event #

15 = While homing
35 = While stepping

Detection

Method

variable is out of
range, a service
alarm occurs.

If event processing
is not allowed
within the current
state, a service
alarm occurs.

When a start
command is
received from
the infusion task,
the rate is verified
to be within the
acceptable range
of values.

The stack is
checked for space
available before a
state is added to
the stack and for no
data present before
a state is removed
from the stack.

If a stack request
cannot be
processed,
a service alarm
occurs.

A timer is used to
control IPRF motor
steps.

If the motor is
homing or stepping
when the timer
expires, a service
alarm occurs.

Error

Description

and

Possible Cause

The motor state
variable was invalid
due to:

RAM chip failure

The motor received
an invalid event
due to:

RAM chip failure

The motor received
an invalid rate
due to:

RAM chip failure
Bus failure

An error was
detected in
processing
the motor stack
due to:

RAM chip failure
Bus failure

A motor step did
not complete
before the next
step was requested
due to:

motor encoder
strobe failure

motor encoder
failure

motor encoder
output failure

motor clutch
failure
(high torque)

Technical Service Manual 6 - 21 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

09

MOTOR_

ERROR

Supplemental

Error

(MMM)

013

MOTOR_RATE_

CONTROL_

ERROR

014

MOTOR_BAD_

STEP_NUM

015

MOTOR_

OVERSHOT

Error

Typ e

(TTT)

Error #

001 = Initial calculation
002 = Normal operation
003 = Rate adjustment

Error log data:

27/aaa/bbb

Where:

aaa = counts steps (1 = on)
bbb = step #

Step # At the end of each

Step # of the second (last)
step that overshot

Error log data:

23/000/sss
23/mmm/nnn
23/kkk/lll
23/ggg/hhh

Where:

sss = motor PWM
mmm/nnn = NetBad2 =

(mmm*100) + nnn
NetBad2 reports the net

counts (FINE_POS)
as of the second
consecutive overshot
step reported in the

09/015 alarm
kkk/lll = NetBad1 =

(kkk * 100) + lll
NetBad1 reports the

net counts (FINE_POS)
as of the step before
the one reported in
the 09/015 alarm

ggg/hhh = NetGood =
(ggg * 100) + hhh

NetGood reports the
net counts (FINE_POS)
of the last step that was
within tolerance (two steps
before the one reported
in the 09/015 alarm)

Detection

Method

The PWM_LOW_
COUNTER value
must always be
between 0 and 10.

When tested,
if PWM_LOW_
COUNTER is ever
greater than 10,
the service alarm
results.

IPRF motor step,
the step number
is incremented and
confirmed to be
within the expected
range for that
delivery rate.

After each IPRF
step, the software
checks the actual
stopping position.

If two consecutive
steps overshoot
the stopping
position by two
points or more,
a service alarm
occurs.

Error

Description

and

Possible Cause

Error due to:

RAM chip failure
Bus failure

The motor was
performing an
invalid step
due to:

RAM chip failure
Bus failure

The motor overshot
the stopping
position, due to:

software control
error

motor encoder
strobe failure

motor encoder
failure

motor servo
failure

430-600203-003 (Rev. 07/05) 6 - 22 GemStar

®

Primary

Error

(NN)

09

MOTOR_

ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

016

MOTOR_
ENCODER_
OVERFLOW

Typ e

(TTT)

Type 1: Pulse accumulator

back counts in previous
stroke

Type 2: Output shaft scan

pulse accumulator
value

Error log data, Type 1:

22/aaa/bbb
22/ccc/ddd
22/eee/fff

Where:

aaa = IPRF step
bbb = total turns (low byte)
ccc/ddd = overflow ticks

as 256 * ccc + ddd
eee/fff = net counts

forward minus backward
as 256 * aaa + bbb

Error log data, Type 2:

28/aaa/bbb
28/ccc/ddd
28/eee/fff
28/ggg/hhh
28/iii/jjj

Where:

aaa = number of overflows
bbb = whether pulse

accumulator has
overflowed since
previous pulse
accumulator interrupt

ccc/ddd = forward limit,
as 256 * ccc + ddd

eee/fff = total forward
counts, as 256 * eee + fff

ggg/hhh = forward counts
on previous turn

iii/jjj = total turns since
starting infuser

6.3 SERVICE ALARM CODES

Error

Detection

Method

For purposes
of this alarm,
the maximum
allowed number
of forward motor
counts per output
shaft revolution
is 432 + 80 + 8*N,
where N is the
number of times
the motor stopped
on the previous
revolution.

If the forward
counts are found
to exceed this
value, a service
alarm occurs.

Error

Description

and

Possible Cause

The motor encoder
overflow count was
not cleared due to:

output shaft
sensor strobe
failure

output shaft
sensor failure

output shaft
encoder levels
out of spec.,
possibly due
to sensor
positioning;
reflectivity
of parts;
component
variations;
supply voltage
variations;
open/short in
OSE subsystem;
flag mismounted

stripped coupling
gearbox failure
other

transmission
failure

Technical Service Manual 6 - 23 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

09

MOTOR_

ERROR

Supplemental

Error

(MMM)

017

MOTOR_BAD_

RESTART

018

MOTOR_

OVER_

DELIVERY

Error

Typ e

(TTT)

N/A The motor ISR

Error

1 = Too fast
2 = Turns exceeded dose

Error log data, if error = 1:

19/aaa/bbb
19/ccc/ddd

Where:

aaa = turns observed
bbb = turns max
ccc = window duration,

seconds
ddd = dose count
Error log data, if error = 2:

19/000/aaa
19/bbb/ccc
19/ddd/eee
19/fff/ggg
19/hhh/iii

Where:

aaa = dose count
bbb/ccc/ddd/eee =

output shaft turns
limit, as:

bbb * 256 ^ 3 +
ccc * 256 ^ 2 +
ddd * 256 ^ 1+
eee * 256 ^ 0

(i.e., high byte
to low byte, and ^
is exponentiation)

fff/ggg/hhh/iii = total
observed output shaft
turns, expressed high byte
to low byte as above

Detection

Method

verifies that the
current rate is
not zero when it
receives a restart
command from the
infusion task.

Every five seconds,
the infusion safety
task tests the
number of output
shaft turns.

If the calculated
number of turns
is more than 25%
above the
expected number
of turns, a service
alarm occurs.

If this code
appears, print out
the error log from
diagnostic mode.

Error

Description

and

Possible Cause

The motor received
an invalid restart
command due to:

RAM chip failure
Bus failure

For 09/018/001
The infuser is

delivering at too
high a rate due to:

V+ regulator
fails high

motor servo
failure

software
control fault

180 degree
miscalibration
of the output
shaft encoder

The indicated rate
is above actual
rate, due to:

spurious
transitions on
output shaft

encoder
For 09/018/002
Extra turns were

detected, possibly
due to:

spurious

transitions on

output shaft

encoder

software failure

to stop motor

at end of dose

motor start

without

permission

430-600203-003 (Rev. 07/05) 6 - 24 GemStar

®

Primary

Error

(NN)

09

MOTOR_

ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

019

MOTOR_

UNDER_

DELIVERY

Typ e

(TTT)

Error

1 = Too fast
2 = Turns exceeded dose

Error log data, if error = 1:

19/pa1/pa2
19/000/sho
19/aaa/bbb
19/ccc/ddd

Where:
pa1 = PACNT_

EXTENDED (high)
pa2 = PACNT_

EXTENDED (low)

sho = short turns
000 = always zero
aaa = turns observed
bbb = turns max
ccc = window duration,

seconds
ddd = dose count
Error log data, if error = 2:

19/pa1/pa2
19/sho/aaa
19/bbb/ccc
19/ddd/eee
19/fff/ggg
19/hhh/iii

Where:
pa1 = PACNT_

EXTENDED (high)
pa2 = PACNT_

EXTENDED (low)

sho = short rev count
aaa = dose count
bbb/ccc/ddd/eee =

output shaft turns
limit, as:

bbb * 256 ^ 3 +
ccc * 256 ^ 2 +
ddd * 256 ^ 1+
eee * 256 ^ 0

(i.e., high byte
to low byte, and ^
is exponentiation)

fff/ggg/hhh/iii = total
observed output shaft
turns, expressed high byte
to low byte as above

6.3 SERVICE ALARM CODES

Error

Detection

Method

Every five seconds,
the infusion safety
task tests the
number of output
shaft turns.

If the calculated
number of turns
is more than 25%
below the expected
number of turns,
a service alarm
occurs.

If this code
appears, print out
the error log from
diagnostic mode.

Error

Description

and

Possible Cause

The infuser is
delivering at too
low a rate due to:

V+ regulator fails
low

motor servo
failure

software control
fault

Technical Service Manual 6 - 25 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

09

MOTOR_

ERROR

10

BEEPER_

ERROR

11

POWER_

SENSING_

ERROR

Supplemental

Error

(MMM)

020

MOTOR_

TAKEOFF

000 0 indicates digital signal

000

OVERVOLT_

5V

001

UNDERVOLT_

5V

Error

Typ e

(TTT)

Count of doses begun
since the infuser was
powered on

Error log data:

19/pa1/pa2
19/obs/sho

Where:
pa1 = PACNT_

EXTENDED (high)
pa2 = PACNT_

EXTENDED (low)
obs = observed turns

(low)
sho = short revs
The infuser counts each

rate change as a new
dose, except when
resuming delivery after
a purge, and during TPN
ramping.

was low and should have
been high.

1 indicates digital signal
was high and should have
been low.

ADC 5 V input reading The 5V line is

ADC 5 V input reading The 5 V line is

Detection

Method

Every two seconds
while the delivery is
not in progress, the
number of output
shaft turns is
compared with
a limit value which
is set whenever
a dose stops
(the current
number of turns
plus three).

If the number of
turns measured
exceeds this limit,
a service alarm
occurs.

At power on, when
non-infusion safety
task is initiated,
a check is
performed to
determine if the
beeper is emitting
sound.

If the signal is high
when the beeper
should be off or
low; or when the
beeper should be
on, a service alarm
is activated.

tested at power on
and once each
second.

If the voltage is
greater than
expected, a service
alarm occurs.

tested at power on
and once each
second.

If the voltage is less
than expected
a service alarm
occurs.

Error

Description

and

Possible Cause

Indicated rate is
above actual rate
due to:

spurious

transitions on

output shaft

encoder
Motor fails to stop

when expected,
due to:

software control

error

An incorrect digital
signal could
indicate that the
beeper is not
functioning
properly or that the
circuitry designed
to check the beeper
is malfunctioning.

More than 5.5 volts
measured on the
5 V line due to:

5 V regulator

failure

power sensing

circuitry failure

Less than 4.5 volts
measured on the
5 V line due to:

5 V regulator

failure

power sensing

circuitry failure

430-600203-003 (Rev. 07/05) 6 - 26 GemStar

®

Primary

Error

(NN)

11

POWER_

SENSING_

ERROR

12

STUCK_KEY

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

002

OVERVOLT_

ALK

003

OVERVOLT_

EXT

004

NO_LITHIUM

N/A Key value At power on the

ADC battery compartment
input reading

ADC external power
input reading

ADC lithium input reading The lithium battery

Typ e

(TTT)

The AA battery
input line is tested
at power on and
once each second.

If the voltage
is greater than
expected, a service
alarm occurs.

The external power
input line is tested
at power on and
once each second.

If the voltage
is greater than
expected, a service
alarm occurs.

input line is tested
at power on and
once each second.

If the voltage is less
than expected,
a service alarm
occurs.

keypad is scanned.
If a key is active,
an error message
is displayed.

If the key continues
to be active for
more than one
minute, a service
alarm occurs.

The keypad ISR
scans for key
presses and tests
each read against
the previous one.

If a key is active
continuously for
more than one
minute, a service
alarm occurs.

6.3 SERVICE ALARM CODES

Error

Detection

Method

Error

Description

and

Possible Cause

More than 3.2 volts
measured on the
battery voltage
input due to:

improper type
of batteries
installed

More than 3.6 volts
measured on
the external input
due to:

power sensing
circuitry failure

Less than 2 volts
measured on the
lithium battery input
due to:

lithium battery
discharged

lithium battery
output shorted

A stuck key press
was detected
due to:

keypad failure

Technical Service Manual 6 - 27 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

13

TIME_BASE_

ERROR

Supplemental

Error

(MMM)

000 Number of RTIs counted The number

001 Number of RTIs counted The number

Typ e

(TTT)

Error

Detection

Method

of elapsed RTIs
is tested once
each second.

If the number is
within the expected
range, the count
is zeroed.

If the number is not
within the expected
range, a service
alarm occurs.

of elapsed RTIs
is incremented
and tested once
each RTI.

If the number
exceeds the upper
limit value since the
last one second
interrupt, a service
alarm occurs.

Error

Description

and

Possible Cause

Timing error due to:

oscillator failure

RTI failure

Timing error due to:

oscillator failure

clock chip failure

IRQ interrupt

failure

430-600203-003 (Rev. 07/05) 6 - 28 GemStar

®

Primary

Error

(NN)

14

WATCHDOG_

ERROR

Table 6-4. Service Alarm Codes - Details

Supplemental

Error

(MMM)

001 Reading of PACNT At power on,

003 Task number

1 = Infusion safety
2 = Non-infusion safety
3 = Pressure
4 = Motor
5 = Display manager
6 = Not used
7 = Keypad
8 = Infusion

Typ e

(TTT)

6.3 SERVICE ALARM CODES

Error

Detection

Method

the watchdog
PIC is tested by
overstrobing it
while trying to
run the motor.

If the motor moves
more than 20
counts, a service
alarm occurs.

Various periodic
tasks update
progress counters
to indicate that they
are still running.

Other periodic
tasks check those
counters and count
the number of
checks that have
gone by without
a change in the
counter.

When the number
of checks without
change exceeds
20, a service alarm
occurs.

Error

Description

and

Possible Cause

Watchdog PIC
circuit is not
functioning,
due to:

PIC being in its
disabled mode

PIC failure
fault in

connection
between PIC
and motor power
regulator SHDN
pin

motor is being
moved by
pushing on
plunger during
PIC test

A periodic task has
stopped updating
its counter, due to:

RAM corruption
or error

task deadlock
programming

error

Technical Service Manual 6 - 29 430-600203-003 (Rev. 07/05)

SECTION 6 TROUBLESHOOTING

Table 6-4. Service Alarm Codes - Details

Primary

Error

(NN)

15

POWER_

DOWN_
ERROR

16

SOFTWARE_

ERROR

Supplemental

Error

(MMM)

N/A System state

001

INVALID_

STATE

002

KEY_EVENT_

TIMEOUT

003

INVALID_

ALARM_

SEMAPHORE

Error

Typ e

(TTT)

0 = Power on
1 = Normal operation
3 = Service alarm
4 = Power off
5 = Power down started

0 The infusion safety

Task ID The callback

Semaphore value The alarm task

Detection

Method

At power on the
system state is
tested.

If power down
processing
is completed,
power on
processing
continues.

If the system began
power down
processing,
but did not
complete it,
a service alarm
message is logged
to the history and
processing is
allowed to
continue.

If the power down
processing did not
start, a service
alarm occurs.

task tests the
air-in-line alarm
status when it
receives a start or
restart command.

If the alarm is
already active,
a service alarm
occurs.

functions failed
to send an
acknowledgement
message to
the IED task within
6 seconds after
receiving a
key-event.

verifies semaphore
values when
received.

If processing
is not defined for
a semaphore
value, a service
alarm occurs.

Error

Description

and

Possible Cause

The infuser did not
perform normal
power down
processing
due to:

hardware reset

The air-in-line
was active when
it should not be
due to:

RAM chip failure

Bus failure

Tasks are in
deadlock condition

The alarm task
received an invalid
alarm semaphore
value due to:

RAM chip failure

Bus failure

430-600203-003 (Rev. 07/05) 6 - 30 GemStar

®