Abbott Plum A Plus3 Infusion Pump - EPS-95424-001 A.T.S. 750 TOURNIQUET SYSTEM REF 60-0750-101-00 Operator & Service Manual

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ABBOTT LABORATORIES - HPD

TECHNICAL SUPPORT OPERATIONS

ELECTRONIC TECHNICAL SERVICE MANUAL

Plum A+3

Infusion Pump

EPS-95424-001 (Rev. 09/03)

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INFUSION SYSTEM

For use with list number 12348-04

Technical Service Manual

Abbott Laboratories North Chicago, IL 60064 USA

430-95424-001 (Rev. 09/03)

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This document and the subject matter disclosed herein are proprietary information. Abbott Laboratories 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 Abbott Laboratories.

430-95424-001 (Rev. 09/03) Plum A+3 Infusion System

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Change History

Part Number Description of Change

430-95424-001 (Rev. 09/03) Original issue

Technical Service Manual i 430-95424-001 (Rev. 09/03)

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CHANGE HISTORY

This page intentionally left blank.

430-95424-001 (Rev. 09/03) ii Plum A+3 Infusion System

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Section 1

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

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

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

1.3 COMPONENT DESIGNATORS . . . . . . . . . . . . . . . . . . 1-2

1.4 ACRONYMS AND ABBREVIATIONS . . . . . . . . . . . . . . . . 1-3

1.5 USER QUALIFICATION . . . . . . . . . . . . . . . . . . . . . 1-5

1.6 ARTIFACTS . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.7 INSTRUMENT INSTALLATION PROCEDURE . . . . . . . . . . . . 1-6

1.7.1 UNPACKING . . . . . . . . . . . . . . . . . . . . . . 1-6

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

1.7.3 SELF TEST. . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.8 BIOMED SETTINGS . . . . . . . . . . . . . . . . . . . . . . 1-9

1.8.1 IV PARAMETERS . . . . . . . . . . . . . . . . . . . . . 1-10

1.8.2 ALARMS LOG . . . . . . . . . . . . . . . . . . . . . . 1-12

1.8.3 SETTING THE TIME AND DATE . . . . . . . . . . . . . . . 1-13

Section 2

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

Section 3

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

Section 4

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

4.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . 4-1

4.2 ELECTRONIC SUBSYSTEM OVERVIEW . . . . . . . . . . . . . . . 4-3

4.2.1 CPU SUBSYSTEM . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.1.1 CPU . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.1.2 SYSTEM MEMORY ADDRESS MAP . . . . . . . . . . . 4-4

4.2.1.3 PROGRAMMABLE READ-ONLY MEMORY . . . . . . . . 4-4

4.2.1.4 STATIC RANDOM ACCESS MEMORY . . . . . . . . . . 4-4

4.2.1.5 CONTROL LOGIC . . . . . . . . . . . . . . . . . 4-4

4.2.1.6 LCD CONTROLLER . . . . . . . . . . . . . . . . . 4-4

4.2.1.7 LCD BACKLIGHT CONTROL . . . . . . . . . . . . . 4-5

4.2.1.8 LCD CONTRAST CONTROL. . . . . . . . . . . . . . 4-5

4.2.1.9 REAL-TIME CLOCK . . . . . . . . . . . . . . . . . 4-6

4.2.1.10 VOLTAGE MONITOR WATCHDOG TIMER . . . . . . . . 4-6

4.2.1.11 ANALOG-TO-DIGITAL CONVERTER . . . . . . . . . . 4-7

4.2.1.12 DIGITAL-TO-ANALOG CONVERTER . . . . . . . . . . 4-9

4.2.1.13 FRONT PANEL KEYPAD MATRIX . . . . . . . . . . . 4-9

4.2.1.14 FRONT PANEL [ON/OFF] KEY . . . . . . . . . . . . . 4-9

4.2.1.15 FRONT PANEL LED INDICATORS . . . . . . . . . . . 4-9

4.2.1.16 KEYPAD LOCKOUT INTERFACE . . . . . . . . . . . . 4-10

4.2.1.17 NURSE CALL INTERFACE . . . . . . . . . . . . . . 4-10

4.2.1.18 AUDIBLE INDICATORS . . . . . . . . . . . . . . . 4-10

4.2.1.19 BARCODE READER INTERFACE . . . . . . . . . . . . 4-10

4.2.1.20 DATAPORT INTERFACE . . . . . . . . . . . . . . . 4-11

4.2.1.21 POWER SUPPLY INTERFACE . . . . . . . . . . . . . 4-11

4.2.1.22 MECHANISM INTERFACE . . . . . . . . . . . . . . 4-12

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CONTENTS

4.2.2 POWER SUPPLY SUBSYSTEM . . . . . . . . . . . . . . . . 4-14

4.2.2.1 MAIN SWITCHING REGULATOR . . . . . . . . . . . 4-14

4.2.2.2 MAIN REGULATOR FAULT DETECTION . . . . . . . . 4-15

4.2.2.3 SYSTEM POWER . . . . . . . . . . . . . . . . . . 4-15

4.2.2.4 AUXILIARY SUPPLIES . . . . . . . . . . . . . . . . 4-15

4.2.2.5 POWER CONTROL . . . . . . . . . . . . . . . . . 4-16

4.2.2.6 BATTERY VOLTAGE MEASUREMENT . . . . . . . . . 4-16

4.2.2.7 BATTERY CHARGE/DISCHARGE CURRENT

MEASUREMENT . . . . . . . . . . . . . . . . . . 4-17

4.2.2.8 BATTERY CHARGER . . . . . . . . . . . . . . . . 4-17

4.2.3 MECHANISM SUBSYSTEM . . . . . . . . . . . . . . . . . 4-17

4.2.3.1 MOTORS/MOTOR DRIVE . . . . . . . . . . . . . . 4-18

4.2.3.2 MOTOR POSITION SENSORS . . . . . . . . . . . . . 4-19

4.2.3.3 V2_5 REFERENCE VOLTAGE . . . . . . . . . . . . . 4-20

4.2.3.4 AIR SENSORS . . . . . . . . . . . . . . . . . . . 4-20

4.2.3.5 PRESSURE SENSORS . . . . . . . . . . . . . . . . 4-21

4.2.3.6 PRESSURE SENSOR CALIBRATION . . . . . . . . . . 4-23

4.2.3.7 CASSETTE TYPE/PRESENCE SELECTION. . . . . . . . . 4-23

4.2.3.8 SERIAL EEPROM . . . . . . . . . . . . . . . . . . 4-23

4.3 PRINTED WIRING ASSEMBLIES . . . . . . . . . . . . . . . . . 4-24

4.3.1 POWER SUPPLY PWA . . . . . . . . . . . . . . . . . . . 4-24

4.3.2 PERIPHERAL PWA . . . . . . . . . . . . . . . . . . . . 4-25

4.3.3 PERIPHERAL/INTERFACE PWA . . . . . . . . . . . . . . . 4-25

4.3.4 CPU PWA . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4.3.5 DRIVER PWA . . . . . . . . . . . . . . . . . . . . . . 4-26

4.3.6 SWITCH PWA . . . . . . . . . . . . . . . . . . . . . . 4-27

4.3.7 APP PWA . . . . . . . . . . . . . . . . . . . . . . . . 4-27

4.4 REMOTE MOUNTED PERIPHERALS . . . . . . . . . . . . . . . . 4-28

4.4.1 LCD . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

4.4.2 SEALED LEAD ACID BATTERY . . . . . . . . . . . . . . . 4-28

4.4.3 BARCODE READER WAND . . . . . . . . . . . . . . . . . 4-28

4.5 MECHANICAL OVERVIEW . . . . . . . . . . . . . . . . . . . 4-28

4.5.1 CASSETTE . . . . . . . . . . . . . . . . . . . . . . . 4-29

4.5.2 MECHANISM ASSEMBLY . . . . . . . . . . . . . . . . . 4-31

4.5.2.1 MOTOR AND VALVE ASSEMBLIES. . . . . . . . . . . 4-31

4.5.2.2 A/B VALVE SUBSYSTEM . . . . . . . . . . . . . . . 4-32

4.5.2.3 INLET/OUTLET VALVE SUBSYSTEM . . . . . . . . . . 4-33

4.5.2.4 PLUNGER DRIVE SUBSYSTEM . . . . . . . . . . . . 4-33

Section 5

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

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

5.1.1 INSPECTING THE INFUSION PUMP . . . . . . . . . . . . . 5-1

5.1.2 CLEANING THE INFUSION PUMP . . . . . . . . . . . . . . 5-1

5.1.3 SANITIZING THE INFUSION PUMP. . . . . . . . . . . . . . 5-2

5.2 PERFORMANCE VERIFICATION TEST . . . . . . . . . . . . . . . 5-3

5.2.1 EQUIPMENT REQUIRED . . . . . . . . . . . . . . . . . . 5-3

5.2.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.3 TEST SETUP . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.4 SELF TEST . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.2.5 CASSETTE ALARM TEST . . . . . . . . . . . . . . . . . . 5-6

5.2.6 FREE FLOW TEST . . . . . . . . . . . . . . . . . . . . . 5-7

5.2.7 DISPLAY TEST . . . . . . . . . . . . . . . . . . . . . . 5-7

5.2.8 KEYPAD VERIFICATION/FUNCTIONAL TEST . . . . . . . . . . 5-7

5.2.9 ALARM LOUDNESS TEST . . . . . . . . . . . . . . . . . 5-8

5.2.10 LOCKOUT SWITCH TEST. . . . . . . . . . . . . . . . . . 5-9

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CONTENTS

5.2.11 PROXIMAL OCCLUSION TEST . . . . . . . . . . . . . . . . 5-10

5.2.12 PROXIMAL AIR-IN-LINE TEST . . . . . . . . . . . . . . . . 5-10

5.2.13 DISTAL AIR-IN-LINE TEST . . . . . . . . . . . . . . . . . 5-11

5.2.14 DISTAL OCCLUSION TEST . . . . . . . . . . . . . . . . . 5-12

5.2.15 DELIVERY ACCURACY TEST . . . . . . . . . . . . . . . . 5-13

5.2.16 ELECTRICAL SAFETY TEST . . . . . . . . . . . . . . . . . 5-14

5.2.17 END OF THE PVT . . . . . . . . . . . . . . . . . . . . . 5-14

5.3 BARCODE READER WAND TEST (OPTIONAL) . . . . . . . . . . . . 5-15

5.4 NURSE CALL TEST (OPTIONAL) . . . . . . . . . . . . . . . . . 5-15

5.5 PERIODIC MAINTENANCE INSPECTION . . . . . . . . . . . . . . 5-15

5.6 BATTERY OPERATION OVERVIEW . . . . . . . . . . . . . . . . 5-16

Section 6

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

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

6.2 ALARM MESSAGES AND ERROR CODES . . . . . . . . . . . . . . 6-1

6.2.1 OPERATIONAL ALARM MESSAGES . . . . . . . . . . . . . 6-2

6.2.2 ERROR CODES REQUIRING TECHNICAL SERVICE . . . . . . . . 6-6

6.3 TROUBLESHOOTING PROCEDURES. . . . . . . . . . . . . . . . 6-11

Section 7

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

7.1 REPLACEABLE PARTS . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . 7-3

7.2.1 SAFETY AND EQUIPMENT PRECAUTIONS . . . . . . . . . . . 7-3

7.2.2 REQUIRED TOOLS AND MATERIALS . . . . . . . . . . . . . 7-3

7.2.3 RUBBER FOOT PAD REPLACEMENT . . . . . . . . . . . . . 7-4

7.2.4 BATTERY ASSEMBLY, BATTERY DOOR,

AND BATTERY DOOR PAD REPLACEMENT. . . . . . . . . . . 7-5

7.2.5 AC (MAINS) POWER CORD, POWER CORD RETAINER,

AND VELCRO RETAINER STRAP REPLACEMENT . . . . . . . . 7-6

7.2.6 SEPARATING THE FRONT ENCLOSURE, REAR ENCLOSURE,

AND MAIN CHASSIS ASSEMBLY . . . . . . . . . . . . . . . 7-7

7.2.7 PERIPHERAL/INTERFACE ASSEMBLY REPLACEMENT . . . . . . 7-9

7.2.8 PERIPHERAL PWA REPLACEMENT . . . . . . . . . . . . . . 7-9

7.2.9 PERIPHERAL/INTERFACE ASSEMBLY COMPONENT

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 7-11

7.2.9.1 VOLUME CONTROL KNOB REPLACEMENT . . . . . . . 7-11

7.2.9.2 PERIPHERAL ASSEMBLY COVER AND ESD SPRING

REPLACEMENT . . . . . . . . . . . . . . . . . . 7-11

7.2.10 FRONT/REAR ENCLOSURE GASKET REPLACEMENT . . . . . . . 7-13

7.2.11 LOWER FRONT ENCLOSURE ASSEMBLY GASKET REPLACEMENT . . 7-13

7.2.11.1 EMI GASKET REPLACEMENT . . . . . . . . . . . . . 7-14

7.2.11.2 KEYPAD GASKET REPLACEMENT . . . . . . . . . . . 7-15

7.2.11.3 TOP SEAL GASKET REPLACEMENT . . . . . . . . . . 7-15

7.2.12 REAR ENCLOSURE ASSEMBLY COMPONENT REPLACEMENT . . . 7-16

7.2.12.1 POLE CLAMP ASSEMBLY AND POLE CLAMP

BACKING PLATE REPLACEMENT . . . . . . . . . . . 7-17

7.2.12.2 INTERNAL AC POWER CORD REPLACEMENT . . . . . . 7-18

7.2.12.3 POLE CLAMP GROUND WIRE REPLACEMENT . . . . . . 7-18

7.2.12.4 AC (MAINS) CONNECTOR REPLACEMENT . . . . . . . . 7-19

7.2.12.5 FUSE REPLACEMENT . . . . . . . . . . . . . . . . 7-19

7.2.12.6 REAR ENCLOSURE GASKET REPLACEMENT . . . . . . . 7-20

7.2.13 MINIPOLE ASSEMBLY REPLACEMENT . . . . . . . . . . . . 7-20

7.2.13.1 COTTER RING REPLACEMENT . . . . . . . . . . . . 7-21

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CONTENTS

7.2.13.2 BAG HANGER REPLACEMENT . . . . . . . . . . . . 7-22

7.2.13.3 CLUTCH HOUSING REPLACEMENT . . . . . . . . . . 7-22

7.2.13.4 CLUTCH SPRING REPLACEMENT . . . . . . . . . . . 7-22

7.2.14 MAIN CHASSIS ASSEMBLY COMPONENT REPLACEMENT . . . . 7-23

7.2.14.1 POWER SUPPLY PWA REPLACEMENT. . . . . . . . . . 7-24

7.2.14.2 KEYPAD REPLACEMENT. . . . . . . . . . . . . . . 7-25

7.2.14.3 LCD REPLACEMENT . . . . . . . . . . . . . . . . 7-26

7.2.14.4 CPU/DRIVER CABLE REPLACEMENT . . . . . . . . . . 7-27

7.2.14.5 MOTOR POWER CABLE REPLACEMENT. . . . . . . . . 7-30

7.2.14.6 CPU PWA REPLACEMENT . . . . . . . . . . . . . . 7-30

7.2.14.7 PIEZO ALARM ASSEMBLY REPLACEMENT. . . . . . . . 7-31

7.2.14.8 MECHANISM ASSEMBLY REPLACEMENT . . . . . . . . 7-32

7.2.14.9 CASSETTE DOOR AND FLUID SHIELD REPLACEMENT . . . 7-32

7.2.14.10 OPENER HANDLE ASSEMBLY REPLACEMENT . . . . . . 7-34

Section 8

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

Section 9

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

Section 10

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Figures

Figure 1-1. LCD and Keypad . . . . . . . . . . . . . . . . . . . . . . 1-8

Figure 1-2. Biomed Settings . . . . . . . . . . . . . . . . . . . . . . 1-9

Figure 1-3. IV Parameters . . . . . . . . . . . . . . . . . . . . . . . 1-11

Figure 1-4. Alarms Log . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Figure 1-5. Setting the Time and Date. . . . . . . . . . . . . . . . . . . 1-13

Figure 1-6. Common IV Parameters . . . . . . . . . . . . . . . . . . . 1-14

Figure 1-7. Macro IV Parameters . . . . . . . . . . . . . . . . . . . . 1-14

Figure 4-1. Electronic Functional Diagram . . . . . . . . . . . . . . . . . 4-2

Figure 4-2. Serial Interface to ADC. . . . . . . . . . . . . . . . . . . . 4-8

Figure 4-3. System Startup and Shutdown Timing, Battery Powered. . . . . . . . 4-16

Figure 4-4. Stepper Motor Coils . . . . . . . . . . . . . . . . . . . . . 4-18

Figure 4-5. Air Sensor Block Diagram. . . . . . . . . . . . . . . . . . . 4-20

Figure 4-6. Pressure Sensor Excitation and Amplifier Block Diagram . . . . . . . 4-22

Figure 4-7. Major Elements of the Dual-Channel Cassette . . . . . . . . . . . 4-30

Figure 4-8. Fluid Path in the Cassette . . . . . . . . . . . . . . . . . . . 4-31

Figure 4-9. Mechanism Valve Pins and Sensor Locations . . . . . . . . . . . . 4-32

Figure 5-1. LCD and Keypad . . . . . . . . . . . . . . . . . . . . . . 5-6

Figure 5-2. Rear Enclosure and Peripheral/Interface Assembly . . . . . . . . . . 5-9

Figure 5-3. Special Cassettes with Bubble Sensor Tips Removed . . . . . . . . . 5-11

Figure 5-4. Distal Occlusion Test Setup . . . . . . . . . . . . . . . . . . 5-13

Figure 7-1. Bottom View . . . . . . . . . . . . . . . . . . . . . . . 7-4

Figure 7-2. AC (Mains) Power Cord, Power Cord Retainer, Velcro Retainer Strap,

and Battery Assembly Replacement . . . . . . . . . . . . . . . 7-6

Figure 7-3. Separating the Front Enclosure, Rear Enclosure, and Main Chassis

Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7-8

430-95424-001 (Rev. 09/03) vi Plum A+3 Infusion System

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CONTENTS

Figure 7-4. Screw Placement Sequence . . . . . . . . . . . . . . . . . . 7-8

Figure 7-5. Peripheral/Interface PWA and Peripheral PWA Replacement . . . . . . 7-10

Figure 7-6. Peripheral/Interface Assembly Component Replacement . . . . . . . . 7-12

Figure 7-7. Lower Front Enclosure Gasket Replacement . . . . . . . . . . . . 7-14

Figure 7-8. External Rear Enclosure Assembly Components . . . . . . . . . . . 7-16

Figure 7-9. Internal Rear Enclosure Assembly Components . . . . . . . . . . . 7-17

Figure 7-10. Minipole Assembly . . . . . . . . . . . . . . . . . . . . . 7-21

Figure 7-11. Main Chassis Components . . . . . . . . . . . . . . . . . . 7-23

Figure 7-12. CPU/Driver Cable Routing . . . . . . . . . . . . . . . . . . 7-28

Figure 7-13. Ferrite Tape Positioning . . . . . . . . . . . . . . . . . . . 7-29

Figure 7-14. Fluid Shield Replacement . . . . . . . . . . . . . . . . . . . 7-33

Figure 7-15. Cassette Door and Opener Handle Assembly Replacement . . . . . . . 7-35

Figure 9-1. Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . 9-5

Figure 9-2. Front Enclosures, Rear Enclosure, and Main Chassis Assemblies . . . . . 9-9

Figure 9-3. Front Enclosure Assemblies . . . . . . . . . . . . . . . . . . 9-11

Figure 9-4. Rear Enclosure Assembly . . . . . . . . . . . . . . . . . . . 9-13

Figure 9-5. Peripheral/Interface Assembly . . . . . . . . . . . . . . . . . 9-17

Figure 9-6. Main Chassis Assembly . . . . . . . . . . . . . . . . . . . 9-19

Figure 9-7. CPU PWA, LCD, and Keypad . . . . . . . . . . . . . . . . . 9-23

Figure 9-8. CPU PWA and Main Chassis . . . . . . . . . . . . . . . . . . 9-25

Figure 9-9. AC Power Cord, Power Cord Retainer, Batteries, and Minipole Assembly . . 9-27

Figure 9-10. Mechanism Assembly . . . . . . . . . . . . . . . . . . . . 9-29

Figure 9-11. Power Supply PWA Schematic . . . . . . . . . . . . . . . . . 9-31

Figure 9-12. Peripheral/Interface PWA Schematic . . . . . . . . . . . . . . . 9-51

Figure 9-13. Peripheral PWA Schematic . . . . . . . . . . . . . . . . . . 9-63

Figure 9-14. CPU PWA Schematic. . . . . . . . . . . . . . . . . . . . . 9-71

Figure 9-15. Driver PWA Schematic . . . . . . . . . . . . . . . . . . . . 9-91

Figure 9-16. Switch PWA Schematic . . . . . . . . . . . . . . . . . . . . 9-97

Figure 9-17. APP PWA Schematic. . . . . . . . . . . . . . . . . . . . . 9-99

Tables

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

Table 1-2. System Configuration Data . . . . . . . . . . . . . . . . . . 1-10

Table 4-1. Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . 4-8

Table 4-2. Keypad Map. . . . . . . . . . . . . . . . . . . . . . . . 4-9

Table 4-3. CPU-Power Supply Interface . . . . . . . . . . . . . . . . . . 4-11

Table 4-4. CPU-Mechanism Interface Signals . . . . . . . . . . . . . . . . 4-12

Table 4-5. Power Supply PWA Interface Connections . . . . . . . . . . . . . 4-24

Table 4-6. Peripheral PWA Interface Connections . . . . . . . . . . . . . . 4-25

Table 4-7. Peripheral/Interface PWA Interface Connections. . . . . . . . . . . 4-25

Table 4-8. CPU PWA Interface Connections . . . . . . . . . . . . . . . . 4-26

Table 4-9. Driver PWA Interface Connections. . . . . . . . . . . . . . . . 4-27

Table 4-10. APP PWA Interface Connections . . . . . . . . . . . . . . . . 4-27

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

Table 6-1. Operational Alarm Messages and Corrective Actions . . . . . . . . . 6-2

Table 6-2. Error Codes Requiring Technical Service . . . . . . . . . . . . . 6-6

Table 6-3. Troubleshooting with the PVT . . . . . . . . . . . . . . . . . 6-11

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

Table 9-2. IPB for the Infusion Pump. . . . . . . . . . . . . . . . . . . 9-2

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Page 11

CONTENTS

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Page 12

Section 1

INTRODUCTION

The Plum A+3™ Infusion System is designed to meet the growing demand for hospital wide device standardization. The Plum A+3 consists of three component pumps which are designated line 1, line 2, and line 3. By incorporating three lines into one unit, the infusion system provides three primary lines, three secondary lines, and piggyback fluid delivery capabilities. The Plum A+3 serves a wide range of general floor and critical care needs. Compatibility with the LifeCare the Plum A+3 infusion system convenient and cost-effective.

1.1

SCOPE

This manual is organized into 11 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

❏ Section 10 Index

❏ Technical Service Bulletins

5000 PlumSet® administration sets and accessories make

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

contact Abbott Laboratories (see Section 6.1, Technical Assistance).

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

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

Therefore, figures may not exactly reflect the product.

 Note: Screen representations in this manual are examples only, and do not necessarily

reflect the most current software version.

Technical Service Manual 1 - 1 430-95424-001 (Rev. 09/03)

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SECTION 1 INTRODUCTION

1.2

CONVENTIONS

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

Table 1-1. Conventions

Convention Application Example

Italic Reference to a section, figure,

table, or publication

[ALL CAPS]

[Lowercase]

ALL CAPS Screen displays CASSETTE TEST IN PROGRESS

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.

In-text references to keys and touchswitches

In-text references to softkeys

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)

[START]

[Choose]

techniques when handling components.

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

1.3

COMPONENT DESIGNATORS

Components are indicated by alpha-numeric designators, as follows:

Battery BT Diode D Resistor R

Capacitor C Fuse F Switch SW

Crystal Y Integrated Circuit U Transistor Q

The number following the letter is a unique value for each type of component (e.g., R1, R2).

 Note: Alpha-numeric designators may be followed with a dash (-) number that

indicates a pin number for that component. For example, U15-13 is pin 13 of the encoder chip [U15] on the interface PWA.

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1.4 ACRONYMS AND ABBREVIATIONS

1.4

ACRONYMS AND ABBREVIATIONS

Acronyms and abbreviations used in this manual are as follows:

A Ampere

AC Alternating current

A/D Analog-to-digital

ADC Analog-to-digital converter

APP Air, pressure, and pin

BCR Barcode reader

CCFT Cold cathode fluorescent tube

CMOS Complementary metal-oxide semiconductor

CPU Central processing unit

DAC Digital-to-analog converter

DC Direct current

DIP Dual in-line package

DMA Direct memory access

DMM Digital multimeter

DPM Digital pressure meter

ECG Electrocardiograph

EEG Electroencephalogram

EEPROM Electrically erasable/programmable read-only memory

EMG Electromyogram

EMI Electromagnetic interference

ESD Electrostatic discharge

ETO Ethylene oxide

FPGA Field programmable gate array

FSR Force sensing resistor

hr Hour

Hz Hertz

ID Identification

I/O Input/output

IPB Illustrated parts breakdown

IV Intravenous

KB Kilobyte

kHz Kilohertz

KVO Keep vein open

lbs Pounds

LCD Liquid crystal display

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SECTION 1 INTRODUCTION

MOSFET Metal-oxide semiconductor field-effect transistor

Op-amp Operational amplifier

LED Light emitting diode

L/S Line select

mA Milliampere

MB Megabyte

MHz Megahertz

min Minute

mL Milliliter

mL/hr Milliliter per hour

MMIO Memory-mapped input/output

ms Millisecond

mV Millivolt

N/A Not applicable

PROM Programmable read-only memory

psi Pounds per square inch

PVT Performance verification test

PWA Printed wiring assembly

PWB Printed wiring board

PWM Pulse width modulator

RAM Random-access memory

rms Root-mean-square

ROM Read-only memory

RTC Real-time clock

SCC Serial communication controller

SCP Serial communication port

SLA Sealed lead acid

SMT Surface mount technology

SPI Serial peripheral interface

SRAM Static random access memory

TQFP Thin quad flat pack

V Volt

Volts AC

Collector supply voltage

VCO Voltage-controlled oscillator

Volts DC

VSC 5 V

supply circuitry

VSO Voltage sweep oscillator

VTBI Volume to be infused

WDI Watchdog input

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1.5 USER QUALIFICATION

1.5

USER QUALIFICATION

The Plum A+3 infusion system 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 pump and the administration of parenteral and enteral fluids and drugs, and whole blood or red blood cell components. Training should emphasize preventing related IV complications, including appropriate precautions to prevent accidental infusion of air. The epidural route can be used to provide anesthesia or analgesia.

1.6

ARTIFACTS

Nonhazardous, low-level electrical potentials are commonly observed when fluids are administered using infusion devices. These potentials are well within accepted safety standards, but may create artifacts on voltage-sensing equipment such as ECG, EMG, and EEG machines. These artifacts vary at a rate that is associated with the infusion rate. If the monitoring machine is not operating correctly or has loose or defective connections to its sensing electrodes, these artifacts may be accentuated so as to simulate actual physiological signals. To determine if the abnormality in the monitoring equipment is caused by the pump instead of some other source in the environment, set the pump so that it is temporarily not delivering fluid. Disappearance of the abnormality indicates that it was probably caused by electronic noise generated by the pump. Proper setup and maintenance of the monitoring equipment should eliminate the artifact. Refer to the appropriate monitoring system documentation for setup and maintenance instructions.

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SECTION 1 INTRODUCTION

1.7

INSTRUMENT INSTALLATION PROCEDURE

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

CAUTION: Infusion pump performance may be degraded by electromagnetic interference (EMI) from devices such as electrosurgical units, cellular phones, and two-way radios. Operation of the infusion pump under such conditions should be avoided.

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

 Note: Do not place the infusion pump in service if the battery is not fully charged.

To make certain the battery is fully charged, connect the infusion pump to AC power for six hours (see Section 8, Specifications).

1.7.1

UNPACKING

Inspect the shipping container as detailed in Section 1.7.2, Inspection. Use care when unpacking the infusion pump. Retain the packing slip and save all packing material in the event it is necessary to return the Plum A+3 to the factory. Verify the shipping container contains a copy of the system operating manual.

1.7.2

INSPECTION

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

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

Inspect the infusion pump periodically for signs of defects such as worn accessories, broken connections, or damaged cable assemblies. Also inspect the infusion pump after repair or during cleaning. Replace any damaged or defective external parts.

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1.7 INSTRUMENT INSTALLATION PROCEDURE

1.7.3

SELF TEST

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

 Note: If an alarm condition occurs during the self test, cycle the power and repeat

the self test. If the alarm condition recurs, note the message and take corrective action

(see Section 6, Troubleshooting). Repeat the self test. If the alarm condition recurs,

remove the Plum A+3 infusion system from service and contact Abbott Laboratories.

 Note: When performing the self test, line 1, line 2, and line 3 must be tested.

However, if appropriate, the test may be performed on all lines concurrently.

To perform the self test, refer to Figure 1-1, LCD and Keypad, and proceed as follows:

1. Connect the AC power cord to a grounded AC outlet. Verify the charging/line

indicator CHARGE illuminates and an alarm beep sounds.

2. Without a cassette installed, press [ON/OFF] to turn on the pump.

3. The LCD briefly displays the SELF TEST screen. Verify the screen display matches

Figure 1-1.

 Note: If the SELF TEST screen does not appear, contact Abbott Laboratories.

4. After the self test is complete, the message “INSERT PLUM SET CLOSE LEVER” appears. Press the decimal [.] key, then [START].

5. Using the [SELECT] arrow keys, select Set Time and Date, and press the [Choose] softkey.

6. Verify the time, year, month, and day are correct. If any parameters are incorrect, refer to Section 1.8.3, Setting the Time and Date.

7. Press [ON/OFF] to exit the SET TIME AND DATE screen.

8. Press [ON/OFF] to turn the pump back on.

9. Open the cassette door and insert a primed cassette. Close the cassette door. The cassette test is complete when the “CASSETTE TEST IN PROGRESS” message disappears.

 Note: The message “MECHANISM INITIALIZATION IN PROGRESS” may briefly

appear prior to the “CASSETTE TEST IN PROGRESS” message.

10. If previously entered programming exists, the “CLEAR SETTINGS?” message appears. Press the [Yes] softkey to clear the settings.

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SECTION 1 INTRODUCTION

LINE FLOW

INDICATORS

ABBOTT Plum A+

STATUS REGION

MESSAGE REGION

SOFTKEY LABEL REGION

LINE INDICATOR

START

STOP

CHARGE

ON OFF

Release XX.X - MM/DD/YY

2002

System Self Test

In Pr

gress

1 4

CLEAR

2 5

3 6

WORKING

REGION

SOFTKEYS

SELECT

KEYPAD

SILENCE

98G01002

Figure 1-1. LCD and Keypad

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1.8 BIOMED SETTINGS

1.8

BIOMED SETTINGS

The biomed settings screens contain the following options that can be changed or reviewed by qualified personnel:

❏ IV screen parameters

❏ Alarms log

❏ Set time and date

 Note: All Plum A+3 infusion devices (new or refurbished) are shipped with factory

settings (see Table 1-2, System Configuration Data).

 Note: Biomed screens do not time out for the Infuser Idle alarm or No Action alarm.  Note: The battery will not be detected in the biomed service mode (see Section 6.2.2,

Error Codes Requiring Technical Service).

To access the service mode, refer to Figure 1-1, then proceed as follows:

1. Open the door and press [ON/OFF] to turn on the pump.

2. After the self test is complete, the message “INSERT PLUM SET CLOSE LEVER”

appears. Press the decimal [.] key, then [START], and verify the BIOMED SETTINGS screen is displayed (see Figure 1-2, Biomed Settings).

BIOMED SETTINGS

IV Screen Parameters

Alarms Log

Set Time and Date

Select, then Choose

Choose

00H03002

Figure 1-2. Biomed Settings

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SECTION 1 INTRODUCTION

Data Options Range Factory Setting

Table 1-2. System Configuration Data

Maximum macro IV mode delivery rate 0.1 - 99.9 mL/hr and

100 - 999 mL/hr

Macro distal occlusion alarm (pressure level)

Deliver together enable Concurrent or Piggyback Piggyback

Delayed start/standby enable Yes or No Yes

Continue rate Rate or KVO KVO

Nurse callback default Yes or No No

Time (24 hr) 00:00 - 23:59 in

Date 1/1/2002 - 12/31/2098 Factory date

1 to 15 psi 6.0 psi

one minute increments

999 mL/hr

Factory time

1.8.1

IV PARAMETERS

Refer to Figure 1-3, IV Parameters. The IV parameters screen contains the following:

❏ Common IV parameters

❏ Macro IV parameters

To change the IV parameters, refer to Figure 1-6, Common IV Parameters, and Figure 1-7,

Macro IV Parameters, then proceed as follows:

1. Access the biomed settings screen as described in Section 1.8.

2. Using the [SELECT] arrow keys, select IV Screen Parameters, and press [Choose].

3. Using the [SELECT] arrow keys, select the parameters to be changed, and press [Choose].

4. Using the [Change Value] softkey, select the desired value, and press [ENTER].

5. Repeat Steps 3 and 4 for each parameter to be changed.

6. If there are no other changes, press [ON/OFF] to power off the infusion device.

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Page 22

BIOMED SETTINGS

IV Parameters

Common IV Parameters

Macro IV Parameters

1.8 BIOMED SETTINGS

Select, then Choose

Figure 1-3. IV Parameters

Choose Back

00H03003

Technical Service Manual 1 - 11 430-95424-001 (Rev. 09/03)

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SECTION 1 INTRODUCTION

1.8.2

ALARMS LOG

To view the alarms log, refer to Figure 1-2 and Figure 1-4, Alarms Log, then proceed as follows:

1. Access the biomed settings screen as described in Section 1.8.

2. Using the [SELECT] arrow keys, select Alarms Log, and press [Choose}.

3. Use the [Page Up] and [Page Down] softkeys to view the alarms log.

4. Press the [Back] softkey to exit the alarms log and return to the main biomed settings screen.

 Note: The alarms log will retain the latest 40 alarm and malfunction codes, listed

in order from the most current to the oldest.

ALARMS LOG

6/23/03 01:43 E437 S/W Failure # 202

6/23/03 09:18 N190 Neg. Prox. Occl. A

6/22/03 23:44 N102 Infuser Idle 2 minutes

6/22/03 21:43 N161 Line A VTBI complete

6/22/03 11:44 N106 Distal occlusion

6/22/03 09:43 N161 Line A VTBI complete

6/22/03 06:23 N160 Line B VTBI complete

6/22/03 03:40 N101 No action alarm

Page

Figure 1-4. Alarms Log

Page

Down

Back

02H03008

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Page 24

1.8 BIOMED SETTINGS

1.8.3

SETTING THE TIME AND DATE

To set the time and date, refer to Figure 1-2 and Figure 1-5, Setting the Time and Date, then proceed as follows:

 Note: The Plum A+3 will automatically display February 29 on leap years.  Note: Daylight savings and time zone changes must be made manually.

1. Access the biomed settings screen as described in Section 1.8.

2. Using the [SELECT] arrow keys, select Set Time and Date, and press [Choose].

3. Using the [SELECT] arrow keys, select the parameter to be changed.

4. Using the numerical keypad, enter the desired value, and press [Enter].

5. Repeat Steps 3 and 4 for each parameter to be changed.

6. If there are no other changes, press [ON/OFF] to power off the infusion device.

BIOMED SETTINGS

Set Time and Date

Time : 15 hr:min Year Month Day

Enter value using keypad

2003

Figure 1-5. Setting the Time and Date

Enter

Cancel/

Back

00K13004

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SECTION 1 INTRODUCTION

BIOMED SETTINGS

Common IV Parameters

Continue Rate Deliver Together Enable Delay/Standby

KVO

Concurrent

Yes

Callback Default

Select using Change Value

Change

Value

Figure 1-6. Common IV Parameters

Enter

Cancel/

BIOMED SETTINGS

Macro IV Parameters

Back

02K03004

Default Distal Press Max Rate

Enter Value using keypad

Enter

Figure 1-7. Macro IV Parameters

6.0 psi

999 mL/hr

Cancel/

Back

00K13005

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Page 26

Section 2

WARRANTY

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

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

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

The foregoing warranty shall also be void in the event any person, including the Purchaser, performs or attempts to perform any major repair or other service on the product without having been trained by an authorized representative of Abbott and using Abbott documentation and approved spare parts. For purposes of the preceding sentence, "major repair or other service" means any repair or service other than the replacement 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, Abbott shall have no responsibility or liability for the actions or inactions of the person performing such repair or service, regardless of whether such person has been trained to perform such repair or service. It is understood and acknowledged that any person other than an Abbott representative performing repair or service is not an authorized agent of Abbott.

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SECTION 2 WARRANTY

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Section 3

SYSTEM OPERATING MANUAL

A copy of the system operating manual is included with every Plum A+3 infusion system. Insert a copy here for convenient reference. If a copy of the system operating manual is not available, contact Abbott Laboratories Technical Support Operations

(see Section 6.1, Technical Assistance).

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SECTION 3 SYSTEM OPERATING MANUAL

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Section 4

THEORY OF OPERATION

This section describes the Plum A+3 infusion system theory of operation. Related drawings are provided in Section 9, Drawings. The theory of operation details the general description, electronic subsystem overview, printed wiring assemblies (PWA), remote mounted peripherals, and mechanical overview of the infusion pump.

4.1

GENERAL DESCRIPTION

The infusion system consists of three component pumps which are designated line 1, line 2, and line 3. Each line includes the following features:

- Dose calculation

- Loading dose

- Multi-step programming

- Therapy selection

- Nurse call

- Delayed start setting

- Standby mode

- Drug label library

- Piggyback and concurrent

delivery modes

- Titration

- 0.1-99.9 mL/hr flow rate range

for both lines (in 0.1 mL/hr increments)

- 100-999 mL/hr flow rate range

for both lines (in 1.0 mL/hr increments)

- Anti free-flow protection

- Air removal/backpriming

- Battery gauge

- Long battery life (6 hours) for

emergency backup and temporary portable operation

- Air detection (proximal and distal)

- Serial communication

- Alarm history

- Plug-in barcode reader

for drug identification (optional)

- Volumes infused

(A, B, total volumes)

- KVO at dose end (1.0 mL/hr

or less depending on delivery rate) or continue rate to continue

- Variable distal pressure setting

- Nonpulsatile volumetric accuracy

- Microprocessor control

- Large LCD

- Panel back illumination

on mains power

- Lockout switch

- Standard fullfill, partfill, syringe,

and vial use

- Enteral and parenteral fluid delivery

- Blood and blood product delivery

- Wide range of standard and

specialty administration sets

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SECTION 4 THEORY OF OPERATION

Alarms include the following:

- Distal occlusion

- Proximal occlusion

- Proximal air-in-line

- Distal air-in-line

- Low battery

- Door open while pumping

Battery

Pressure Sensors

Plunger, LS, & IO Motors

MECHANISM

SYSTEM 1

Power Supply PWA

APP PWA

Switches PWA

Flex FSR

Driver PWA

- Lockout violation

- VTBI complete

- Valve/cassette test failure

- Nurse call

- No action alarm

- Infuser idle for two minutes

Peripheral PWA

LCD Display

CPU PWA

Keypad

LEDs

On/Off Switch

FRONT PANEL

Main Piezo Buzzer

Battery

Pressure Sensors

SYSTEM 2

Battery

Pressure Sensors

SYSTEM 3

PLUM A+3

Power Supply PWA

APP PWA

Switches PWA

Flex FSR

Plunger, LS, & IO Motors

MECHANISM

Power Supply PWA

APP PWA

Switches PWA

Flex FSR

Plunger, LS, & IO Motors

MECHANISM

Driver

PWA

Driver

PWA

CPU PWA

Main Piezo Buzzer

Interface/Peripheral PWA

Figure 4-1. Electronic Functional Diagram

Peripheral PWA

LCD Display

Keypad

LEDs

On/Off Switch

FRONT PANEL

LCD Display

Keypad

LEDs

On/Off Switch

FRONT PANEL

Main Piezo Buzzer

Lockout Switch Volume Control Nurse Call Jack Barcode Reader DataPort

Driver

PWA

01K07015

430-95424-001 (Rev. 09/03) 4 - 2 Plum A+3 Infusion System

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4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2

ELECTRONIC SUBSYSTEM OVERVIEW

This section describes the function and electronic circuitry (see Figure 4-1, Electronic

Functional Diagram) of three main subsystems in the infusion pump: CPU subsystem,

power supply subsystem, and mechanism subsystem. Schematic diagrams of subsystem PWAs are in Section 9, Drawings.

 Note: An asterisk (*) denotes an active low or negative true logic signal.

4.2.1

CPU SUBSYSTEM

The CPU subsystem contains the main microcontroller, which is responsible for controlling the display/keyboard interface, external communications interfaces, barcode reader interface, and system management (see Figure 9-12, Peripheral PWA Schematic, and Figure 9-14, CPU PWA Schematic).

The CPU subsystem provides the following functions:

- External memory devices access

- LCD interfaces

- Real-time clock generator interface

- System watchdog

- Analog-to-digital and digital-to-analog converter interface

- Keypad interfaces

- Control and monitor status signals, such as LEDs, audible alarms,

volume control, nurse call switch, and lockout switch

- Serial communication with host computer (DataPort) and barcode reader

- Power supply subsystem interface

- Mechanism subsystem interface

4.2.1.1

CPU

The central processing unit is a Motorola MC68302 CPU. The CPU has a closely coupled 16 bit data bus and 24 bit address bus, MC68000 microprocessor core, a system integration block for peripherals, and an RISC communications processor. The MC68302 is packaged in a 144 pin thin quad flat pack (TQFP) package and operates from a 3.3 V power supply.

The on-chip peripheral devices are isolated from the system through the dual port RAM. The 1152 byte dual port RAM has 576 bytes of system RAM and 576 bytes of parameter RAM, which contains various peripheral registers, parameters, and the buffer descriptors for each of the three serial communication controller (SCC) channels and the serial communication port (SCP) channels. The 24 bit address bus is capable of accessing up to 16 MB of data.

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SECTION 4 THEORY OF OPERATION

4.2.1.2

SYSTEM MEMORY ADDRESS MAP

The CPU has a 24 bit address bus when combined with UDS*/A0. The address bus is a bi-directional, three state bus capable of addressing 16 MB of data that is configured as 16 bits per word (including the IMP internal address space).

Each of the four programmable chip-select lines has two registers that define the starting address of a particular address space and the block size.

4.2.1.3

PROGRAMMABLE READ-ONLY MEMORY

The CPU subsystem has two 512 K x 8 bit programmable read-only memory (PROM) memory devices, which provide a total of 1024 KB. The PROM space is expandable up to 2 MB. The PROM memory devices operate off the 3.3 V

The CPU chip-select 0 pin (CS0*), is connected to the PROM chip-enable (CE*) pin (signal CSROM*). This special chip-select signal can support bootstrap operation after reset. The interface to the CPU is the 16 bit data bus, and a 19 bit address bus. The address bus is connected to the ADDR<19:1> lines, and the data bus is connected to the DATA<15:0> lines.

supply.

4.2.1.4

STATIC RANDOM ACCESS MEMORY

There are two 512 K x 8 bit CMOS static random access memory (SRAM) devices, which provide a total of 1024 KB of data memory. During an SRAM read or write cycle, the chip-enable (CE*) is controlled by the CPU chip-select pin 1 (CS1*, signal name (CSRAM*)). The SRAM space is expandable up to 2 MB. The SRAM operates off the 3.3 V The CPU subsystem includes the additional SRAM for video buffer and real-time clock. See Section 4.2.1.6, LCD Controller, and Section 4.2.1.9, Real-Time Clock.

4.2.1.5

supply.

CONTROL LOGIC

The CPU PWA uses field programmable gate arrays (FPGA), which are high density, high speed, I/O intensive general purpose devices. They are used to implement all the digital control functions, including: memory-map address decoding; memory read-write enable; direct memory access (DMA) request; I/O status signals; chip-select control; motor control; sensor select; and power up/system reset control.

4.2.1.6

LCD CONTROLLER

The liquid crystal display (LCD) controller is used to interface the LCD to the CPU. The device displays layered text and graphics, scrolls the display in any direction, and partitions the display into multiple screens. It stores bit-mapped graphic data in external frame buffer memory. The display controller functions include: transferring data from the controlling microprocessor to the buffer memory; reading memory data; converting data to display pixels; and generating timing signals for the buffer memory and LCD panel.

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4.2 ELECTRONIC SUBSYSTEM OVERVIEW

The LCD controller accesses 32 KB of frame buffer SRAM (video) via the controller’s video address and data busses (VA<14:0> and VD<7:0>). The LCD controller external clock frequency is 8 MHz.

The interface to the CPU is through the lower 8 bits of the data bus, which is connected to DATA<7:0> lines, address line A1, and LCD chip-select signal CSLCD* (CS2*). This controller is also configured as 8080 family compatible interface device with all the control signals, such as WRLCD* (WR*) and RDLCD* (RD*), generated by the FPGA logic.

The LCD controller and the display memory are operated off the 3.3 V signal levels are shifted up to 5 V

by buffers for interface with the 5 VDC LCD panel.

supply. The output

4.2.1.7

LCD BACKLIGHT CONTROL

The LCD panel is backlit by a cold cathode fluorescent tube (CCFT) lamp. The CCFT lamp requires 300 V to deliver a current regulated sine wave to the lamp. A switching regulator regulates the CCFT current by monitoring feedback pin 3, and varies its output duty cycle to drive a DC/AC inverter. Intensity control is achieved by superimposing a DC control signal with the feedback signal. The DC control signal is sourced by a voltage divider consisting of a digitally controlled non-volatile potentiometer and three series diodes.

The CPU can adjust LCD backlight intensity by selecting the digitally controlled non-volatile potentiometer and controlling TUBU/D and TUBINC* signals. The potentiometer has a five bit up/down counter with non-volatile memory. It is used to store one of 31 settings of the potentiometer. Each count represents 323 Ω with a range of 323 to 10 KΩ. The current counter value is stored in non-volatile memory after CSTUB* is returned high while the TUBINC* input is also high. The current counter value is not stored if CSTUB* is returned high and TUBINC* is low. The CCFT intensity is directly proportional to the CCFT current, where 0 mA is maximum intensity. The CCFT current is inversely proportional to the counter value.

to operate; a current controlled DC to AC voltage inverter circuit is used

rms

is minimum intensity and 5 mA

rms

4.2.1.8

LCD CONTRAST CONTROL

A digitally adjustable LCD bias supply is used to control the LCD contrast over a range of -24 converter (DAC). The CPU provides two signals, LCDADJ (ADJ) and LCDCTL (CTL), to interface with this device. On power up or after a reset, the counter sets the DAC output to the mid-range value.

Each rising edge of LCDADJ increments the DAC output. When incremented beyond full scale, the counter rolls over and sets the DAC to the minimum value. Therefore, a single pulse applied to LCDADJ increases the DAC set point by one step, and 63 pulses decrease the set point by one step.

Technical Service Manual 4 - 5 430-95424-001 (Rev. 09/03)

to -8 VDC. It is digitally adjustable in 64 equal steps by an internal digital-to-analog

Page 35

SECTION 4 THEORY OF OPERATION

4.2.1.9

REAL-TIME CLOCK

The watchdog timekeeper chip includes a complete real-time clock/calendar (RTC), watchdog timer, alarm, and interval timer. The time/date information includes hundredths of seconds; seconds; minutes; hours; day; date; month; and year. The date at the end of the month is automatically adjusted for months with less than 31 days, including correction for leap year. The watchdog timekeeper operates in either 24-hour or 12-hour format with an AM/PM indicator. The device can be programmed to set up an interval timer, and it can generate an alarm every day, hour, or minute. These alarm functions may be used to schedule real-time related activities. A parallel resonant 32,768 Hz crystal oscillator drives the internal time base.

The external interface is a separate (non-multiplexed) 8 bit data bus and 6 bit address bus, with a contiguous address space of 64 bytes. When system power is turned off, a battery voltage input is available, which makes the RTC data non-volatile. The address bus is connected to the ADDR<6:1> lines, and the data bus is connected to DATA<7:0> lines. Since the CPU accesses are 16 bits wide, the RTC data is on the lower byte of the word.

The RTC chip-enable pin (CE*) is active low enabled for read and write operations. It is driven by the FPGA control logic, chip-select RTC signal (CSRTC*), which involves address decoding circuitry (see Section 4.2.1.2).

4.2.1.10

VOLTAGE MONITOR WATCHDOG TIMER

It is important to protect the system during power transitions, and the CPU is reset after the V automatic reset output during power up, power down, or brownout conditions. When the V

and holds the microprocessor in reset for approximately 200 ms after V threshold. The supervisory circuit includes a chip-select inhibit circuit, which is used to disable access to the real-time clock’s non-volatile SRAM during power transitions and power down mode.

This device also provides a watchdog timer function to monitor the activity of the microprocessor. To service the watchdog timer immediately after reset, the device has a longer time-out period (1.6 second minimum) right after a reset. The normal time-out period (70 ms minimum) is effective after the first transition of watchdog input (WDI) after RESET* is inactive. If the microprocessor does not toggle WDI within the time-out period, both RESET* and watchdog out (WDO*) outputs are asserted low. The RESET* remains active low for a minimum of 140 ms and it resets the CPU. The WDO* remains low as long as the WDI remains either high or low for longer than the watchdog time-out period. After a reset, the software reads this memory-mapped bit to determine if the latest reset was a watchdog time-out.

power supply is applied. The microprocessor supervisory circuit generates an

falls below the reset threshold voltage of 2.90 VDC, the reset signal (RESET*) goes low

rises above the

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4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.1.11

ANALOG-TO-DIGITAL CONVERTER

The analog-to-digital converter (ADC) monitors the proximal pressure sensor, distal pressure sensor, proximal air sensor, distal air sensor, battery charge/discharge current, battery voltage, buzzer test signal, LCD contrast voltage, CCFT test signal, and two chopper motor drive reference voltages. The ADC is an advanced 10 bit accurate, 11 channel, switched-capacitor, successive-approximation device. It has three inputs and a three-state output (chip-select, I/O clock, address input, and data out) that provide a direct four-wire interface to the serial communication port of the CPU. The ADC is designed to be used in conjunction with multiple serial devices on a common bus; consequently, the data-out pin is driven only when the chip-select (CS*) pin is asserted. Figure 4-2, Serial Interface

to ADC, illustrates the serial interface between the ADC and the CPU.

In addition to a high-speed ADC and versatile control capability, this device has an on-chip 14 channel multiplexer that can select any one of 11 analog inputs or any one of three internal self test voltages. The sample-and-hold function is automatic. The end-of-conversion (EOC) output goes high to indicate that conversion is complete. The CPU polls the EOC signal.

Channel selection and conversion results are transferred through the SCP pins. A serial transfer synchronizing clock (SPCLK) must be fed into the I/O clock input pin when the CS* pin is driven low. The address to be converted is serially transmitted into the address pin, and the conversion results are serially shifted out the data-out pin. Typical access time is 21 microseconds. The air, pressure, and pin (APP) PWA is the source of the 2.5 V reference voltage.

The analog inputs are selected by the channel multiplexer according to the input address

(see Table 4-1, Analog Inputs). The input multiplexer is a break-before-make type to reduce

input-to-input noise injection resulting from channel switching.

Technical Service Manual 4 - 7 430-95424-001 (Rev. 09/03)

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SECTION 4 THEORY OF OPERATION

ANALOG INPUTS

A10

GND

CS*

I/O CLOCK

ADDRESS

DATA OUT

EOC

REF+

REF-

GDIG

Figure 4-2. Serial Interface to ADC

CPU

I/O

SPCLK

SPTXD SCP

SPRXD

I/O (OR INTERRUPT)

2.5V

GANA

98K01022

Table 4-1. Analog Inputs

Signal Name Analog Input Address (hex) Description

PRPRS A0 $00 Proximal pressure sensor

DIPRS A1 $01 Distal pressure sensor

PXAIR A2 $02 Proximal air sensor

DIAIR A3 $03 Distal air sensor

IBATT A4 $04 Battery current

VBATT A5 $05 Battery voltage

BUZTST A6 $06 Buzzer test voltage

LCDTST A7 $07 LCD contrast test voltage

TUBTST A8 $08 CCFT intensity test voltage

MI_STA A9 $09 Motor current A control

MI_STB A10 $0A Motor current B control

$0B (V

$0C V

ref(+)

ref(-)

- V

ref(-)

) / 2

$0D V

430-95424-001 (Rev. 09/03) 4 - 8 Plum A+3 Infusion System

ref(+)

Page 38

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.1.12

DIGITAL-TO-ANALOG CONVERTER

The dual 8 bit digital-to-analog converter (DAC) generates two analog signals to control the phase A and phase B motor coil currents. The interface between the DAC device and the CPU is the 8 bit data bus, which is connected to DATA15:8. All the control signals for this DAC are generated by FPGA logic devices. Buffer amplifier/ground compensation circuits (U6 and U7) condition the DAC outputs.

4.2.1.13

FRONT PANEL KEYPAD MATRIX

A 5 x 5 membrane switch keypad matrix is located on the front panel. The keypad column lines (COL4:0) are driven by open collector type memory mapped input ports, while the keypad row lines (ROW4:0), are read by memory mapped input ports. The keypad strobing, scanning, and switch de-bouncing is accomplished by software. The keypad interface is designed with ESD protection. Refer to Table 4-2, Keypad Map.

Table 4-2. Keypad Map

COL 0 COL 1 COL 2 COL 3 COL 4

Row 4 Softkey 1 Softkey 2 Softkey 3 Softkey 4

Row 3 Start123[

Row 2 Stop456

Row 1 789[

Row 0 On/Off Clear 0

4.2.1.14

]

]

Silence

FRONT PANEL [ON/OFF] KEY

The [ON/OFF] key on the front panel provides a start up (STRTUP) signal to wake up the power supply when the system is shutdown. When activated during normal operation, the [ON/OFF] key interrupts (STRUPD*) the CPU, signaling a request for shutdown.

4.2.1.15

FRONT PANEL LED INDICATORS

The CPU drives the three light emitting diode (LED) indicators embedded in the front panel. Two memory mapped I/O signals activate the two LED lights used to indicate which channel is in delivery mode (LEDAE*, LEDBE*). The AC power on LED indicates the status of AC power (LEDAC) and that the system is in the battery charge mode. A buffered AC on signal (BACON) drives the LED and is active only when AC power is present.

Technical Service Manual 4 - 9 430-95424-001 (Rev. 09/03)

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SECTION 4 THEORY OF OPERATION

4.2.1.16

KEYPAD LOCKOUT INTERFACE

A lockout switch (SW1) on the peripheral/interface PWA locks the front panel keypad for all three infusers. A memory mapped input port (LOTSW*) reads the switch. The switch serves as a lockout request and software performs the lockout.

4.2.1.17

NURSE CALL INTERFACE

A nurse call relay switch on the peripheral/interface PWA indicates alarm conditions to a remote operator. A memory-mapped output signal (NURSE) activates the relay during alarm conditions. The relay has both normally open and normally closed contacts. A jumper on the peripheral/interface board selects the contact type. The factory setting is normally open.

4.2.1.18

AUDIBLE INDICATORS

There are two audible indicators on the CPU subsystem. Three loud, main audible indicators are mounted on the main chassis, one per infuser. This main alarm is used for alerting the operator to alarm conditions. A keypad beeper (LS1), with lower power and a distinctly different tone, is used to provide audible feedback to the operator. The keypad beeper is driven by a memory-mapped output (KEYALM). It is used to indicate keypad activation, and confirmation to the operator.

The main alarm has an adjustable volume control on the peripheral/interface PWA (R2), mounted on the rear of the instrument. The main alarm can be activated by either a memory-mapped control (MAINALM), the reset pulse(s), or by a power failure alarm latch. The main alarm will sound a chirp for every reset pulse sent by the watchdog timer IC. Continuous chirping indicates a stuck processor.

The alarm is activated continuously during power failure. If the control software does not shut down power in a proper sequence, a latch on the CPU PWA (U2), powered by a backup supply (0.1 F supercap), will activate a continuous alarm. This continuous alarm sounds until either the backup supply is discharged or the user resets the latch by pressing the front panel [ON/OFF] key. Reliable operation of the main alarm is assured by software monitoring of a buzzer test signal (FBUZTST) via the ADC.

4.2.1.19

BARCODE READER INTERFACE

The CPU communicates with a barcode wand that is connected to the peripheral/interface PWA from the rear of the infusion device. The barcode wand reads and decodes a Code 128 barcode symbology and outputs the barcode data via an RS-232 port using an asynchronous, serial ASCII format.The software controls power to the barcode reader and to the interface circuits via memory-mapped outputs BARPWR and COMPWR*. The barcode reader is isolated from the main system by an optical data path on the peripheral PWA (U10, U11, and U13) and an isolated power supply (U3 and T1).

430-95424-001 (Rev. 09/03) 4 - 10 Plum A+3 Infusion System

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4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.1.20

DATAPORT INTERFACE

The CPU communicates with an external computer by way of a DataPort interface. The DataPort interface provides for remote monitoring of up to four pumps using a host computer with a modified RS-232-D serial interface. Pumps are either connected directly to the host or in a daisy chain configuration using junction boxes that provide a 5 bit hard ID via DIP switches on the junction box. The DIP switches are buffered (peripheral PWA U8) and read by the CPU via the memory-mapped input/output (MMIO) port.

The DataPort system conforms to the EIA-232-D standard, with the following exceptions:

- DataPort uses non-standard DB-15 and 6 pin modular connectors in addition

to the standard DB-25 and DB-9 connectors

- With DataPort, more than one pump is allowed on the line

- The minimum line impedance is 2 KΩ (EIA-232-D standard: 3 KΩ min.)

- The maximum line impedance is 30 KΩ (EIA-232-D standard: 7 KΩ max.)

- The maximum line capacitance is 13 nF (EIA-232-D standard: 2,500 pF)

The communications default is 1200 BAUD, no parity, 8 data bits and 1 stop bit. The Plum A+3 BAUD rate is selectable (1200, 2400, 4800, and 9600). The data format on the serial port is a 10 bit frame with asynchronous start and stop. The CTS line is held high and the RTS line is disconnected.

The DataPort is isolated from the main system by an optical data path on the peripheral PWA (U10, U11, and U13) and an isolated power supply (U3 and T1).

4.2.1.21

POWER SUPPLY INTERFACE

The CPU subsystem interfaces the power supply subsystem by providing the MMIO signals needed for power control and battery management. Additionally, the CPU subsystem measures the battery terminal voltage and charge/discharge current via the ADC

(see Table 4-3, CPU-Power Supply Interface).

Table 4-3. CPU-Power Supply Interface

Signal Name Typ e Description

PWRHLD D, O Holds system power on

STRTUP A, I Startup pulse from the [ON/OFF] key

STRUPD* D, I Digital startup pulse, used as interrupt to the CPU

V3_3 P 3.3 volt system power

V5_0/VANA P 5.0 volt analog and interface power

VMOT P Raw, unregulated charger voltage or battery voltage

V2_7 P 2.7 volt backup power for RTC and non-volatile SRAM

VSC P Full time 5 volt supply, backed up by supercap

V12_0 P 12 volt, low current supply for audio alarm

Technical Service Manual 4 - 11 430-95424-001 (Rev. 09/03)

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SECTION 4 THEORY OF OPERATION

Table 4-3. CPU-Power Supply Interface

Signal Name Typ e Description

OVRVLT* D, I Signal that indicates overvoltage, regulation problem

on the power supply main regulator

BACON D, I Buffered AC on signal

IBATT A, I Voltage proportional to integration of battery

charge/discharge current

VBATT A, I Divided battery terminal voltage

CHG* D, O Battery charger enable

VFLOAT* D, O Set the main regulator voltage to battery float charge level

ITGRST D, O Reset the charge current integrator

Legend: P = Power; A = Analog; D = Digital; I = Input; O = Output

4.2.1.22

MECHANISM INTERFACE

The CPU subsystem provides the MMIO ports for interface to the mechanism subsystem, in addition to the analog interface mentioned in the ADC and DAC sections

(see Section 4.2.1.11 and Section 4.2.1.12). Refer to Table 4-4 for CPU-mechanism interface

signals.

Table 4-4. CPU-Mechanism Interface Signals

Signal Name Type Description

MI_STA A, O Motor current set for phase A

MI_STB A, O Motor current set for phase B

GDAC A, O Ground signal from chopper (for compensation)

M_PHA D, O Motor phase A

M_PHB D, O Motor phase B

M_SEL1, M_SEL0 D, O Motor select bits

FLCAME D, O I/O and L/S cam flag sensors enable

FLPINE D, O L/S pin motion detectors enable

FLPLE D, O Plunger motor sensor pair enable

FLLS_C D, I Flag, L/S valve cam sensor

FLIO_C D, I Flag, I/O valve cam sensor

FLLS_A D, I Flag, L/S valve A pin detector

FLLS_B D, I Flag, L/S valve B pin detector

FLPLRO D, I Flag, plunger rotation sensor

430-95424-001 (Rev. 09/03) 4 - 12 Plum A+3 Infusion System

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4.2 ELECTRONIC SUBSYSTEM OVERVIEW

Table 4-4. CPU-Mechanism Interface Signals

Signal Name Type Description

FLPLTR D, I Flag, plunger translation sensor

PXPRE D,O Proximal pressure sensor enable

PXPRS A, I Proximal pressure sensor

DIPRE D, O Distal pressure sensor enable

DIPRS D, O Distal pressure sensor

PXARE D, O Proximal air sensor enable

PXAIR A, I Proximal air sensor

DIARE D, O Distal air sensor enable

DIAIR A, I Distal air sensor

CASPR* D, I Cassette present

CASS2*, CASS1*, CASSO* D, I Cassette type coding: Macro (111), Micro (010),

all others are invalid

SPCLK D, O SCP clock output

SPRXD D, I SCP receive data

SPTXD D, O SCP transmit data

CSSEP* D, O Chip select, EEPROM

V5_0 P 5.0 volt supply for interface power

V3_3 P 3.3 volt supply for logic power

GDIG P Digital ground

VANA P 5.0 volt supply for analog power

GANA P Analog ground

VMOT, GMOT P Motor power is directly from power supply PWA

V2_5 A, I Reference voltage for ADC and DAC

Legend: P = Power; A = Analog; D = Digital; I = Input; O = Output

Technical Service Manual 4 - 13 430-95424-001 (Rev. 09/03)

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SECTION 4 THEORY OF OPERATION

4.2.2

POWER SUPPLY SUBSYSTEM

The power supply subsystem provides DC power to system circuits and interface software controlled power and battery management (see Figure 9-11, Power Supply PWA Schematic). The power supply subsystem provides for the following functions:

- Main switching regulator

- AC power detection

- Main regulator fault detection

- System power (secondary regulators)

- Auxiliary supplies

- Power control

- Battery charging circuitry

- Battery terminal voltage measurement

- Battery charge/discharge current measurement

4.2.2.1

MAIN SWITCHING REGULATOR

The main source of power for the Plum A+3 is the AC line. The main switching regulator is a pulse width modulated, AC-to-DC converter which provides the system an isolated DC voltage of 6.9 V preceded by: line fuses F1 and F2, surge suppressor VR1, and a line filter (T3, T4, C54-56). The bridge rectifier U14 and capacitors C52 and C53 provide the DC voltage required for the switching circuit. Voltage regulator U13 provides the pulse width modulator (PWM) device U12 startup supply voltage. After startup, supply voltage for U12 is supplied by half wave rectifier circuitry CR14, R76, and C51.

The PWM oscillation frequency is approximately 40 kHz, determined by external resistor R72 and capacitor C45. U12 controls the power delivered by varying the duty cycle of the power metal-oxide-semiconductor field-effect transistor (MOSFET) Q9, which drives T2. A half-wave rectifier (CR9 and C37-C41) rectifies the transformer’s secondary voltage, which provides the raw DC voltage for the battery charger and system power. There are three feedback mechanisms that maintain control: a main loop for normal control, a secondary loop for overvoltage protection, and a current limit loop.

4.2.2.1.1

(or 7.5 VDC in battery charger boost mode). The main regulator is

Main Loop

The main loop uses an optical feedback path to regulate the charger voltage (BATPOS) at 6.9 V control of the VFLOAT* line). A shunt regulator and opto-isolator provide feedback to the PWM error amplifier.

430-95424-001 (Rev. 09/03) 4 - 14 Plum A+3 Infusion System

(except during boost charge, when the limit is raised to 7.5 VDC by software

Page 44

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.2.1.2

Secondary Loop

Diode CR10 and opto-isolator U10 provide overvoltage protection. CR10 conducts and activates U10 when secondary voltage exceeds approximately 10 V U12 is reduced until the excessive voltage is removed.

4.2.2.1.3

. The duty cycle of

Current Limit Loop

The current limit loop is activated when the primary current, sensed by R71, exceeds

3.0 A. Resistor R70 and capacitor C46 filter the voltage across R71 and feed it back to the current sense input (1.5 V excessive load is removed.

4.2.2.2

threshold) of U12. The duty cycle of U12 is reduced until the

MAIN REGULATOR FAULT DETECTION

If the switching regulator’s main loop fails, the secondary voltage limit loop takes over. However, the battery charger and motors must be disabled, and an alarm must be generated. A comparator is used to monitor the raw DC (+BUSS) for overvoltage. A 3.3 V logic signal (OVRVLT*) is provided to the CPU subsystem.

4.2.2.3

SYSTEM POWER

Along with the unregulated VMOT supply, a secondary switching regulator provides system power. The secondary switching regulator includes IC U4, transformer T1, and transistors Q4 and Q5. The regulator is a triple output, wide supply range, fly-back converter that provides regulated 3.3 V winding transformer T1. The regulator operates over an input range of 4 to 10 V provides output current limit as well as voltage overshoot limit. Primary feedback is metered through a bias arrangement on transistor Q3. A Schottky rectifier diode CR4 provides feedback in the event of V3_3 or V12_0 failure, and transistor Q10 provides feedback in the event of V5_0 failure. The positive terminal of the battery provides the raw DC voltage, VMOT, for the motors and backlight of the display.

4.2.2.4

, 5.0 VDC, and 12.0 VDC outputs from the five

and

AUXILIARY SUPPLIES

The power supply subsystem provides full time 5.0 V active when battery or AC voltage is present. The full time 5.0 V linear low dropout voltage regulator U6, whose power source is directly from the battery and is backed up by a 0.1 F capacitor. VSC is used for the ON/OFF switch and a power failure alarm latch. The full time 2.7 V to supply the ultra-low current needed to power the real-time clock and non-volatile SRAM during shutdown.

supply (V2_7) is derived from VSC and is used

and 2.7 VDC supplies, which are

supply (VSC) uses a

Technical Service Manual 4 - 15 430-95424-001 (Rev. 09/03)

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SECTION 4 THEORY OF OPERATION

4.2.2.5

POWER CONTROL

The infusion pump will operate in one of three modes: normal, standby, or shutdown. During normal operation, the user interface is active and either on battery or AC line power. During standby mode the user interface is inactive while the CPU is still operating, servicing the battery management and waiting for a startup interrupt. Shutdown mode is when system power is off. Shutdown mode only occurs during battery operation; otherwise, +BUSS holds the system power on.

The infusion pump is activated when the [ON/OFF] key is pressed or the AC line is plugged in. The [ON/OFF] key activates the STRTUP signal, triggering a three second one-shot circuit (C3, R10, CR1, and Q1) that will temporarily turn the system power on. This three second one-shot period allows the CPU enough time to power up, initialize, and turn on the PWRHLD signal. The CPU monitors the STRTUP signal, via interrupt, to signal a user request for turning off the infuser.

Figure 4-3, System Startup and Shutdown Timing, Battery Powered illustrates the system

startup/shutdown sequence while battery powered. System power is always on while AC powered.

STRTUP

3 SEC

ONE-SHOT

V3_3, V5_0, V12V

PWRHLD

98K01021

Figure 4-3. System Startup and Shutdown Timing, Battery Powered

4.2.2.6

BATTERY VOLTAGE MEASUREMENT

The battery terminal voltage (BATPOS - BATNEG) is measured with a differential amplifier consisting of U1, R1, R2, R4, R7, and R8. It has a gain of 0.317 to generate a single ended VBATT signal. The VBATT signal is then provided to the CPU A/D converter as input for the battery management algorithms.

430-95424-001 (Rev. 09/03) 4 - 16 Plum A+3 Infusion System

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4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.2.7

BATTERY CHARGE/DISCHARGE CURRENT MEASUREMENT

The battery management algorithms measure battery charge/discharge current for battery capacity estimation and charger control. The charge/discharge current is measured by integrating the voltage across current sense resistor R57. An operational amplifier (op-amp) integrator circuit, consisting of U2, C5, R12, R13, R19, and R20, provides a voltage proportional to the integration of battery current (IBATT) over a CPU controlled measurement period. The IBATT signal is fed to the CPU A/D converter, where it is sampled at the end of the measurement period. The battery management algorithm further accumulates the charge/discharge current for battery capacity estimation. The op-amp integrator is reset by the CPU system at the beginning of each measurement period by parallel analog switches U3, controlled by the CPU’s ITGRST signal. The battery management algorithm periodically calibrates the op-amp integrator.

4.2.2.8

BATTERY CHARGER

The software battery management algorithm controls the battery charger. The charging scheme is a current limit/two stage voltage limit charger. The charge current is limited to

1.3 A and the voltage is limited to either 6.9 V

or 7.5 VDC.

The source of the charge current is power MOSFET transistor Q7 operating in the linear mode. Charge current passes through a current sense resistor R57, where it develops a feedback signal for the charger control amplifier consisting of U7, Q6, and associated parts. The feedback signal is compared against a 2.5 V A .5 A fuse (F4) protects against damage due to a short circuit. The battery management algorithm maintains on/off control of the charger by the charger enable signal CHG*. When set high, CHG* activates a comparator U7, which overrides the feedback signal and disables the charger. Excessive voltage on the BATNEG terminal indicates that there is a shorted battery cell, and will disable the charger through the same comparator.

voltage reference U8.

4.2.3

MECHANISM SUBSYSTEM

The mechanism subsystem includes the electronics and electromechanical components that interface the Plum A+3 pumping mechanism (see Figure 9-15, Driver PWA Schematic;

Figure 9-16, Switch PWA Schematic; and Figure 9-17, APP PWA Schematic). Refer to Table 4-4 for mechanism interface signals.

The mechanism subsystem provides the following functions:

- Chopper motor drive for three stepper motors (plunger, L/S valve, I/O valve)

- Four motor position sensors (flag detectors)

- Precision voltage reference

- Two air sensors (distal, proximal)

- Two pressure sensors (distal, proximal)

- Cassette presence and type detection

- Serial electrically erasable PROM (EEPROM)

Technical Service Manual 4 - 17 430-95424-001 (Rev. 09/03)

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SECTION 4 THEORY OF OPERATION

4.2.3.1

MOTORS/MOTOR DRIVE

The Plum A+3 infusion system uses three stepper motors for pumping: one for fluid displacement and two for cassette valve actuation. The stepper motors are driven, under step-by-step control from software, by a unipolar chopper drive.

4.2.3.1.1

Stepper Motors

Each motor is named by its function:

- Plunger motor for driving the plunger screw

- I/O valve motor for moving the input-output valve pins

- L/S valve motor for moving the line select valve pins A and B

All three motors are four phase stepper types. One electrical revolution is accomplished after four motor steps (phases) are completed. The step-angle (the number of steps per shaft revolution) resolutions are 3.6 degrees/step (100 steps/rev) for the plunger motor, and 7.5 degrees/step (48 steps/rev) for the I/O and L/S valve motors.

The unipolar motor windings have a center tap connected on each of the two coils as shown in Figure 4-4, Stepper Motor Coils. Unidirectional current enters the center tap and is steered to one end of the coil or the other end by the driver electronics, creating positive or negative flux lines in the motor coil. With two coils each with a choice of flux polarity, four electrical combinations or phases are possible.

ACOM

BCOM

B B

98K01020

Figure 4-4. Stepper Motor Coils

430-95424-001 (Rev. 09/03) 4 - 18 Plum A+3 Infusion System

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4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.3.1.2

Chopper Motor Drive

The Plum A+3 stepper motor drive is a chopper drive, which is a pulse width modulation of the coil current in each motor winding. Current is switched on and off to maintain a predetermined coil current independent of supply voltage and motor speed. The motor winding inductance acts as a filter to smooth out the switching currents, slowing the current rise when turned on and storing a decaying current when turned off.

Each motor coil is modulated independently, allowing different coil currents in the two motor windings. The coil current is sensed and compared to a reference input for each winding. Modulation circuits correct for any error between the sensed current and the reference. This reference input can be changed to set a different coil current.

4.2.3.2

MOTOR POSITION SENSORS

Motor position is estimated by counting the motor steps, relative to a position reference. Optical switches and flags serve as position references, which are used to find the motor home positions and to verify proper motion. Flag positions are anticipated by software. Optical switch flag sensors are used for tracking the following:

- Plunger motor rotational position (coupler flag)

- Plunger translational (linear) position

- I/O valve motor rotational position (cam flag)

- L/S valve motor rotational position (cam flag)

Each optical switch consists of an infrared LED, which shines through a rectangular aperture, across a slot, to illuminate a photo-transistor. The photo-transistor is activated as long as the beam is on and not blocked (by a flag in the slot). The optical switches are distributed throughout the mechanism, near their associated flags. The motor rotational optical switches (U5, U9, and U10) are mounted on the driver PWA along with the control circuitry. The plunger translational optical switch is mounted remotely on the switch PWA. The switches are used intermittently to save power. There are two control signals that enable associated switch pairs:

- FLCAME flag, valve motor cam sensor enable

- FLPLE flag, plunger motor rotation and translation sensors enable

Each of these control signals enables a constant current source which turns on the associated switch’s infrared LEDs. The photo transistor states are sensed by Schmidt trigger inverters (U11 on driver PWA) which provide a 3.3 volt logic high when the optical path is blocked or a logic low when the optical path is clear. The Schmidt trigger output is high when the sensor is disabled. The following output signals are provided to the CPU subsystem:

- FLIO_C flag I/O valve motor cam sensor

- FLLS_C flag L/S valve motor cam sensor

- FLPLRO flag plunger motor rotation sensor

- FLPLTR flag plunger motor transition sensor

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SECTION 4 THEORY OF OPERATION

4.2.3.3

V2_5 REFERENCE VOLTAGE

A precision 2.50 VDC reference voltage is generated on the APP PWA for use by the pressure sensor excitation circuits, the air sensor amplifier circuits, and the ADC and DAC reference voltage. The precision 2.50 V

reference (U1) is buffered by a voltage follower (U3).

The signal name is V2_5.

4.2.3.4

AIR SENSORS

The mechanism subsystem includes two air sensors, used to detect air passage into (proximal) or out of (distal) the cassette. Both sensors are piezoelectric crystal transmitter receiver pairs. Liquid between the transmitter and receiver will conduct the ultrasonic signal, while air will not (see Figure 4-5, Air Sensor Block Diagram).

VSO

CPU

XTL TX

VCO/PLL

A/D

G_TX

OUTPUT

AMP

Figure 4-5. Air Sensor Block Diagram

XTL RX

G_RX

PEAK

DETECTOR

98K01019

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4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.3.4.1

Transmitter Circuitry

The transmitter circuitry consists of a voltage sweep oscillator, a voltage-controlled oscillator (VCO), and a transmitter amplifier, and are located on the APP PWA.

The voltage sweep oscillator circuit (U10B, R24, C12, and part of U9) oscillates at approximately 12 kHz at 50 percent duty cycle. The output of the sweep oscillator is between +2 V sensor’s peak coupling frequency, which is between 3.0 and 6.0 MHz. A resistor and capacitor (R28 and C13) are used to configure the VCO center frequency. The VCO is enabled when the CPU asserts either DIARE or PXARE control signals.

The transmitter amplifier consists of a push-pull, emitter-follower, complementary pair of transistors (Q15 and Q16). The transmitter amplifier drives both proximal and distal sensors simultaneously.

4.2.3.4.2

and +3 VDC, and is used to sweep the VCO. The VCO sweeps through the

Receiver Circuitry

When the cassette’s test port is filled with fluid, the transmitted signal will be coupled to an identical piezoelectric crystal, where it is amplified and detected by the receiver circuitry. The receiver circuitry consists of an amplifier, a peak detector, and an adjustable gain buffer stage. There is a separate, symmetrical receiver circuit for each channel (proximal and distal). Component references (called out in this design description) will be made to the distal channel only.

The first amplifier includes two, directly coupled common emitter stages (Q5 and Q7), biased from the V2_5 supply. DIARE and PXARE are used to enable the distal and proximal sensors, respectively.

The detector stage consists of an emitter follower (Q3), charging a 400 microsecond time constant, refreshed every 40 microseconds (twice per VCO sweep).

The peak detector output is buffered by an op-amp (U7) configured as a basic non-inverting amplifier with a trimming potentiometer (R31) for gain adjustment. Each sensor has an independent gain adjustment. The two air sensor, gain-trimming potentiometers are accessible for calibration in an assembled mechanism.

These final signals are read by the CPU subsystem via the ADC.

- PXAIR Proximal air sensor output

- DIAIR Distal air sensor output

4.2.3.5

PRESSURE SENSORS

The mechanism subsection contains two strain gauge-type pressure sensors, one at the proximal and the other at the distal cassette ports. Electrically, the strain gauge is a Wheatstone bridge made of four strain gauge resistors. When the bridge is electrically excited, the bridge will output a millivolt level signal proportional to the applied pressure. The output signal is amplified and offset adjusted before being read by the ADC. Each pressure sensor circuit includes an excitation voltage supply, sensor amplifiers, and a low pass filter.

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SECTION 4 THEORY OF OPERATION

The pressure sensor circuitry is on the APP PWA. Each of the two channels has an identical topology, but different gain and filter response. A block diagram of this circuit is shown in Figure 4-6, Pressure Sensor Excitation and Amplifier Block Diagram.

 Note: Component references are made to the distal channel only.

PRESSURE SENSOR ENABLE (FROM CPU)

BRIDGE

EXCITATION

3.75 V

REFERENCE

2.5 V

WHEATSTONE

DIFFERENTIAL

AMPLIFIER

AND OFFSET

ADJUST

OUTPUT

AMPLIFIER

AND FILTER

BRIDGE

PRESSURE

SIGNAL OUTPUT

(TO CPU)

98G01018

Figure 4-6. Pressure Sensor Excitation and Amplifier Block Diagram

4.2.3.5.1

Bridge Excitation Supply

The bridge excitation voltage is 3.75 VDC, and is derived from the 2.5 VDC reference signal (V2_5), gained 1.5 times by amplifier (U8A, Q13). The CPU subsystem may independently enable power to each pressure sensor bridge.

These enable signals are active high 3.3 volt logic level inputs:

- PXPRE Proximal pressure sensor enable

- DIPRE Distal pressure sensor enable

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4.2 ELECTRONIC SUBSYSTEM OVERVIEW

4.2.3.5.2

Amplifier and Low Pass Filter

The pressure sensor amplifiers include a high gain differential pre-amplifier (U4), followed by a second stage non-inverting amplifier (U6B) with low gain. A trimming potentiometer (R48) is adjusted to minimize any offset in the impedance of the bridge.

A two-pole filter is used to filter the pressure signals. The first pole is formed by a capacitor (C39, multiplied by 230 due to Miller effect) and a Thevenin resistance (seen at U4-2). The second pole is the RC filter at the ADC input, which is located on the CPU PWA.

These output signals to the A/D converter in the CPU PWA are:

- PXPRS Proximal pressure signal

- DIPRS Distal pressure signal

4.2.3.6

PRESSURE SENSOR CALIBRATION

Pressure sensors are calibrated for offset and gain during mechanism calibration. A trimming potentiometer is used to adjust the initial, zero pressure offset. The proximal and distal pressure sensors have independent offset adjustments.

The final system gain (cassette pressure to corrected amplifier output) is adjusted in software. During mechanism calibration, each channel’s gain (amplifier output/cassette pressure) will be measured, and stored in the serial EEPROM on the driver PWA.

4.2.3.7

CASSETTE TYPE/PRESENCE SELECTION

The mechanism subsystem includes four force sensing resistor (FSR) switches, which are coupled to the cassette. Three FSRs are used for cassette type decoding and one is used for cassette present detection.

The FSR is a polymer thick film device, which exhibits a decrease in resistance with any increase in force applied to the active surface. The FSRs have a resistance that is either very large (> 1 MΩ) or relatively small (< 100 KΩ). The large resistance is defined as a logical ‘0’, and the small resistance is defined as logical ‘1’. Each FSR is arranged in a voltage divider configuration with a fixed resistor, followed by a comparator with hysteresis. The comparator circuits are located on the CPU PWA. The comparators (CPU PWA: U8 and associated passives) are designed to trip as the FSR’s resistance falls below 120 KΩ.

4.2.3.8

SERIAL EEPROM

The driver PWA holds the 8 K x 8 bit, serial EEPROM, which is used to store event, alarm, malfunction, and calibration data specific to the pumping mechanism. It is accessed through a serial peripheral interface (SPI) compatible interface, which is a high-speed serial interface to the CPU. The CPU PWA accesses this device through its SCP serial interface. This interface is a subset of the SPI, and consists of clock (SPCLK), data in (SPRXD), and data out (SPTXD) pins. This device is in the driver PWA to allow the calibration data to stay with the mechanism.

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SECTION 4 THEORY OF OPERATION

4.3

PRINTED WIRING ASSEMBLIES

The Plum A+3 electronics are packaged into six printed wiring assemblies (PWA) and several remote mounted peripherals (see Section 4.4, Remote Mounted Peripherals). The following sections provide a brief description of the functional interfaces of each PWA.

4.3.1

POWER SUPPLY PWA

The power supply PWA (see Figure 9-11) contains the following functions of the power supply subsystem:

- Main switching regulator

- AC power detection

- Main regulator fault detection

- System power

- Auxiliary supplies

- Power control

- Battery management

The power supply PWA is a four-layer printed wiring board (PWB), with primarily surface mount technology (SMT) components. The board is fully testable from the bottom side. An insulating tape covers the back of the power supply PWA. Open system troubleshooting should be done under battery power. If connection to the AC line is required, an isolation transformer should be used since AC line potentials are present on the power supply PWA.

See Section 4.2.2 for a functional description, and refer to Table 4-5 for power supply PWA interface connections.

Table 4-5. Power Supply PWA Interface Connections

Connector Type Interface

P2 30 pin receptacle Board-to-board connection to CPU PWA

J16 4 pin header Motor power connection to driver PWA

J21 3 pin receptacle AC power cord connection

J22 2 pin header Battery cable connection

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4.3 PRINTED WIRING ASSEMBLIES

4.3.2

PERIPHERAL PWA

The peripheral PWA (see Figure 9-13) contains part of the CPU subsystem circuitry, including system program and data memories (PROM and SRAM), and external communication interface circuits. The peripheral PWA is designed to be field replaceable, to facilitate software upgrades or additional external interfaces. The peripheral PWA is a four-layer PWB, including one ground plane, one power plane, and two signal layers. In its initial configuration, all of the components are mounted on the top side.

See Section 4.2.1 for a functional description, and refer to Table 4-6 for peripheral PWA interface connections.

Table 4-6. Peripheral PWA Interface Connections

Connector Type Interface

P1 96 pin receptacle Board-to-board connection to CPU PWA

J26 15 pin D-sub DataPort

J27 9 pin D-sub Barcode reader connection

J28 3 pin phone jack Nurse call jack

4.3.3

PERIPHERAL/INTERFACE PWA

The peripheral/interface PWA (see Figure 9-12) contains part of the CPU subsystem circuitry, including system program and data memories (PROM and SRAM), external communication interface circuits, and rear instrument user controls. The peripheral/ interface PWA has internal logic to control selection of the barcode reader and lock out the selection of the barcode reader by another infuser until the operator completes the selection in process.

Refer to Table 4-7 for peripheral/interface PWA interface connections.

Table 4-7. Peripheral/Interface PWA Interface Connections

Connector Type Interface

P1 96 pin receptacle Board-to-board connection to CPU PWA

J29 and J30 50 pin plug Board-to-board connection to peripheral PWA

J26 15 pin D-sub DataPort

J27 9 pin D-sub Barcode reader connection

J28 3 pin phone jack Nurse call jack

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SECTION 4 THEORY OF OPERATION

4.3.4

CPU PWA

The CPU PWA (see Figure 9-14) contains most of the CPU subsystem functions, with the exception of main memory and communications ports, which are located on the peripheral PWA. The CPU PWA also accommodates system interconnect. The CPU PWA is an eight-layer PWB, with one ground plane, one power plane, and six signal layers. The CPU PWA primarily contains SMT components. Most of the components are on the top side, while the bottom side holds wave-solder compatible SMT resistors and capacitors.

See Section 4.2.1 for a functional description, and refer to Table 4-8 for CPU PWA interface connections.

Table 4-8. CPU PWA Interface Connections

Connector Type Interface

J7 96 pin header Connection to peripheral PWA (CPU bus, rear

panel I/O, and communication ports)

J2 30 pin header Connection to power supply PWA

J3 50 pin SMT Ribbon cable connection to driver PWA

(mechanism)

J4 21 pin header Front panel connector (keypad, LEDs,

on/off switch)

J5 14 pin SMT Flat flex cable to LCD panel

J20 4 pin header CCFT backlight connector

J24 2 pin header Main audible alarm connector

4.3.5

DRIVER PWA

The driver PWA (see Figure 9-15) contains the mechanism subsystem’s motor drive circuitry, motor position sensors, and serial EEPROM. The driver PWA is mounted in the mechanism sub-chassis. The driver PWA is a four-layer PWB, with one ground plane, one power plane and two signal layers. The driver PWA primarily uses SMT components. Most of the components are located on the top side of the board, while the bottom side holds wave-solder compatible resistors and capacitors.

See Section 4.2.3 for a functional description, and refer to Table 4-9 for driver PWA interface connections.

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4.3 PRINTED WIRING ASSEMBLIES

Table 4-9. Driver PWA Interface Connections

Connector Type Interface

J7 6 pin header Plunger motor

J8 6 pin header Input/output motor

J9 6 pin header Line select motor

J10 20 pin SMT Flat flex cable to APP PWA

J11 50 pin header Ribbon cable to CPU PWA

J12 6 pin SMT FSR flex circuit

J13 4 pin header Motor power, from power supply PWA

J14 8 pin SMT Flat flex cable to switch PWA

4.3.6

SWITCH PWA

The switch PWA (see Figure 9-16) contains the plunger translation position sensor, which is one of four position sensors in the system. The switch PWA is located at the side of the mechanism sub-chassis, and connects to the driver PWA (see Section 4.2.3.2).

4.3.7

APP PWA

The APP (air, pressure, and pin) PWA (see Figure 9-17) is mounted in the mechanism sub-chassis. The APP PWA contains the following mechanism subsystem circuitry:

- Proximal and distal air sensors and circuitry

- Proximal and distal pressure sensor amplifiers and excitation

- V2_5 precision voltage reference

- Pin detector optical switch module

The APP PWA is a four-layer PWB, with one ground plane, one power plane and two signal layers. The APP PWA uses SMT components, mounted on both sides of the board. The air sensors and the pin detector module are board mounted.

See Section 4.2.3 for a functional description, and refer to Table 4-10 for APP PWA interface connections.

Table 4-10. APP PWA Interface Connections

Connector Type Interface

J15 20 pin SMT Flat flex cable to driver PWA

J11 10 pin SMT Pressure sensor connector

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SECTION 4 THEORY OF OPERATION

4.4

REMOTE MOUNTED PERIPHERALS

The following sections describe the major remote mounted peripherals.

4.4.1

LCD

The infusion pump uses a graphic LCD module with a CCFT. The CCFT provides a backlight source for the LCD. The LCD requires a nominal -16 V control, which is controlled by the CPU. The pump’s graphic display data is shifted out to the LCD by the CPU LCD controller, which interfaces directly with the CPU

(see Section 4.2.1.6). The display is configured as a 240 x 240 dot matrix with a viewing

angle of approximately 60 degrees.

4.4.2

SEALED LEAD ACID BATTERY

supply for contrast

The infusion pump uses a nominal 6.0 VDC rechargeable sealed lead acid battery with 4.0 amp-hour capacity.

4.4.3

BARCODE READER WAND

The barcode reader (BCR) wand connects to the BCR port J27 on the peripheral/interface PWA (see Figure 9-12). A PLD serving as a serial multiplexer installed in the peripheral/ interface PWA determines which one of the three systems can use the BCR. The BCR wand interfaces through the infusion pump’s optically isolated, TTL logic level, asynchronous interface. The BCR wand is also capable of interfacing at RS-232 levels. The infusion pump provides an isolated +5.0 V of the BCR wand is swiped across a barcode label, the reflected light is scanned and processed. After a successful scan, the data is sent over the communication interface to the CPU.

regulator to power the BCR wand. When the LED at the tip

4.5

MECHANICAL OVERVIEW

The principal mechanical elements of the infusion pump include the cassette and the mechanism assembly. When a cassette is locked into the operating position and the [ON/OFF] switch is pressed, the infusion pump performs a self test to verify the integrity of the internal systems. The operation of the mechanism assembly moves a plunger, causing a pumping action. A valve motor selects the A or B valve, depending on the command. An additional valve motor alternately opens and closes an inlet valve and outlet valve to control fluid flow through the cassette pumping chamber.

The following sections detail the cassette and the mechanism assembly.

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4.5 MECHANICAL OVERVIEW

4.5.1

CASSETTE

The cassette operates on a fluid displacement principle to volumetrically deliver fluid

(see Figure 4-7, Major Elements of the Dual-Channel Cassette and Figure 4-8, Fluid Path in the Cassette). Refer to the system operating manual for a description of the major

cassette functions.

The pumping cycle begins when the outlet valve is opened and the inlet valve is closed. The plunger extends to deflect the cassette diaphragm and expel fluid. At the end of the pumping stroke, the outlet valve is closed, the inlet opens, the appropriate A or B valve opens, and the plunger retracts to allow fluid to refill the pumping chamber. After the pumping chamber is filled, the inlet and outlet valves are reversed, the A and B valves are closed, and the cycle repeats.

The cassette contains two chambers: an upper air trap chamber and a pumping chamber. The two chambers are separated by an inlet valve (see Figure 4-7 and Figure 4-8) and operate together to detect air. The air trap chamber receives fluid from the intravenous (IV) container through either the A or B valve. The air trap chamber collects air bubbles from the IV line and container to prevent them from entering the pumping chamber and can collect a substantial amount of air.

A proximal air-in-line sensor (bubble detector) is located between the A/B valves and the upper air-trap chamber. The proximal air-in-line sensor detects air entering the upper air-trap chamber and initiates an audible alarm if the predetermined air collection threshold is exceeded. Similarly, a second air-in-line sensor located distal to the pumping chamber initiates an audible alarm if a predetermined amount of air is detected. The infusion pump expels air from the cassette.

The pumping chamber receives fluid from the upper air-trap chamber through an inlet valve. A pressure sensor located in the upper air-trap chamber monitors pressure on the proximal side of the cassette. When the diaphragm covering the pumping chamber is deflected by the plunger, the pumping chamber expels fluid through an outlet valve. A pressure sensor located distal to the pumping chamber monitors pressure on the distal side of the cassette.

A flow regulator is incorporated into the cassette distal end. This flow regulator is used to manually control flow when the cassette is not inserted in the infusion pump. When the cassette is properly inserted into the pump and the door is closed, a mechanism opens the flow regulator to allow the pump to control fluid flow. When the door is opened, the same mechanism closes the flow regulator to disable fluid flow.

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SECTION 4 THEORY OF OPERATION

SECONDARY PORT

PRESSURE SENSOR

RIGHT VIEW

(Y-RESEAL OR LOCKING CAP)

B VALVE

AIR-IN-LINE

SENSOR

(PROXIMAL)

AIR TRAP

CHAMBER

INLET VALVE

FROM PRIMARY

CONTAINER

REAR VIEW

PRECISION GRAVITY

(CONTROL NOT SHOWN)

A VALV E

AIR-IN-LINE

SENSOR (DISTAL)

PRESSURE SENSOR

(DISTAL)

OUTLET VALVE

PUMPING CHAMBER

FLOW REGULATOR

FINGER

GRIP

OUTLET

PATIENT

LEFT VIEW

98G01017

Figure 4-7. Major Elements of the Dual-Channel Cassette

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Page 60

LINE A

4.5 MECHANICAL OVERVIEW

A VALV E

AIR TRAP CHAMBER

INLET VALVE

OUTLET VALVE

LINE B

B VALVE

AIR-IN-LINE SENSOR (PROXIMAL)

PRESSURE SENSOR (PROXIMAL)

PUMPING CHAMBER

PRESSURE SENSOR (DISTAL)

AIR-IN-LINE SENSOR (DISTAL)

PRECISION GRAVITY

FLOW REGULATOR (AND SHUT OFF)

98G01001

Figure 4-8. Fluid Path in the Cassette

4.5.2

MECHANISM ASSEMBLY

The mechanism assembly is a fully self-contained unit consisting of the motor and valve assemblies, A/B valve subsystem, inlet/outlet valve subsystem, plunger drive subsystem, air bubble (ultrasonic) sensor assemblies, cassette door, and pressure sensor assemblies. The motor and valve assemblies, A/B valve subsystem, inlet/outlet valve subsystem, and plunger drive subsystem are detailed in the following sections.

During pump operation, the mechanism assembly plunger motor drives a lead screw that is coupled to the plunger. The motor action and lead screw move the plunger forward to cause the delivery of approximately 0.33 mL of fluid per cycle. The plunger motion is synchronized to the valve motors to provide controlled fluid delivery.

4.5.2.1

MOTOR AND VALVE ASSEMBLIES

The mechanism assembly pumping action is controlled by three stepper motors. The first stepper motor, in conjunction with an associated valve assembly, activates the A or the B valve of the cassette, depending on the command. The second stepper motor alternately opens and closes the inlet and outlet valve to control fluid delivery through the cassette pumping chamber. A third stepper motor controls plunger movement.

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SECTION 4 THEORY OF OPERATION

4.5.2.2

A/B VALVE SUBSYSTEM

The A/B valve subsystem includes a motor designed to rotate a cam (see Figure 4-9,

Mechanism Valve Pins and Sensor Locations). When the cam is positioned at

top-dead-center (home position), both valves are closed. Clockwise rotation (when viewed from the motor side) from the home position opens the A valve, while the B valve remains closed. Counterclockwise rotation opens the B valve, while the A valve remains closed.

The A/B valve subsystem consists of a stepper motor with attached cam and integral cam flag, A and B rockers and valve pins, and a pin detector assembly. The cam flag passes through an interrupter module as it rotates with the cam. Valve home position is determined by this cam flag/interrupter module combination through predetermined factory calibration data. During operation, if the cam flag passes through the interrupter module at the incorrect time sequence, a motor phase loss is detected. The rocker is the connecting link between the cam and the valve pin.

A VALV E

REGULATOR ACTUATOR

AIR-IN-LINE SENSOR (DISTAL)

PRESSURE SENSOR (DISTAL)

CASSETTE LOCATOR

OUTLET VALVE

Figure 4-9. Mechanism Valve Pins and Sensor Locations

PLUNGER

INLET VALVE

B VALVE

AIR-IN-LINE SENSOR

(PROXIMAL)

PRESSURE SENSOR

(PROXIMAL)

FORCE SENSING

RESISTOR

02K01023

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4.5 MECHANICAL OVERVIEW

4.5.2.3

INLET/OUTLET VALVE SUBSYSTEM

The inlet/outlet valve subsystem is similar in function and build to the A/B valve subsystem (see Section 4.5.2.2).

4.5.2.4

PLUNGER DRIVE SUBSYSTEM

The main components of the plunger drive subsystem are: plunger, lead screw and coupler, and stepper motor. When the pump is turned on, the plunger moves from the retracted, PARK position to the HOME position. The cassette diaphragm is engaged. The stepper motor rotates approximately 1 2/3 revolutions per pump cycle to permit a 0.33 mL fluid displacement every pump cycle. The stepper motor then reverses and the plunger returns to HOME position. This cycle repeats for the duration of fluid administration.

The screw/coupler assembly links the motor and the plunger. This assembly includes a flag that passes through an interrupter module. This screw/coupler, flag/interrupter module combination is used in conjunction with predetermined factory calibration data to determine the plunger position. During operation, if the screw/coupler flag passes through the interrupter module at the incorrect time sequence, a motor phase loss is detected.

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SECTION 4 THEORY OF OPERATION

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Section 5

MAINTENANCE AND SERVICE TESTS

A complete maintenance program promotes infusion pump longevity and trouble-free instrument operation. Such a program should include routine maintenance, periodic maintenance inspection, and following any repair procedure, performance verification testing.

5.1

ROUTINE MAINTENANCE

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

5.1.1

INSPECTING THE INFUSION PUMP

Inspect the infusion pump periodically for signs of defects such as worn accessories, broken instrument connections, or damaged cables. In addition, inspect the infusion pump after repair or during cleaning. Replace any damaged or defective external parts. See Section 5.2.2, Inspection, for a detailed list of areas to be inspected.

5.1.2

CLEANING THE INFUSION PUMP

The following procedures are designed to maintain the infusion pump, sustain system longevity, and promote trouble-free instrument operation.

Follow hospital protocol for establishing the infusion pump cleaning schedule.

WARNING:

CAUTION: Do not immerse the infusion pump in liquids. Immersion could damage the instrument. Do not allow liquids to enter the infusion pump electronics compartment.

DISCONNECT THE INFUSION PUMP FROM AC POWER PRIOR TO CLEANING THE INSTRUMENT. FAILURE TO COMPLY WITH THIS WARNING COULD RESULT IN ELECTRICAL SHOCK.

CAUTION: Do not spray cleaning solutions toward any openings in the infusion pump.

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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 Abbott Laboratories 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 infusion pump with a soft, lint-free cloth dampened with one of the cleaning solutions listed in Table 5-1, Cleaning Solutions, or a mild solution of soapy water. Remove soap residue with clear water. Do not use solvents that are harmful to plastic, such as isopropyl alcohol or acetone. Do not use abrasive cleaners.

CAUTION: To avoid infusion pump damage, 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

HB Steris Corporation Per manufacturer's

recommendation

Dispatch

Caltech Industries Per manufacturer's

recommendation

Formula C

JohnsonDiversey Per manufacturer's

recommendation

Manu-Klenz

Steris Corporation Per manufacturer's

recommendation

Precise

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

5.1.3

SANITIZING THE INFUSION PUMP

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

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

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

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5.2 PERFORMANCE VERIFICATION TEST

5.2

PERFORMANCE VERIFICATION TEST

The Performance Verification Test (PVT) consists of the tests described in the following sections. The PVT can be used for diagnostic purposes during the troubleshooting of a malfunctioning infusion pump. The PVT should be used for performance verification before an infusion pump is placed back in service after repair. If any malfunction is detected as a result of the PVT, refer to Table 6-3, Troubleshooting with the PVT.

 Note: The PVT must be performed exactly as described in this manual to assure

effective and reliable product evaluation information.

 Note: When performing the PVT, all lines must be tested. However, if appropriate,

the test may be performed on all lines concurrently.

5.2.1

EQUIPMENT REQUIRED

The PVT requires the following equipment (or equivalents):

❏ Graduated cylinder, 25 mL, with 0.2 mL graduations (Type A)

❏ Sterile water or tap water in an IV bag/container

❏ Digital pressure meter (DPM), 0 to 50 psi (Fluke

❏ Three-way stopcock, latex-free (List No. 3233-01, or equivalent)

❏ IV Set (List No. 11419, or equivalent)

❏ 21-gauge butterfly needle, latex-free (List No. 4492-01, or equivalent),

or 18-gauge blunt cannula

❏ Safety analyzer (Fluke Biomedical 232D)

❏ Stopwatch

❏ Digital multimeter (DMM), (Fluke Biomedical 8012A) (optional)

❏ Barcode directory (optional)

❏ Nurse call test cable (P/N 561-88416-001, or equivalent) (optional)

Biomedical DPM3)

Technical Service Manual 5 - 3 430-95424-001 (Rev. 09/03)

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SECTION 5 MAINTENANCE AND SERVICE TESTS

5.2.2

INSPECTION

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

Inspect the following areas for missing or damaged parts:

- Labels

- AC power cord

- Velcro

- Rubber foot pads

- Door assembly and handle

- Keypad

retainer straps

- External screws

- Pole clamp assembly

- Front and rear enclosures

- Battery access cover

- LCD

- LEDs

5.2.3

TEST SETUP

WARNING:

To set up the infusion pump for the PVT, proceed as follows:

1. Confirm the infusion pump and appropriate accessories are assembled.

2. Hang two sterile water containers at a height of 18 ± 6 inches (46 ± 15.3 cm) above the pumping chamber of the device.

3. Connect the infusion pump to AC power. Conduct all tests with the pump connected to AC power unless otherwise specified.

4. Press [ON/OFF] to turn on the pump.

5. Verify the infusion pump is in the unlocked mode. Toggling the [LOCKOUT] switch alternates between unlocked [DOWN] and locked [UP] modes.

6. Press [ON/OFF] to turn off the pump.

A PATIENT SHOULD NEVER BE CONNECTED TO THE INFUSION PUMP DURING DEVICE TESTING.

5.2.4

SELF TEST

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

 Note: If an alarm condition occurs during the self test, cycle the power and repeat

the self test. If the alarm condition recurs, note the message and take corrective action

(see Section 6, Troubleshooting). Repeat the self test. If the alarm condition recurs,

remove the Plum A+3 infusion system from service and contact Abbott Laboratories.

 Note: Screen representations are examples only, and do not necessarily reflect the

most current software version.

430-95424-001 (Rev. 09/03) 5 - 4 Plum A+3 Infusion System

Page 68

5.2 PERFORMANCE VERIFICATION TEST

To perform the self test, refer to Figure 5-1, LCD and Keypad, and proceed as follows:

1. Connect the AC power cord to a grounded AC outlet. Verify the charging/line

indicator CHARGE illuminates and an alarm beep sounds.

2. Without a cassette installed, press [ON/OFF] to turn on the pump.

3. The LCD screen briefly displays the SELF TEST screen. Verify the screen display

matches Figure 5-1.

 Note: If the SELF TEST screen does not appear, contact Abbott Laboratories.

4. After the self test is complete, the message “INSERT PLUM SET CLOSE LEVER” appears. Press the decimal [.] key, then [START].

5. Using the [SELECT] key, select Set Time and Date, and press the [Choose] softkey.

6. Verify the time and date. To set the time and date, refer to Section 1.8.3, Setting the

Time and Date.

7. Press [ON/OFF] to exit the SET TIME AND DATE screen.

8. Press [ON/OFF] to turn the pump back on.

9. Open the cassette door and insert a primed cassette. Close the cassette door. The cassette test is complete when the “CASSETTE TEST IN PROGRESS” message disappears.

 Note: The message “MECHANISM INITIALIZATION IN PROGRESS” may briefly

appear prior to the “CASSETTE TEST IN PROGRESS” message.

10. If previously entered programming exists, the “CLEAR SETTINGS?” message appears. Press the [Yes] softkey to clear the settings.

Technical Service Manual 5 - 5 430-95424-001 (Rev. 09/03)

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SECTION 5 MAINTENANCE AND SERVICE TESTS

ABBOTT Plum A+

LINE FLOW

INDICATORS

STATUS REGION

MESSAGE REGION

SOFTKEY LABEL REGION

LINE INDICATOR

START

STOP

CHARGE

ON OFF

Release XX.X - MM/DD/YY

2002

System Self Test

ogress

In Pr

1 4

CLEAR

2 5

8 0

3 6

WORKING

REGION

SOFTKEYS

SELECT

KEYPAD

SILENCE

98G01002

Figure 5-1. LCD and Keypad

5.2.5

CASSETTE ALARM TEST

To perform the cassette alarm test, proceed as follows:

1. Verify the infusion pump is on. Insert an empty cassette and close the door.

2. Verify the “CASSETTE TEST FAIL” message is flashing on the display and the alarm

sounds after the cassette test is complete.

3. Open the door and remove the cassette.

4. Press [ON/OFF] to turn off the pump.

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5.2 PERFORMANCE VERIFICATION TEST

5.2.6

FREE FLOW TEST

To perform the free flow test, proceed as follows:

1. With a primed cassette installed, press [ON/OFF] to turn on the pump.

2. After the self test, press [Yes] to clear settings.

3. Place the distal end of tubing into a collection container a minimum of 36 inches below the cassette.

4. With the cassette door closed, check the distal end of the tubing for fluid flow. Verify a minimal flow of fluid occurs (a few drops maximum).

5. Open the cassette door and check the distal end of the tubing for fluid flow. Verify a minimal flow of fluid occurs (a few drops maximum).

 Note: A small amount of fluid may be expelled from the cassette when opening

or closing the door.

6. Close the cassette door.

5.2.7

DISPLAY TEST

To perform the display test, refer to Figure 5-1, then proceed as follows:

1. Verify the LCD backlight is illuminated and the display is clearly legible at eye level from approximately 18 inches.

2. With the pump in the DELIVERY screen, press the [Options/Vol Inf] softkey to select the OPTIONS screen.

3. Using the [SELECT] key, select Lighting/Contrast, and press [Choose].

4. Press the [Decrease Setting] and [Increase Setting] softkeys to change backlight intensity. Verify intensity decreases and increases.

5. Using the [SELECT] key, select Display Contrast.

6. Press [Decrease Setting] and [Increase Setting] to change display contrast. Verify the display contrast decreases and increases.

7. Press the [Cancel] softkey to return to the OPTIONS screen.

8. Press the [Back] softkey to return to the DELIVERY screen.

5.2.8

KEYPAD VERIFICATION/FUNCTIONAL TEST

To perform the keypad verification/functional test, refer to Figure 5-1, then proceed as follows:

1. With the pump in the DELIVERY screen, press the [A] softkey to select Line A.

2. Verify the PROGRAM screen is displayed.

3. Using the numeric keypad, enter a rate of 123 mL/hr.

4. Using the [SELECT] key, select VTBI.

5. Using the numeric keypad, enter a VTBI of 4567 mL.

6. Press [START]. Verify fluid is pumping, the message “PUMPING” is displayed in the line A status bar, and the line A LED flashes.

Technical Service Manual 5 - 7 430-95424-001 (Rev. 09/03)

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SECTION 5 MAINTENANCE AND SERVICE TESTS

7. Press [STOP], then press and hold the [Backprime] softkey.

8. Verify the “BACKPRIMING” and “RELEASE BACKPRIME TO STOP” messages are displayed, and verify the pump is actually backpriming.

9. Release the [Backprime] softkey, press [START], and verify normal pumping operation.

10. Press the [B] softkey.

11. Verify PIGGYBACK is the displayed delivery mode. If necessary, change the delivery

mode by pressing the [Change Mode] softkey.

12. Using the [SELECT] key, select Rate.

13. Using the numeric keypad, enter a rate of 890 mL/hr.

14. Using the [SELECT] key, select VTBI.

15. Using the numeric keypad, enter a VTBI of 2.0 mL.

16. Press [START] and verify fluid is pumping. Verify the message “PUMPING” is displayed in the line B status bar, the line B LED flashes, and line A goes into Delayed mode.

17. After 20 seconds, verify pumping has switched to line A.

18. Press [STOP].

19. Press [Options/Vol Inf]. Select Volume Infused, and press [Choose].

20. Using the [SELECT] key, select Line A.

21. Press the [CLEAR] key. Verify the line A volume is 0.0 mL and press [Enter].

5.2.9

ALARM LOUDNESS TEST

To perform the alarm loudness test, refer to Figure 5-2, Rear Enclosure and Peripheral/

Interface Assembly, then proceed as follows:

1. Press the [A] softkey to select Line A.

2. Enter a rate of 400 mL/hr and a VTBI of 1 mL, then press [START].

3. Verify the alarm sounds when the dose has been delivered.

4. Turn the volume control knob between HIGH and LOW and verify the alarm loudness changes. The volume control knob is located on the peripheral/interface assembly.

5. Press the [SILENCE] key, and verify the alarm is silenced.

6. Press [STOP].

430-95424-001 (Rev. 09/03) 5 - 8 Plum A+3 Infusion System

Page 72

VOLUME CONTROL KNOB

LOCKOUT SWITCH

NURSE CALLBACK

BARCODE

DATAPORT

PERIPHERAL/ INTERFACE ASSEMBLY

5.2 PERFORMANCE VERIFICATION TEST

REAR ENCLOSURE

01K07016

Figure 5-2. Rear Enclosure and Peripheral/Interface Assembly

5.2.10

LOCKOUT SWITCH TEST

To perform the lockout switch test, refer to Figure 5-2, then proceed as follows:

1. Press the [A] softkey to select Line A.

2. Enter a rate of 400 mL/hr and a VTBI of 50 mL.

3. Press [START], and verify the pump is operating.

4. Toggle the lockout alarm switch up (ON) to engage the alarm. The lockout switch is located on the peripheral/interface assembly.

5. Press any key except [STOP], and verify an alarm sounds and the “HARD LOCKOUT ENABLED” message is displayed. Verify the pump continues to operate until [STOP] is pressed.

6. Press [STOP] and verify the “HARD LOCKOUT VIOLATION” message appears.

7. Toggle the lockout alarm switch down (OFF). Verify the “HARD LOCKOUT VIOLATION” message disappears and the alarm stops.

8. Press [START].

9. Open the door and verify the “DOOR OPEN WHILE PUMPING” message is displayed and the audio alarm activates.

10. Close the cassette door.

11. Press [No] at the “CLEAR SETTINGS?” prompt.

Technical Service Manual 5 - 9 430-95424-001 (Rev. 09/03)

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SECTION 5 MAINTENANCE AND SERVICE TESTS

5.2.11

PROXIMAL OCCLUSION TEST

To perform the proximal occlusion test, proceed as follows:

1. Press the [A] softkey to select Line A.

2. Enter a rate of 400 mL/hr and a VTBI of 50 mL.

3. Press [START].

4. After several pumping cycles, clamp line A tubing proximal to the cassette. Verify the “PROX OCCL A/AIR” message flashes and the alarm sounds before three pumping cycles are completed.

5. Press the [SILENCE] key and verify the alarm stops while the message on the display continues to flash.

6. Unclamp the proximal line and press [START]. Verify pumping resumes.

7. Press [STOP].

5.2.12

PROXIMAL AIR-IN-LINE TEST

To perform the proximal air-in-line alarm test, refer to Figure 5-3, Special Cassettes

with Bubble Sensor Tips Removed, then proceed as follows:

1. Install the special cassette marked proximal, and close the cassette door.

 Note: Confirm the special cassette proximal bubble sensor tips are removed

(see Figure 5-3).

2. Press [Yes] to clear settings.

3. Press the [A] softkey to select Line A.

4. Enter a rate of 400 mL/hr and a VTBI of 50 mL.

5. Press [START].

6. Before 1 mL of fluid is delivered, verify the alarm sounds and the “PROX AIR A. BACKPRIME” message is flashing on the display.

7. Press [STOP], open the door, and remove the special cassette.

430-95424-001 (Rev. 09/03) 5 - 10 Plum A+3 Infusion System

Page 74

PROXIMAL BUBBLE SENSOR BULB TIPS (REMOVED FOR PROXIMAL-AIR-IN-LINE ALARM TEST)

5.2 PERFORMANCE VERIFICATION TEST

(REMOVED FOR DISTAL-AIR-IN-LINE ALARM TEST)

CASSETTE CENTERING DEVICE

DISTAL BUBBLE SENSOR BULB TIPS

98G01024

Figure 5-3. Special Cassettes with Bubble Sensor Tips Removed

5.2.13

DISTAL AIR-IN-LINE TEST

To perform the distal air-in-line alarm test, refer to Figure 5-3, then proceed as follows:

1. Install the special cassette marked distal, and close the cassette door.

 Note: Confirm the special cassette distal bubble sensor tips are removed

(see Figure 5-3).

2. Press [Yes] to clear settings.

3. Press the [A] softkey to select Line A.

4. Enter a rate of 400 mL/hr and a VTBI of 50 mL.

5. Press [START].

6. Before 1 mL of fluid is delivered, verify the alarm sounds and the “DISTAL AIR” message is flashing on the display.

7. Press [STOP], open the door, and remove the special cassette.

Technical Service Manual 5 - 11 430-95424-001 (Rev. 09/03)

Page 75

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.2.14

DISTAL OCCLUSION TEST

To perform the distal occlusion test, refer to Figure 5-4, Distal Occlusion Test Setup, then proceed as follows:

1. Install the cassette and connect the distal tubing to the DPM through a three-way stopcock as illustrated in Figure 5-4. Close the cassette door.

 Note: A reflux valve may be attached between the stopcock and the DPM

to keep moisture out of the DPM.

 Note: The height of the DPM must be 0 ± 12 inches from the midline of the

pumping chamber.

2. Press [ON/OFF] to turn on the pump.

3. Press [Yes] to clear settings.

4. Press [Options/Vol Inf] to select the OPTIONS screen.

5. Using the [SELECT] key, select Pressure/Post Infusion Rate, and press [Choose].

6. Verify the distal pressure Limit is set at 6.0 psi. If the pressure limit is not 6.0 psi, use the numeric keypad to enter 6.0 and press [Enter].

7. Press the [A] softkey to select Line A.

8. Enter a rate of 40 mL/hr and a VTBI of 50.0 mL.

9. Open the three-way stopcock to air.

10. Press [START] and allow the infusion pump to stabilize for one minute. Verify all air is cleared from the tubing.

11. Set the three-way stopcock to measure pressure.

12. Verify the distal occlusion audible alarm occurs at 6.0 ± 2.0 psi. Verify the “DISTAL OCCLUSION” message is flashing on the screen.

13. Open the three-way stopcock to air.

14. Open and close the door. Press [No] at the “CLEAR SETTINGS?” prompt.

15. Press [Options/Vol Inf] to select the OPTIONS screen.

16. Using the [SELECT] key, select Pressure/Post Infusion Rate, and press [Choose].

17. Using the [SELECT] key, select Distal Pressure Limit.

18. Using the numeric keypad, enter 10.0 psi, and press [Enter].

19. Set the three-way stopcock to measure pressure, then press [START].

20. Verify the distal occlusion audible alarm occurs at 10.0 ± 2.0 psi. Verify the “DISTAL OCCLUSION” message is flashing on the screen.

21. Open the door and remove the cassette.

430-95424-001 (Rev. 09/03) 5 - 12 Plum A+3 Infusion System

Page 76

5.2 PERFORMANCE VERIFICATION TEST

OFF

mmHg

cmOFHO

-13.5TO15

-13.5TO75

PSI

INCHES OFH O

UNIVERSAL

PRESSUREMETER

PRESSUREINPUT

OFF

mmHg

cmOFHO

-13.5TO15

-13.5TO75

PSI

INCHES OFH O

UNIVERSAL

PRESSUREMETER

PRESSUREINPUT

FROM FLUID CONTAINERS

DPM

THREE-WAY STOPCOCK

UNIVERSAL

PRESSUREMETER

0.00

INCHES OFH O

cmOFHO

mmHg

-13.5TO15

mmHg

-13.5TO15

PSI

OFF

-13.5TO75

PRESSUREINPUT

-13.5TO75

01K07018

Figure 5-4. Distal Occlusion Test Setup

5.2.15

DELIVERY ACCURACY TEST

 Note: Accuracy testing is for informational purposes only, and is not to be used

as a re-release test. If there is any concern as to infusion pump accuracy,

contact Abbott Laboratories.

CAUTION: Do not remove the protective cover from the 21-gauge needle.

To perform the delivery accuracy test, proceed as follows:

1. Install an 18-gauge blunt cannula or a 21-gauge needle to the distal end of the tubing. Verify the fluid container is 18 to 24 inches above the pumping chamber. Verify all lines are unclamped.

2. Place the distal output end of tubing into the graduated cylinder.

3. Press the [A] softkey to select Line A.

4. Enter a rate of 200 mL/hr and a VTBI of 10 mL. Start the stopwatch and press [START] simultaneously.

5. Press the [B] softkey to select Line B.

6. Verify the pump is in the PIGGYBACK delivery mode. Press [Change Mode] to change the delivery mode, if necessary.

7. Enter a rate of 200 mL/hr and a VTBI of 10 mL.

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SECTION 5 MAINTENANCE AND SERVICE TESTS

8. Press [START], and verify the pump switches to line B.

9. Verify the “KVO” message flashes on the display and an audible alarm sounds when total delivery is complete on line A.

 Note: When the “KVO” message appears, stop the stopwatch and press

[STOP].

10. Verify the volume delivered is 20 mL ± 0.8 mL.

11. Use the following formula to calculate the delivery accuracy.

[(Total volume delivered (mL) x (18 sec/mL)]

Total delivery time (sec)

An example:

[(20.4 mL) x (18 sec/mL)]

360 sec

12. Verify the accuracy is 1.0 ± 0.04.

1.02

5.2.16

ELECTRICAL SAFETY TEST

To perform the electrical safety test, proceed as follows:

1. Connect the infusion pump AC power cord to a safety analyzer.

2. Connect the safety analyzer ground lead to the infusion pump ground test-point located on the rear of the pump.

3. Check the leakage current with the safety analyzer. Leakage current (both open and closed ground) must not exceed 100 microamperes AC

4. Measure the resistance of the AC connector ground lug with the safety analyzer. Resistance should not exceed 0.1 ohm.

rms

5.2.17

END OF THE PVT

If all performance verification tests have been successful, proceed as follows:

1. Press [Options/Vol Inf]. Select Volume Infused, and press [Choose].

2. Press [CLEAR] to clear the volume infused.

3. Press [Enter].

4. Press the [A] softkey.

5. Press the [Clear Program] softkey.

6. Press [Yes] at the “CLEAR LINE A SETTINGS?” prompt.

7. Press [Cancel/Back] to return to the delivery screen.

8. Press the [B] softkey.

9. Press the [Clear Program] softkey.

10. Press [Yes] at the “CLEAR LINE B SETTINGS?” prompt

430-95424-001 (Rev. 09/03) 5 - 14 Plum A+3 Infusion System

Page 78

5.3 BARCODE READER WAND TEST (OPTIONAL)

11. Reset the infusion pump to the original configuration.

12. Turn off the pump and return it to service.

 Note: If any tests fail, refer to Section 6, or contact Abbott Laboratories.

5.3

BARCODE READER WAND TEST (OPTIONAL)

 Note: The barcode reader wand test may be bypassed if the barcode reader function

is not used.

To perform the barcode reader wand test, proceed as follows:

1. Remove the plastic cover from the 9-pin connector on the peripheral/interface assembly, and connect the barcode reader wand to the 9-pin connector.

2. Insert a primed cassette and close the door.

3. Press [ON/OFF] to turn on the infusion pump. Press [Yes] to clear settings.

4. Set the rate to 100 mL and the VTBI to 50 mL.

5. Verify the “WAND ACTIVE” message appears on the display.

6. Scan a barcode label from the barcode directory, and verify the corresponding drug name is displayed.

5.4

NURSE CALL TEST (OPTIONAL)

 Note: The nurse call test may be bypassed if the nurse call function is not used.

To perform the nurse call test, attach the nurse call test cable and proceed as follows:

1. Set the primary delivery rate to 400 mL/hr, and the primary dose limit to 1 mL.

2. Connect the DMM to the nurse call test cable.

3. Press [START] and verify pumping action.

4. After “DOSE END” and “KVO” appear on the display, observe a short circuit on the DMM (approximately 1 ohm on a scale of 0 to 100 ohms).

5.5

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 an infusion pump periodic maintenance inspection schedule. Product specifications for this inspection are listed in Section 8, Specifications.

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

Technical Service Manual 5 - 15 430-95424-001 (Rev. 09/03)

Page 79

SECTION 5 MAINTENANCE AND SERVICE TESTS

5.6

BATTERY OPERATION OVERVIEW

The Plum A+3 infusion pump is intended to operate on battery power on an exception basis only, such as emergency backup or temporary portable operation. Examples of emergency backup include AC power failure or inadvertent disconnection of the AC power cord. An instance of temporary portable operation includes patient transfer from one location to another.

The infusion pump should be connected to AC power whenever possible to allow the battery to remain fully charged. The line power indicator turns off and the BATTERY legend illuminates when the infusion pump is operating on battery power. The backlight extinguishes after one minute of pump operation on battery power.

Factors that most commonly affect battery life are the depth and frequency of discharge and the length of the recharge period. As a general rule, the more often the battery is discharged and recharged, the sooner it will need replacement. The primary cause of damage is leaving the battery in a less than fully charged state for any period of time. Battery damage can occur in a matter of hours and cause a permanent loss of battery capacity. The amount of lost capacity depends on the degree of discharge, the storage temperature, and the length of time the battery was stored in a discharged state.

 Note: A permanently damaged battery cannot be recharged to full capacity.

When the battery discharges below the acceptable level while the infusion pump is operating, the alarm sounds and the “LOW BATTERY” message displays. Although it is not recommended to continue operating the device on battery power at this point, the battery continues providing power until discharged. At this point, the infusion pump enters the battery discharged mode, a continuous audible alarm sounds and, after three minutes, operation ceases.

CAUTION: As soon as the LOW BATTERY alarm occurs, connect the infusion pump to AC power.

Recharging occurs any time the infusion pump is connected to AC power. It is recommended that the pump be connected to AC power whenever practical to maximize available battery charge during transport or ambulation. The device does not have to be on for the battery to recharge. Recharging while the infusion pump is operating is rate dependent.

 Note: The infusion pump should be operated on battery power for six continuous

hours at least once every six months for optimum battery performance and life.

430-95424-001 (Rev. 09/03) 5 - 16 Plum A+3 Infusion System

Page 80

Section 6

TROUBLESHOOTING

This section contains information on technical assistance, alarm messages and error codes, and troubleshooting procedures for the Plum A+3 infusion system.

6.1

TECHNICAL ASSISTANCE

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

Operations.

1-800-241-4002

For additional technical assistance, including Technical Service Bulletins, technical training, and product information, visit the website at:

www.abbotthpd.com/service

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

Abbott Laboratories

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 Abbott Laboratories sales office.

6.2

ALARM MESSAGES AND ERROR CODES

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

There are two types of alarm conditions:

- alarm codes that can be cleared by the operator

- error codes that require qualified service personnel

See Table 6-1, Operational Alarm Messages and Corrective Actions, and Table 6-2,

Error Codes Requiring Technical Service.

Technical Service Manual 6 - 1 430-95424-001 (Rev. 09/03)

Page 81

SECTION 6 TROUBLESHOOTING

6.2.1

OPERATIONAL ALARM MESSAGES

Table 6-1 lists infusion pump alarm codes that can be cleared by the operator. Also listed

in Table 6-1 are the alarm messages, descriptions, possible causes, and corrective actions.

 Note: Operational alarm messages are displayed on the LCD screen. Associated error

codes are displayed in the alarms log (see Section 1.8.2).

 Note: If an alarm message persists, contact Abbott Laboratories.  Note: Air-in-line on either line applies to both lines.

Table 6-1. Operational Alarm Messages and Corrective Actions

Alarm

Code

N100

E100

(URC)

N101

E101

(NAA)

N102

E102

(RL)

N103

E103

(SEEP

CRC)

N104

E104

(NC2)

Alarm Description Possible Cause

Unrecognizable cassette

No action No operator action

Infuser idle 2 minutes

NV RAM lost thrpy data

Nurse Callback B Delivery line B

Incorrect cassette type

and no delivery for two minutes during delivery parameters entry

Infuser in reset or idle for over two minutes

Therapy data is lost Infuser did not

has changed (if alarm is enabled)

An incorrect cassette is inserted

Interruption or a partial change to a program

Programming set without start for two minutes

complete the previous non-volatile memory write successfully

End of delivery step on line B other than VTBI complete while callback is enabled

Corrective

Action

Insert proper cassette

Complete programming of the pump

Press [START]

Re-enter all programmed data

Press [SILENCE]

N105

E105

(NC1)

N160

E160

(VTB2)

430-95424-001 (Rev. 09/03) 6 - 2 Plum A+3 Infusion System

Nurse Callback A Delivery line A

has changed (if alarm is enabled)

Line B VTBI complete

Programmed volume to be infused completed on line B

End of delivery step on line A other than VTBI complete while callback is enabled

VTBI is complete on line B

Press [SILENCE]

Press [SILENCE] and replace IV bag, and restart line B

Page 82

6.2 ALARM MESSAGES AND ERROR CODES

Table 6-1. Operational Alarm Messages and Corrective Actions

Alarm

Code

N161

E161

(VTB1)

N180

E180

(OD1)

N181

E181

(OD1)

N182

E182

(OP2)

Alarm Description Possible Cause

Line A VTBI complete

Programmed volume to be

VTBI is complete

on line A infused completed on line A

Distal Occl Peak distal

occlusion, non-delivery

Distal Occl Negative distal

occlusion, non-delivery

Prox. Occl B Negative proximal

occlusion B, non-delivery

Distal occlusion

detected during

non-delivery

Distal occlusion

detected during

non-delivery

Proximal

occlusion

detected on

line B during

non-delivery

Corrective

Action

Press [SILENCE] and replace IV bag, and restart line A

Backprime the cassette and restart pump

Backprime the cassette and restart line B or Stop all lines, backprime the cassette, and restart all lines

N183

E183

(OP2)

N184

E184

(OP1)

N185

E185

(OP1)

Prox. Occl B Peak proximal

occlusion B, non-delivery

Prox. Occl A Negative proximal

occlusion A, non-delivery

Prox. Occl A Peak proximal

occlusion A, non-delivery

Proximal

occlusion

detected on

line B during

non-delivery

Proximal

occlusion

detected on

line A during

non-delivery

Proximal

occlusion

detected on

line A during

non-delivery

Backprime the cassette and restart line B or Stop all lines, backprime the cassette, and restart all lines

Backprime the cassette and restart line A or Stop all lines, backprime the cassette, and restart all lines

N186

E186

(OD1)

Technical Service Manual 6 - 3 430-95424-001 (Rev. 09/03)

Distal Occl Peak distal

occlusion, delivery

Distal occlusion

detected during

delivery

Fix occlusion (closed clamps; kinked tubing), and restart pump

Page 83

SECTION 6 TROUBLESHOOTING

Table 6-1. Operational Alarm Messages and Corrective Actions

Alarm

Code

N187

E187

(OD1)

N188

E188

(OP2)

N189

E189

(OP2)

Alarm Description Possible Cause

Distal Occl Negative distal

occlusion, delivery

Prox. Occl B Negative proximal

occlusion B, delivery

Distal occlusion detected during delivery

Proximal occlusion detected during delivery on line B

Prox. Occl B Peak proximal

occlusion B, delivery

Proximal occlusion detected during delivery on line B

Corrective

Action

Fix occlusion (closed clamps; kinked tubing), and restart pump

Fix occlusion (closed clamps; kinked tubing), and restart line B or Stop all lines, fix occlusion (closed clamps; kinked tubing), and restart pump

N190

E190

(OP1)

N191

E191

(OP1)

Prox. Occl A Negative proximal

occlusion A, delivery

Prox. Occl A Peak proximal

occlusion A, delivery

Proximal occlusion detected during delivery on line A

Fix occlusion (closed clamps; kinked tubing), and restart line A or Stop all lines, fix occlusion (closed clamps; kinked tubing), and restart pump

430-95424-001 (Rev. 09/03) 6 - 4 Plum A+3 Infusion System

Page 84

6.2 ALARM MESSAGES AND ERROR CODES

Table 6-1. Operational Alarm Messages and Corrective Actions

Alarm

Code

N230

E230

(APT)

N231

E231

(APB)

N232

E232

(APA)

Alarm Description Possible Cause

Prox. Air Total Proximal

air-in-line total

Prox. Air on B Proximal

air-in-line on line B

500 microliters

of air entered

the cassette

500 microliters

of air entered

the cassette

on line B

Prox. Air on A Proximal

air-in-line on line A

500 microliters

of air entered

the cassette

on line A

Corrective

Action

Backprime the cassette and restart pump or Remove and manually reprime the cassette, and restart pump

Backprime the cassette and restart line B or Remove and manually reprime the cassette and restart pump

Backprime the cassette and restart line A or Remove and manually reprime the cassette and restart pump

N233

E233

(ADC)

N234

E234

(ADB)

N250

E250

(DCO1)

N251

E251

(CS1)

N252

E252

(BDP)

Distal Air Cumulative

Distal air cumulative

500 microliters

of air detected

in the last 5.3 mL

of fluid delivered

Distal Air Bolus Distal air bolus 100 microliters

bolus of air

detected at

distal sensor

Door opened while pumping

Valve/Cass Test Fail

Door opened while pumping

Valve/cassette test failure

Door opened

while pumping

Valve/cassette

fails the leak test

Depleted Battery Discharged battery The battery is

discharged to the

recommended

maximum

discharge

condition

Remove and manually reprime the cassette and restart pump

Turn off the pump or Insert the cassette and close the door

Replace cassette and retest or backprime and retest

Connect the pump to AC power or Recharge or replace the battery

Technical Service Manual 6 - 5 430-95424-001 (Rev. 09/03)

Page 85

SECTION 6 TROUBLESHOOTING

Table 6-1. Operational Alarm Messages and Corrective Actions

Alarm

Code

N253

E253

(LOV)

N254

E254

(FPL)

N255

E255

(SLV)

N256

E256

(SLE)

Alarm Description Possible Cause

Lockout Violation Lockout violation The use of the

[STOP] key or an attempt to open the door while lockout switch is locked

Lockout Enabled Keypad locked Any action not

resulting in stopping of the delivery while the lockout switch is locked

Soft lockout violation

Soft lockout enabled

Soft lockout violation

Soft lockout enabled

The use of the [STOP] key or an attempt to open the door while soft lockout is locked

Any action not resulting in stopping of the delivery while the soft lockout locked

Corrective

Action

Unlock the lockout switch

Enter .963 key code

6.2.2

ERROR CODES REQUIRING TECHNICAL SERVICE

Table 6-2 lists infusion pump error codes that require technical service. Also listed

in Table 6-2 are malfunction descriptions, possible causes, and corrective actions.

Table 6-2. Error Codes Requiring Technical Service

Error

Code

E300 ADC failure Analog to digital

E301 Audio alarm

Malfunction Possible Cause Corrective Action

Replace CPU PWA

failure

converter failure

Piezo is off but sensed on or Piezo is on but sensed off

(see Section 7.2.14.6)

Reset time and date, if required

(see Section 1.8.3)

Turn power off, then on, to reset the pump

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date, if required

(see Section 1.8.3)

430-95424-001 (Rev. 09/03) 6 - 6 Plum A+3 Infusion System

Page 86

Error

Code

6.2 ALARM MESSAGES AND ERROR CODES

Table 6-2. Error Codes Requiring Technical Service

Malfunction Possible Cause Corrective Action

E302 Backlight failure Backlight (CCFT tube)

is not at the expected range

E320 Battery charge

current out

Battery charge current is out of range after six hours

of range

E321 Battery not

charging

Battery charging timed out

Complete battery discharge has occurred

E322 Battery current

calibration value

Battery integrator calibration value is out of range

out of range

E323 Battery trickle

charge current

Battery trickle charge current is out of range

out of range

Turn power off, then on, to reset the pump

Replace LCD

(see Section 7.2.14.3)

and/or CPU PWA

(Section 7.2.14.6)

Reset time and date, if required

(see Section 1.8.3)

Replace battery

(see Section 7.2.4)

Replace power supply PWA

(see Section 7.2.14.1)

Reset time and date, if required

(see Section 1.8.3)

Charge battery for additional six hours

Replace power supply PWA

(see Section 7.2.14.1)

Reset time and date, if required

(see Section 1.8.3)

E324 Supply

overvoltage

E325 Battery

overvoltage

E326 Battery

disconnected

E340 Critical

instruction failure

An overvoltage condition is detected in the charging circuit

An overvoltage condition is detected in the battery

Battery disconnected while pump is powered on

Power-up CPU register test failed (no malfunction message displayed)

Check for loose battery connections

Replace battery

(see Section 7.2.4)

Reset time and date, if required

(see Section 1.8.3)

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date, if required

(see Section 1.8.3)

Technical Service Manual 6 - 7 430-95424-001 (Rev. 09/03)

Page 87

SECTION 6 TROUBLESHOOTING

Table 6-2. Error Codes Requiring Technical Service

Error

Code

Malfunction Possible Cause Corrective Action

E341 Critical data

memory failure

Critical data memory failure Replace mechanism

assembly

(see Section 7.2.14.8)

Reset time and date, if required

(see Section 1.8.3)

E342 Display failure Defective display Replace LCD

(see Section 7.2.14.3)

and/or CPU PWA

(Section 7.2.14.6)

Reset time and date, if required

(see Section 1.8.3)

E343 Distal air sensor

failure 1

E344 Distal air sensor

failure 2

E345 Distal pressure

sensor failure 1

With the cassette removed, the distal air sensor self test detects liquid

With the cassette inserted, the distal air sensor self test detects sensor out of range

Distal pressure sensor failed while pump is OFF

Replace mechanism assembly

(see Section 7.2.14.8)

Reset time and date, if required

(see Section 1.8.3)

E346 Distal pressure

sensor failure 2

E347 Hardware

watchdog failure

E371 I/O valve motor

failure 1

E372 I/O valve motor

failure 2

E373 L/S valve motor

failure 1

E374 L/S valve motor

failure 2

E375 Motor position

sensor failure

E376 Plunger synch

failure 1

Distal pressure sensor failed while pump is ON

Hardware watchdog failure

I/O valve motor malfunction when a total of four resynchronizations failed

I/O valve motor malfunction when three consecutive resynchronizations failed

L/S valve motor malfunction when a total of four resynchronizations failed

L/S valve motor malfunction when three consecutive resynchronizations failed

Motor position sensor failure

Plunger malfunction when resynchronization has failed a total of four times

430-95424-001 (Rev. 09/03) 6 - 8 Plum A+3 Infusion System

Page 88

Error

Code

6.2 ALARM MESSAGES AND ERROR CODES

Table 6-2. Error Codes Requiring Technical Service

Malfunction Possible Cause Corrective Action

E377 Plunger synch

failure 2

E378 I/O valve

phase loss

E379 L/S valve

phase loss

E380 Plunger motor

phase loss

E430 Proximal

air sensor failure 1

Plunger malfunction when three consecutive resynchronizations failed

Replace mechanism assembly

(see Section 7.2.14.8)

Reset time and date, if required

(see Section 1.8.3)

Generic I/O valve failure Turn power off, then on,

to reset infusion pump

Replace mechanism assembly

(see Section 7.2.14.8)

Reset time and date, if required

(see Section 1.8.3)

Generic L/S valve failure

Generic plunger motor failure

Proximal air sensor ongoing test detects liquid with cassette removed

Replace mechanism assembly

(see Section 7.2.14.8)

Reset time and date, if required

(see Section 1.8.3)

E431 Proximal

air sensor failure 2

E432 Proximal

pressure

Proximal air sensor self test detects liquid with cassette removed

Proximal pressure sensor failed while pump is OFF

sensor 1

E433 Proximal

pressure

Proximal pressure sensor failed while pump is ON

sensor 2

E434 RAM failure RAM failure Turn power off, then on,

to reset infusion pump

E435 RTC fail Real-time clock failure

E436 ROM failure ROM checksum failure

E437 Software failure Generic software failure

E438 Stack

Stack out-of-range failure

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date, if required

(see Section 1.8.3)

out-of-range failure

Technical Service Manual 6 - 9 430-95424-001 (Rev. 09/03)

Page 89

SECTION 6 TROUBLESHOOTING

Table 6-2. Error Codes Requiring Technical Service

Error

Code

Malfunction Possible Cause Corrective Action

E439 Stuck key A key is sensed as pressed

for over two minutes

Replace LCD

(see Section 7.2.14.3)

and/or CPU PWA

E440 Power hold stuck Power hold signal stuck

Power cannot be turned off

(Section 7.2.14.6)

Reset time and date, if required

(see Section 1.8.3)

E441 Valve self test

failure

I/O or L/S valve self test failed Replace mechanism

assembly

(see Section 7.2.14.8)

Reset time and date, if required

(see Section 1.8.3)

E443 LCD failure LCD bias is out of range Replace LCD

(see Section 7.2.14.3)

and/or CPU PWA

(Section 7.2.14.6)

Reset time and date, if required

(see Section 1.8.3)

E444 CPU timebase

inaccurate

E445 RTC memory

failure

CPU timer 2 and RTC measured times disagree

Real-time clock memory is corrupt

Turn power off, then on, to reset infusion pump

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date,

E446 CPU timer failure CPU timer 1 and timer 2

measured times disagree

if required

(see Section 1.8.3)

E447 Battery ADC

reading failure

16 consecutive readings have been either all zero or the max value

E448 SEEP write

SEEP data write failed

failure

E449 SEEP calibration

data corrupted

E450 MMIO port

Calibration data block corrupted

I/O port read/write failure read/write failure

E451 Inaccurate

Over/underdelivery detected delivery

E452 Software failure Miscellaneous software

failure

430-95424-001 (Rev. 09/03) 6 - 10 Plum A+3 Infusion System

Page 90

Error

Code

6.3 TROUBLESHOOTING PROCEDURES

Table 6-2. Error Codes Requiring Technical Service

Malfunction Possible Cause Corrective Action

E453 Two SEEP CRC

errors

E454 NVRAM over

capacity

NVRAM data block corrupted Turn power off, then on,

to reset infusion pump

Software trying to write into non-existent NVRAM space

Replace CPU PWA

(see Section 7.2.14.6)

Reset time and date, if required

(see Section 1.8.3)

 Note: Some error codes include sub-ID codes. These sub-ID codes are intended

for Abbott Laboratories internal use only, and should be included when contacting

Abbott Laboratories Technical Support Operations (see Section 6.1).

6.3

TROUBLESHOOTING PROCEDURES

This section details recommended procedures for problems not associated with malfunction alarms. Before performing any troubleshooting procedure, turn the infusion pump off, then on. Allow the self test to complete and proceed as follows:

1. If a malfunction exists, carefully inspect the infusion pump for damage as described in Section 5.2.2.

2. If an infusion pump inspection has not disclosed a malfunction, perform the PVT in Section 5.2. Refer to Table 6-3, Troubleshooting with the PVT, for section reference, probable cause, and corrective actions.

3. If, after completing Steps 1 and 2, a malfunction has not been located, or if the infusion pump persistently fails, contact Abbott Laboratories Technical Support

Operations.

Table 6-3. Troubleshooting with the PVT

Test Failure Probable Cause Corrective Action

Self test

Section 5.2.4

Cassette alarm test

Section 5.2.5

Technical Service Manual 6 - 11 430-95424-001 (Rev. 09/03)

Cassette not properly installed

Defective CPU PWA Replace CPU PWA

Cassette not properly seated

Defective cassette Replace cassette

Reseat cassette

(see Section 7.2.14.6)

Reseat cassette

Page 91

SECTION 6 TROUBLESHOOTING

Table 6-3. Troubleshooting with the PVT

Test Failure Probable Cause Corrective Action

Free flow test

Section 5.2.6

Display test

Section 5.2.7

Keypad test

Section 5.2.8

Alarm loudness test

Section 5.2.9

Cassette not properly

Reseat cassette

seated

Defective cassette Replace cassette

Defective or dirty valve pins Clean valve pins

Replace mechanism assembly

(see Section 7.2.14.8)

Defective display/CPU assembly

Replace LCD

(see Section 7.2.14.3)

and/or CPU PWA

(Section 7.2.14.6)

Defective display/CPU assembly

Replace LCD

(see Section 7.2.14.3)

and/or CPU PWA

(Section 7.2.14.6)

Defective CPU Replace CPU PWA

(see Section 7.2.14.6)

Defective peripheral PWA Replace peripheral PWA

(see Section 7.2.8)

Defective piezo alarm assembly

Replace piezo alarm assembly

(see Section 7.2.14.7)

Lockout switch test

Section 5.2.10

Proximal occlusion test

Section 5.2.11

Proximal air-in-line test

Section 5.2.12

Distal air-in-line test

Section 5.2.13

Defective peripheral PWA Replace peripheral PWA

(see Section 7.2.8)

Closed proximal clamp Open clamp

Cassette not properly

Re-prime cassette

primed

Defective cassette Replace cassette

Dirty sensor pin Clean sensor pin

Defective APP PWA Replace mechanism assembly

(see Section 7.2.14.8)

Defective special cassette Replace special cassette

Dirty sensors Clean sensors

Defective APP PWA Replace mechanism assembly

(see Section 7.2.14.8)

Defective special cassette Replace special cassette

Dirty sensors Clean sensors

Defective APP PWA Replace mechanism assembly

(see Section 7.2.14.8)

430-95424-001 (Rev. 09/03) 6 - 12 Plum A+3 Infusion System

Page 92

6.3 TROUBLESHOOTING PROCEDURES

Table 6-3. Troubleshooting with the PVT

Test Failure Probable Cause Corrective Action

Distal occlusion test

Section 5.2.14

Delivery accuracy test

Section 5.2.15

Electrical safety test

Section 5.2.16

Cassette not properly

Re-prime cassette

primed

Defective cassette Replace cassette

Dirty sensor pin Clean sensor pin

Defective APP PWA Replace mechanism assembly

(see Section 7.2.14.8)

Set not properly primed Re-prime cassette

Damaged or faulty cassette Replace cassette

Defective mechanism assembly

Replace mechanism assembly

(see Section 7.2.14.8)

Defective AC power cord Replace AC power cord

(see Section 7.2.5)

Technical Service Manual 6 - 13 430-95424-001 (Rev. 09/03)

Page 93

SECTION 6 TROUBLESHOOTING

This page intentionally left blank.

430-95424-001 (Rev. 09/03) 6 - 14 Plum A+3 Infusion System

Page 94

Section 7

REPLACEABLE PARTS AND REPAIRS

This section itemizes all parts and subassemblies of the Plum A+3 infusion system that are repairable within the scope of this manual. In addition, this section details replacement procedures for all listed parts.

7.1

REPLACEABLE PARTS

Replaceable parts for the Plum A+3 are itemized in the spare parts price list and are identified in Figure 9-1, Illustrated Parts Breakdown. Table 9-2, IPB for the Infusion Pump identifies each part by an index number that correlates to Figure 9-1.

To request a copy of the current spare parts price list, contact Abbott Laboratories

(see Section 6.1, Technical Assistance), or to view the catalog online, visit the website at:

www.abbotthpd.com/parts

For convenient reference, insert a copy of the spare parts price list here.

Technical Service Manual 7 - 1 430-95424-001 (Rev. 09/03)

Page 95

SECTION 7 REPLACEABLE PARTS AND REPAIRS

This page intentionally left blank.

430-95424-001 (Rev. 09/03) 7 - 2 Plum A+3 Infusion System

Page 96

7.2 REPLACEMENT PROCEDURES

7.2

REPLACEMENT PROCEDURES

This section contains safety and equipment precautions, required tools and materials, and step-by-step procedures for replacing parts in the infusion pump. Unless otherwise stated, always perform the PVT after a replacement procedure.

7.2.1

SAFETY AND EQUIPMENT PRECAUTIONS

Before opening the front enclosure of the infusion pump, take all necessary precautions for working on high-voltage equipment.

WARNING: POSSIBLE EXPLOSION HAZARD EXISTS IF THE INFUSION PUMP

WARNING: UNLESS OTHERWISE INDICATED, DISCONNECT THE INFUSION

CAUTION: Use proper ESD grounding techniques when handling components. Wear an antistatic wrist strap and use an ESD-protected workstation. Store PWAs in antistatic bags before placing them on any surface.

IS SERVICED OR REPAIRED IN THE PRESENCE OF FLAMMABLE ANESTHETICS.

PUMP FROM AC POWER BEFORE PERFORMING ANY REPLACEMENT PROCEDURE.

7.2.2

REQUIRED TOOLS AND MATERIALS

The following tools and materials, or equivalents, are required for the replacement procedures in this section. In addition, the beginning of each procedure lists tools and materials required for that specific procedure.

❏ Set of standard and metric nutdrivers

❏ Set of flat blade screwdrivers

knife

screwdrivers

❏ Set of Phillips

❏ Custom nutdriver (P/N 519-95056-001)

❏ Long needle nose pliers

❏ X-acto

❏ Mild solvent

Technical Service Manual 7 - 3 430-95424-001 (Rev. 09/03)

Page 97

SECTION 7 REPLACEABLE PARTS AND REPAIRS

7.2.3

RUBBER FOOT PAD REPLACEMENT

The recommended tool for this procedure is a No. 2 Phillips screwdriver.

To replace the rubber foot pads, refer to Figure 7-1, Bottom View, then proceed as follows:

1. Press [ON/OFF] to turn off the infusion pump, and disconnect the pump from AC power.

2. Place the pump face down on a soft flat surface.

3. Using the Phillips screwdriver, remove the 6-32 x 1/2 screw securing the rubber foot pad.

4. Install the replacement rubber foot pad in the exact reverse order of removal.

5. Connect the infusion pump to AC power.

Replacement of the rubber foot pads is routine maintenance and no verification procedure is normally required. However, if the infusion pump may have been damaged during a rubber foot pad replacement, perform the PVT in Section 5.2.

Figure 7-1. Bottom View

RUBBER FOOT (4)

BATTERY DOOR (3)

6-32 x 1/2 SCREW (4)

01K06006

430-95424-001 (Rev. 09/03) 7 - 4 Plum A+3 Infusion System

Page 98

7.2 REPLACEMENT PROCEDURES

7.2.4

BATTERY ASSEMBLY, BATTERY DOOR, AND BATTERY DOOR PAD REPLACEMENT

Recommended tools for this procedure are a medium size flat blade screwdriver, an X-acto knife, and mild solvent.

To replace the battery, battery door, and battery door pad, refer to Figure 7-1 and

Figure 7-2, AC (Mains) Power Cord, Power Cord Retainer, Velcro Retainer Strap, and Battery Assembly Replacement, then proceed as follows:

1. Press [ON/OFF] to turn off the infusion pump, and disconnect the pump from AC power.

2. Place the pump face down on a soft flat surface.

3. Using the flat blade screwdriver, remove the 6-32 x 1/2 screw that attaches the battery door to the pump, and remove the door.

4. Inspect the battery door and door pad for damage. Replace the door, if necessary.

5. If the battery door pad is defective, remove it and clean the door with mild solvent. Dry the battery door thoroughly, and install the replacement pad on the door.

6. Disconnect the battery harness from the charger circuit cable. Carefully pull the battery harness wires and connector outside the enclosure, and remove the battery.

7. Connect the replacement battery harness to the charger circuit cable, and insert the replacement battery into the enclosure.

 Note: The cable connectors are keyed so that cables cannot be connected

incorrectly.

 Note: Confirm the battery harness is not pinched between the battery and

the enclosure.

8. Replace the battery door using the screw that was removed in Step 3.

To verify successful replacement of the battery, press [ON/OFF] with the infusion pump disconnected from AC power, and verify the front panel battery symbol illuminates.

Replacement of the battery door and battery door pad is routine maintenance and no verification procedure is normally required. However, if the infusion pump may have been damaged during these procedures, perform the PVT in Section 5.2.

Technical Service Manual 7 - 5 430-95424-001 (Rev. 09/03)

Page 99

SECTION 7 REPLACEABLE PARTS AND REPAIRS

COTTER RING

BATTERY ASSEMBLY (3)

DOOR PAD (3)

RETAINING RING (3)

BATTERY DOOR (3)

6-32 x 1/2

SCREW (3)

HANGER ASSEMBLY

VELCRO STRAP

POWER CORD

4-40 X 3/8

SCREW

POWER CORD

RETAINER

01H06001

Figure 7-2. AC (Mains) Power Cord, Power Cord Retainer, Velcro Retainer Strap,

and Battery Assembly Replacement

7.2.5

AC (MAINS) POWER CORD, POWER CORD RETAINER, AND VELCRO RETAINER STRAP REPLACEMENT

The recommended tool for this procedure is a No. 2 Phillips screwdriver.

 Note: For Velcro retainer strap replacement only, proceed to Step 5.

To replace the AC power cord, power cord retainer, and Velcro retainer strap, refer to

Figure 7-2, then proceed as follows:

1. Press [ON/OFF] to turn off the infusion pump, and disconnect the pump from AC power.

2. Using the Phillips screwdriver, remove the 4-40 x 3/8 screw from the power cord retainer. Turn the power cord retainer approximately 1/8 turn counterclockwise.

3. Unplug the power cord, and slide the plug through the retainer.

 Note: Remove the AC power cord from its receptacle by grasping the plug.

Do not pull the cord.

4. Remove the Velcro strap from the power cord. Inspect the Velcro strap for wear and replace the strap, if necessary.

5. Attach the Velcro strap to the replacement power cord.

430-95424-001 (Rev. 09/03) 7 - 6 Plum A+3 Infusion System

Page 100

7.2 REPLACEMENT PROCEDURES

6. Install the replacement AC power cord in the exact reverse order of removal.

7. Connect the infusion pump to AC power. Press [ON/OFF] and verify the pump powers on.

To verify successful AC power cord, power cord retainer, and Velcro retainer strap replacement, perform the PVT in Section 5.2.

7.2.6

SEPARATING THE FRONT ENCLOSURE, REAR ENCLOSURE, AND MAIN CHASSIS ASSEMBLY

The recommended tool for this procedure is a No. 2 Phillips screwdriver.

 Note: The front enclosure consists of an upper assembly and a lower assembly.

The main chassis consists of an upper assembly and a lower assembly.

To separate the front enclosure, rear enclosure, and main chassis assembly, refer to

Figure 7-3, Separating the Front Enclosure, Rear Enclosure, and Main Chassis Assembly

then proceed as follows:

1. Remove the battery doors and batteries as described in Section 7.2.4.

2. Using the Phillips screwdriver, remove the five 6-32 x 1 1/4 inch screws; three 8-32 x 3 1/2 inch screws; and one 6-32 x 1/2 inch screw from the rear enclosure

(see Figure 7-4, Screw Placement Sequence).

3. Remove the rear enclosure by lifting it up and to the side.

4. Disconnect the three internal power connectors.

5. Using the Phillips screwdriver, remove the two 6-32 x 2 3/4 inch screws from the bottom corners of the center mechanism.

6. Set the pump upright and remove the front upper enclosure by pulling it away from the upper chassis assembly.

7. Remove the lower front enclosure by tilting the pump back approximately 10 degrees, being careful not to damage the peripheral/interface PWA. Pull the lower front enclosure away from the lower chassis assembly.

8. Reassemble the front enclosure, rear enclosure, and main chassis assembly in the exact reverse order of disassembly. Follow the screw placement sequence in

Figure 7-4.

 Note: When reassembling the upper front enclosure, lift all three door

handles first.

To verify successful assembly, perform the PVT in Section 5.2.

Technical Service Manual 7 - 7 430-95424-001 (Rev. 09/03)

Abbott Plum A Plus3 Infusion Pump - EPS-95424-001 A.T.S. 750 TOURNIQUET SYSTEM REF 60-0750-101-00 Operator & Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Change History

Contents

Figures

Tables

430-95424-001 (Rev. 09/03) viii Plum A+3 Infusion System

SCOPE

❏ Section 1 Introduction

CONVENTIONS

COMPONENT DESIGNATORS

1.4 ACRONYMS AND ABBREVIATIONS

1.5 USER QUALIFICATION

ARTIFACTS

INSTRUMENT INSTALLATION PROCEDURE

UNPACKING

INSPECTION

SELF TEST

1.8 BIOMED SETTINGS

IV PARAMETERS

430-95424-001 (Rev. 09/03) 1 - 10 Plum A+3 Infusion System

Technical Service Manual 1 - 11 430-95424-001 (Rev. 09/03)

ALARMS LOG

430-95424-001 (Rev. 09/03) 1 - 12 Plum A+3 Infusion System

SETTING THE TIME AND DATE

Technical Service Manual 1 - 13 430-95424-001 (Rev. 09/03)

430-95424-001 (Rev. 09/03) 1 - 14 Plum A+3 Infusion System

GENERAL DESCRIPTION

4.2 ELECTRONIC SUBSYSTEM OVERVIEW

CPU SUBSYSTEM

CPU

SYSTEM MEMORY ADDRESS MAP

PROGRAMMABLE READ-ONLY MEMORY

STATIC RANDOM ACCESS MEMORY

CONTROL LOGIC

LCD CONTROLLER

LCD BACKLIGHT CONTROL

LCD CONTRAST CONTROL

REAL-TIME CLOCK

VOLTAGE MONITOR WATCHDOG TIMER

ANALOG-TO-DIGITAL CONVERTER

DIGITAL-TO-ANALOG CONVERTER

FRONT PANEL KEYPAD MATRIX

FRONT PANEL [ON/OFF] KEY

FRONT PANEL LED INDICATORS

KEYPAD LOCKOUT INTERFACE

NURSE CALL INTERFACE

AUDIBLE INDICATORS

BARCODE READER INTERFACE

430-95424-001 (Rev. 09/03) 4 - 10 Plum A+3 Infusion System

DATAPORT INTERFACE

POWER SUPPLY INTERFACE

Technical Service Manual 4 - 11 430-95424-001 (Rev. 09/03)

MECHANISM INTERFACE

430-95424-001 (Rev. 09/03) 4 - 12 Plum A+3 Infusion System

Technical Service Manual 4 - 13 430-95424-001 (Rev. 09/03)

POWER SUPPLY SUBSYSTEM

MAIN SWITCHING REGULATOR

Main Loop

430-95424-001 (Rev. 09/03) 4 - 14 Plum A+3 Infusion System

Secondary Loop

Current Limit Loop

MAIN REGULATOR FAULT DETECTION

SYSTEM POWER

AUXILIARY SUPPLIES

Technical Service Manual 4 - 15 430-95424-001 (Rev. 09/03)

POWER CONTROL

BATTERY VOLTAGE MEASUREMENT

430-95424-001 (Rev. 09/03) 4 - 16 Plum A+3 Infusion System

BATTERY CHARGE/DISCHARGE CURRENT MEASUREMENT

BATTERY CHARGER

MECHANISM SUBSYSTEM

Technical Service Manual 4 - 17 430-95424-001 (Rev. 09/03)

MOTORS/MOTOR DRIVE

Stepper Motors

430-95424-001 (Rev. 09/03) 4 - 18 Plum A+3 Infusion System

Chopper Motor Drive

MOTOR POSITION SENSORS