Aitecs 2016 Service manual
Service Manual
Aitecs 2016
S Y R I N G E I N F U S I O N P U M P
BS049055EN-P01
Prior to servicing this pump, read this manual and the pump’s
Operator’s Manual carefully to fully understand the pump’s
functionality and to ensure safe and proper servicing.
CONTENTS
1. INTRODUCTION............................................................................................................................... 3
1.1.
GENERAL INFORMATION..................................................................................................... 3
1.2.
GENERAL PRECAUTION........................................................................................................ 3
1.3.
SERVICE CONTACT................................................................................................................ 4
2. TECHNICAL DESCRIPTION............................................................................................................ 5
2.1.
GENERAL.................................................................................................................................. 5
3. SERVICE MENU................................................................................................................................ 7
3.1.
MAINTENANCE MENU .......................................................................................................... 7
3.2.
PROGRAM LOADING.............................................................................................................. 7
3.3.
MOTOR PROGRAM LOADING .............................................................................................. 8
3.4.
CALIBRATION ......................................................................................................................... 8
3.5.
TESTING.................................................................................................................................. 10
4. RECOMMENDED ROUTINE MAINTENANCE AND TESTING................................................ 13
4.1.
AC MAINS / BATTERY OPERATION CHECK ................................................................... 13
4.2.
GENERAL CLEANING AND INSPECTION FOR DAMAGE ............................................. 13
4.3.
BATTERY TEST...................................................................................................................... 14
4.4.
INFUSION RATE CHECK...................................................................................................... 14
4.5.
OCCLUSION PRESSURE LEVEL CHECK........................................................................... 14
5. TROUBLE-SHOOTING................................................................................................................... 15
5.1.
SAFETY WARNINGS............................................................................................................. 15
5.2.
PUMP HAS BEEN DROPPED OR DAMAGED.................................................................... 15
5.3.
PUMP HAS BEEN EXPOSED TO FLUIDS........................................................................... 15
5.4.
TROUBLE-SHOOTING BY FAULT SYMPTOM ................................................................. 16
5.5.
TROUBLE-SHOOTING BY FAILURE CODES.................................................................... 18
6. REPAIR............................................................................................................................................. 23
6.1.
ACCESS TO THE PUMP ........................................................................................................ 24
6.2.
FRONT CASE AND SUB-ASSEMBLIES .............................................................................. 27
6.3.
REAR CASE AND SUB-ASSEMBLIES................................................................................. 40
6.4.
TORQUE GUIDE..................................................................................................................... 47
6.5.
PART LIST............................................................................................................................... 49
7. ELECTRICAL SCHEMATIC DIAGRAMS, COMPONENT LOCATION DIAGRAMS.............. 52
7.1.
ELECTRICAL BLOCK DIAGRAM OF THE SYRINGE PUMP........................................... 52
7.2.
ELECTRICAL SCHEMATIC DIAGRAM OF THE PUMP ................................................... 53
7.3.
MAIN ELECTRONIC BOARD COMPONENT LOCATION DIAGRAM............................ 56
7.4.
DRIVE UNIT BOARD COMPONENT LOCATION DIAGRAM.......................................... 57
7.5.
POWER SUPPLY UNIT COMPONENT LOCATION DIAGRAM....................................... 58
8. SPARE PARTS LISTING................................................................................................................. 59
8.1.
SPARE ACCESSORIES .......................................................................................................... 59
8.2.
SPARE LABELS / PUBLICATIONS...................................................................................... 59
8.3.
SPARE ELECTRICAL COMPONENTS................................................................................. 60
8.4.
SPARE MECHANICAL COMPONENTS .............................................................................. 60
ANNEX A ROUTINE MAINTENANCE & CHECKOUT PROCEDURE.......................................... 61
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1. INTRODUCTION
1.1. GENERAL INFORMATION
The AITECS 2016 syringe pump is designed to accurately control the delivery of solution to the
patient by means of a disposable syringe.
The AITECS 2016 syringe pump is compatible with a wide range of standard, single-use,
disposable Luer-lock syringes, ranging from 5 ml to 60 ml in size.
This SERVICE MANUAL describes the theory of operation, how to check, troubleshoot and
repair AITECS 2016 syringe infusion pump.
Ensure that you are fully familiar with this equipment by carefully studying the Operator’s
Manual and this Service Manual prior to attempting any repairs or servicing.
1.2. GENERAL PRECAUTION
Please read the general Operating Precautions described in the Operator’s
Manual carefully prior to using this syringe pump.
This pump contains static-sensitive components. Observe strict precautions
for the protection of static sensitive components when attempting to repair and
service the syringe pump.
An explosion hazard exists if the syringe pump is used in the presence of
flammable materials. Exercise care to locate the pump away from any such hazardous
sources.
An electrical shock hazard exists if the syringe pump casing is opened or
removed. Refer all servicing to qualified service personnel.
This syringe pump is protected against the effects of high energy radio
frequency emissions and is designed to fail safe if extremely high levels of
interference are encountered. Should false alarm condition be encountered, either
remove the source of the interference or regulate the infusion by another appropriate
means.
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If the syringe pump is dropped, subjected to excessive moisture,
humidity or high temperature, or otherwise suspected to have been damaged, remove
it from service for inspection by qualified service personnel.
1.3. SERVICE CONTACT
VILTECHMEDA, 125 Kalvarijų Str., 08221 Vilnius, Lithuania
E-mail: service@aitecs.com
Tel. : +370-52-737509
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2. TECHNICAL DESCRIPTION
2.1. GENERAL
The Block Diagram of the syringe pump is given in the section 7.1. The Electrical Schematic
Diagram is given in the section 7.2. The syringe pump is composed of the following elements:
- Keypad
- Syringe barrel sensor
- Syringe size sensor
- Main Electronic board (MEB)
- Pusher sensors unit
- Motor
- Encoder
- Pressure sensor
- Pusher home sensors
- Drive Unit board
- Switching power supply
- Battery unit
- IrDA unit
- Power supply unit
Below follows a description of these elements, refer the appropriate diagram for full
understanding of the functionality:
2.1.1. Keypad
Keypad comprises of a 6 x 4 key matrix connected to the Main Electronic board at connector
JP3. ON/OFF key, C key and BATTERY & MAINS LED’s are also located on the keypad.
2.1.2. Syringe barrel sensor
The syringe barrel sensor comprises photo interrupter D1. When the syringe is loaded, the
shutter is drawn out of the slot of the photo interrupter D1, enabling its optical link. The LED of
the photo interrupter is supplied with pulse-modulated current through pin 3 of JP4 connector of
the Main Electronic board.
2.1.3. Syringe size sensor
The syringe size sensing is achieved using the linear potentiometer R1. The signal from the
potentiometer slider is applied to the Main Electronic board via pin 2 of JP8 connector.
2.1.4. Pusher sensors unit
The plunger push-button sensors are composed of two photo interrupters D1, D2. The grippers
latched sensor comprises photo interrupter D3. The LED’s of the photo interrupters are supplied
with pulse-modulated current through pin 3 of JP8 connector of the Drive Unit board.
When the syringe is loaded, the shutter is outside the slot of D1 is and inside the slot of D2.
When the syringe is loaded, the shutter controlling the photo interrupter D3 is outside of its slot.
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2.1.5. Motor
A two-phase bipolar stepper motor with 1.8º step-angle is used in the pump drive. The motor is
connected to the Drive Unit board via connector P6 and is driven in micro stepping mode. There
are 200 steps to complete one full revolution of the motor shaft. The motor is connected to the
lead screw by means of timing belt. The belt ratio is 1.6(6):1; as a result 333.3(3) motor steps
move the drive carriage by 1.25 mm.
2.1.6. Encoder
Motor speed and direction is monitored by means of the encoder. It is composed of two photointerrupters D1, D2 and a 12 slot-encoding disk mounted on the lead screw. Quadrature signals
(Tax1, Tax2) are transferred to the Drive Unit board via JP5 connector.
2.1.7. Pressure sensor
As a pressure sensor is used a strain gauge TZ1 mounted on a steel plate. When this plate is
deflected by applied force on the plunger, a differential voltage is generated at gauge output.
This signal, which magnitude is proportional to the applied force, is transferred to the Drive Unit
board.
2.1.8. Pusher home sensor
The pusher home sensors are composed of two photo interrupters D1, D2. When the syringe
pusher is in the right end position, the shutter is outside the slot of D1 is and inside the slot of
D2.
2.1.9. Switching power supply
A 30W single output 12V, 2.5A medical type switching power supply is used in the pump.
2.1.10. Battery unit
The battery unit comprises the Ni-MH (7,2V x 2.5Ah) battery GB1 together with the battery
monitoring circuit. The integrated circuit U1 monitors battery voltage, temperature and
charge/discharge current. This data is used to calculate battery charge state and remaining
working time when pump runs on battery. Data is transferred to the microcontroller via 1-Wire
interface (pin 4 of the JP1 connector). R2 is a current sense resistor; R3 and C1 constitute a low
pass filter for the current monitoring circuit. Thermistor R1 terminates battery charging if battery
temperature exceeds the permissible value. The resettable fuse F1 protects against a short circuit
of the battery.
2.1.11. IrDA unit
Serial infrared data communication is operating in accordance with the IrDA standard using
modulator-demodulator U1 and transceiver U2. The transceiver is mounted on the rear of the
PCB, in front of the window at the back of the pump. The window is covered with dark IRtransparent plastic.
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3. SERVICE MENU
While keeping pressed the key turn the pump on. Enter code
751
using the numerical
keypad. Press OK to confirm the code. The Service Menu will be displayed. Use the
keys to select the required parameter.
3.1. MAINTENANCE MENU
Select the MAINTENANCE MENU from the Service menu and press the OK softkey. Use the
keys to select the required parameter. Press the OK softkey:
- to set DEFAULT PARAMETERS
- to modify the NEXT SERVICE DATE
- to view the selected LOG (event, use, key or service)
- to set ALARM PITCH
- to set ALERT PITCH
- to view serial number
Press the BACK softkey to return to Service menu.
3.2. PROGRAM LOADING
3.2.1. Loading main program
To perform a programming operation, the following is required:
- A2016 Firmware Upload Utility must be installed and configured on the computer that is being
used.
- Either USB cable must be connected between the USB port of the computer and the USB
connector in the rear of the pump.
While keeping pressed the key, turn the pump on. The Loader USB message shall appear
on the screen. The pump is ready for loading the program.
Programming sequence:
- Start A2016 Firmware Upload Utility application by clicking on the appropriate icon.
- Select USB interface.
- Click on Firmware
key in order to load program.
- Click on Firmware key to start the programming operation.
When programming completed switch off the pump using the ON/OFF key. Having loaded new
program it is necessary to set DEFAULT PARAMETERS and execute full testing (see Section
3.4.1).
3.2.2. Loading Bootstrap
In order to perform a programming operation, the following should be in place:
- A2016 Firmware Upload Utility should be installed and configured on the computer that is
being used.
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- Having opened the pump housing, Bootstrap Loader Unit should be connected between the
Main Electronic board connector JP7 and the COM port of the computer. Bootstrap Loader Unit
switch should be in ON position.
Switch on the pump. Press the Reset key on the Bootstrap Loader Unit. The pump is now ready
to download a Bootstrap.
Programming sequence:
- Start A2016 Firmware Upload Utility application by clicking on the appropriate icon.
- Select which COM port is going to be used.
- Click on Bootloader key in order to load Bootstrap.
- Click on Bootloader key to start the programming operation.
After Bootstrap downloading process is completed, it is necessary to switch Bootstrap Loader
Unit switch into OFF position and to press the Reset key.
Having loaded new bootloader it is necessary to set DEFAULT PARAMETERS and execute full
testing (see Section 3.4.1).
3.3. MOTOR PROGRAM LOADING
To perform a programming operation, the following is required:
- A2016 Firmware Upload Utility must be installed and configured on the computer that is being
used.
- Either USB cable must be connected between the USB port of the computer and the USB
connector in the rear of the pump.
Select the MOTOR PROGRAM LOADING and press the OK softkey. The MOTOR
PROGRAM UPGRADE message shall appear on the screen. The pump is ready for loading the
motor program.
Programming sequence:
- Start A2016 Firmware Upload Utility application by clicking on the appropriate icon.
- Select USB interface.
- Click on Motor
key in order to load program.
- Click on Motor key to start the programming operation.
When programming completed switch off the pump using the ON/OFF key. Having loaded new
program it is necessary to set DEFAULT PARAMETERS and execute full testing (see Section
3.4.1).
3.4. CALIBRATION
Select the CALIBRATION from the Service menu and press the OK softkey. Select item to be
calibrated using the keys and press the OK softkey.
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3.4.1. Syringe size calibration
The syringe size detection system stores the characteristics of the syringe clamp assembly,
including the travel of the linear potentiometer in non-volatile memory.
Equipment:
- Spacer (gauge) SP0 (B8640027-04);
- Spacer (gauge) SP1 (B8640037-01);
- Spacer (gauge) SP2 (B8640037-02);
- Spacer (gauge) SP3 (B8640037-03).
Select the Syringe size from calibration menu and press the OK softkey. With the syringe clamp
at the lowermost position press the OK softkey. One after another insert spacers from 0 to 3,
each time closing the syringe clamp and pressing the OK softkey to acknowledge. Finally fix the
syringe clamp at the uppermost position and again press the OK softkey.
3.4.2. Pusher button and pusher position calibration
Equipment:
- Calibration spacer (gauge) SP1 (B8640037-01).
Select the Pusher button & pusher position from calibration menu and press the OK softkey.
Press the pusher lever if appropriate message appears. When display reads the Insert spacer SP1
and press OK message, insert the SP1 spacer and press the OK softkey. Syringe pusher shall
move forward until it comes in contact with the spacer. When syringe pusher stops automatically
and display reads a CONFIRM softkey, press the CONFIRM softkey.
3.4.3. Force (pressure) calibration
Equipment:
- Digitron pressure meter, model: 2022P (0-1500 mmHg);
- 50 ml BD PLASTIPAK or 60 ml BD syringe with extension line.
Screws fastening rear case to front case must be unscrewed.
Select the Force sensor from calibration menu and press the OK softkey. Then follow directions
on the display.
When the Is pusher free? message appears, make sure that pushing surface of the retainer is not
in contact with any part of pump or extraneous object.
When Adjust readings... message appears check the value indicated at left bottom corner of
screen and adjust it, if out of above indicated on the screen range, by means of potentiometer
R30 on the Drive Unit.
Upon prompt of inserting syringe, fill syringe with 10-20 ml of water, and fit it to the pump.
Connect pressure meter to the syringe by means of the extension line. Locate the pressure meter
at the same height as the syringe and press the OK softkey.
After the pusher comes in contact with syringe plunger press the > softkey and keep it depressed,
allowing the transmission to run until the pressure meter reads (120±1.5) cmHg. When
approaching the target value, it is recommended to run transmission in short steps, pressing the >
key momentarily. If you fail to stop movement timely and target value is overridden, calibration
procedure must be repeated from the beginning.
When pressure is adjusted as required, press the OK softkey.
Press the BACK softkey to exit.
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NOTE. When calibrating force sensor after repairing or replacing drive or pusher, it is necessary
to go through described above procedure three times, first and second time running transmission
until pressure goes to 140-150 cmHg, and the last time – exactly as described.
3.4.4. Battery capacity calibration
Battery capacity calibration cycles the battery through a charge, discharge, re-charge sequence
during which the fuel gauge within the Battery Unit will be updated with a measurement of the
current capacity of the cells.
This calibration allows the fuel gauge to monitor accurately the charge in the pack. Over time the
estimate of capacity may drift from the actual cell capacity, which generally decreases with time.
Recalibration will update the fuel gauge with the measured capacity of the cells.
Remove the battery pack lid to ensure a stable pack environment during calibration. It is
recommended that the pack is removed from the battery compartment and placed behind the
pump. Connect the pump without syringe to the mains.
Select the Battery Capacity from calibration menu and press the OK softkey. Press START
softkey in the following window. Leave pump in calibration mode for up to 20 hours. The cycle
should run passing automatically three phases one by one:
• Initial charge phase – up to 4 hours
• Measured discharge phase. Pack is discharged using typical load down to 1.1 V per cell
to determine how much charge is available from the pack – up to 12 hours
• Final charge phase. Pack is fully recharged ready for use. Early in this phase the
measured discharge value is transferred to the pack gas gauge to be stored as the new
capacity (mAh).
During the course of calibration the battery related information is displayed on the pump screen.
At the end the CALIBRATION COMPLETED message appears. Press the BACK softkey to
exit.
3.5. TESTING
Select the TESTING from the Service menu and press the OK softkey. Select the item to be
tested using the keys and press the OK softkey.
3.5.1. Full testing
This section provides a complete pump test procedure. Follow each stage test and follow the
instructions on the display use the NEXT softkey to move to the other test.
3.5.2. Program testing
This test is intended to calculate program and bootstrap CRC. Select the Program from testing
menu and press the OK softkey. Software version, bootstrap version and calculated CRC values
are indicated in the display. Press the BACK softkey to return to TESTING menu.
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3.5.3. Drive sensors test
This test enables checking of the following sensors: pusher home, pusher button, grippers
unlatch and syringe barrel.
Select Drive Sensors from the testing menu and press the OK softkey.
Home sensors can be checked moving pusher by means of the < and > soft keys and watching
number of home zone indicated on screen. Zone 0 should be indicated when pusher is at the
rightmost position, and zone number shall shift in order to 1, 2, and 3 when moving pusher to the
left. Zone 3 indication shall appear not more than 10 mm from the rightmost position and shall
be retained all the rest way to the left.
Pusher sensors can be checked pressing smoothly pusher button with finger and watching
number of pusher zone indicated on screen (grippers must be in open position). While pusher
button is released, the zone C shall be indicated. As pressure on button increases, zone indication
shall switch in order to B, and C.
To check unlatch sensor, open pusher grippers and make sure that status of unlatch sensor
indicated on the display is OFF. Press the UNLATCH softkey. Grippers shall close and status of
unlatch sensor shall change to ON.
Once complete press the BACK softkey to return to TESTING menu.
3.5.4. Syringe size test
This test is enables checking the operation of syringe size sensor.
Select Syringe size sensor from the testing menu and press the OK softkey. Slowly lift the
syringe clamp. Check if syringe size sensor value changes (mV and mm). Having finished
testing press the BACK softkey to return to TESTING menu.
3.5.5. Pusher position test
This test enables checking pusher position calibration. Select Pusher position sensor from the
testing menu and press the OK softkey. Insert the SP1 spacer. Press the OK softkey. Syringe
pusher shall move until coming into contact with the spacer. Pusher position value of
(22 ± 0.5) mm should be indicated on the display. Having finished testing press the BACK
softkey to return to TESTING menu.
3.5.6. Motor test
This test enables checking motor operation. During test no syringe should be installed. Select
Motor from the testing menu and press the OK softkey. Keep the < softkey depressed and make
sure that pusher moves to the left. Check reverse movement when > key is depressed. Having
finished testing press the BACK softkey to return to TESTING menu.
3.5.7. Display test
This test checks that all of the display pixels (256x64) illuminate. Select Display from testing
menu and press the OK softkey. Observe “chess-board” structure fields that appear in the
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display. All the rectangles should be same shaped and evenly filled. Having finished testing
press the BACK softkey to return to TESTING menu.
3.5.8. Nurse call test
Equipment:
- Nurse call cable (B6650034);
- Ohmmeter.
This test checks the nurse call circuit operation. Select Nurse call from testing menu and
press the OK softkey. Using a meter check the circuit between the Nurse call contact 9 (com)
and contacts 10 (NO), 8 (NC). The contacts should toggle each time the CHANGE softkey is
pressed, as indicated on the display. Press the BACK softkey to return to TESTING menu.
3.5.9. Speaker/buzzer test
This test checks the speaker and buzzer operation. Select Speaker/buzzer from the testing menu
and press the OK softkey. Check for the alternating volume sound from the speaker. Check for
the sound from the buzzer. Press the BACK softkey to return to TESTING menu.
3.5.10. Keypad test
This test enables checking the keypad operation. Select Keypad from the testing menu and press
the OK softkey. Press one by one all keys and make sure that after pressing any key its image on
the display is highlighted. Press the BACK softkey to return to TESTING menu.
NOTE. This test does not apply to the ON/OFF key.
3.5.11. LEDs test
This test is intended to check the LED operation. Select LEDs from testing menu and press the
OK softkey. The following LEDs should activate one after another: GREEN (INFUSION), RED
(ALARM), YELLOW(ALERT) and BATTERY. In order to check the operation of BATTERY
LED it is necessary to connect the power cable. In order to check the operation of MAINS LED
it is necessary to remove and reconnect the power cable. Press the BACK softkey to return to
TESTING menu.
In order to check the operation of red backup battery LED it is necessary to remove the power
supply cable from Main electronic board.
3.5.12. Watch-dog test
This test enables checking of the watch-dog circuit operation. Select Watch-Dog from testing
menu and press the OK softkey. Clocking of the watch-dog circuits is interrupted for certain
time. This shall trigger watch-dog, which activates red alarm LED and launches the buzzer.
When test completed switch off the pump using the ON/OFF key.
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4. RECOMMENDED ROUTINE MAINTENANCE AND TESTING
It is recommended that routine maintenance be carried out at least once a year. This should
include (see Annex A):
- AC Mains / Battery operational checks (section 4.1).
- General cleaning and inspection for damage (section 4.2).
- Battery test (section 4.3).
- Infusion rate check (section 4.4).
- Occlusion pressure level check (section 4.5).
- Full test (sections 3.4.1-3.4.12).
4.1. AC MAINS / BATTERY OPERATION CHECK
Switch the pump on and plug pump into the mains. Observe that the MAINS indication LED
becomes illuminated. Remover the mains supply and observe that the MAINS LED switches off.
Observe that the battery indication LED becomes illuminated as the mains supply is removed.
4.2. GENERAL CLEANING AND INSPECTION FOR DAMAGE
To ensure that this pump remains in good operating condition, it is important to keep it clean and
carry out the routine procedures described below. Only a qualified service engineer, with
reference to this manual, should perform servicing. The following routine maintenance
procedures should be carried out as required but at least once per year:
Thoroughly clean external surfaces of the pump before and after prolonged periods
of storages by wiping a lint-free cloth lightly dampened with warm water and standard
disinfectant/detergent solution.
Disinfectants known to be corrosive to metals and plastics must not be used.
Before cleaning always switch OFF and disconnect from the AC power supply.
Never allow liquid to enter the casing and avoid excessive fluid build up on the pump.
Do not use aggressive cleaning agents as these may damage the exterior surface of the pump.
Do not steam autoclave, ethylene oxide sterilize or immerse this pump in any fluid.
Check Labels should be flat and legible. Replace as required
Case components must be checked for damage that may affect function, present fluid ingress
routes and present a user hazard must be replaced as necessary.
Check the mounting clamp is not damaged and that it functions correctly.
Inspect the AC power supply inlet and cable for sings of damage.
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4.3. BATTERY TEST
Perform battery calibration in accordance with 3.3.5. When calibration is completed and the
battery is fully charged (at least 5 hours on charge) disconnect the pump from the mains. Load
50 ml BD Plastipak syringe with the plunger at 60.0 ml position on the syringe barrel scale.
Set the 5.0 ml/h rate and start infusion (see the Operator’s Manual for further information on
starting the pump).
Normally pump should be able to work on battery for about 10 hours. If this time is significantly
less battery should be replaced.
After completion of the test the pump should be recharged for a minimum of 3 hours.
4.4. INFUSION RATE CHECK
Equipment:
- stop-watch;
- graduated glass test-tube (one point equals to 0.1 ml, volume 60ml or more).
Take the BD Plastipak 50 ml syringe with extension set and fill it with distilled water up to point
of 60ml. Program the following infusion parameters:
- Rate 50 ml/h.
Insert the free end of extension set into the test-tube and start the infusion. Measure infusion time
with the stop-watch till the moment pump display indicates 50 ml infused and stop the infusion.
Read the volume of water delivered into the test-tube. Calculate the infusion rate. It shall be
50ml/h ±1ml/h (±2%).
4.5. OCCLUSION PRESSURE LEVEL CHECK
Equipment:
- Digitron pressure meter, model: 2022P (0-1500mmHg).
Fill the 50 ml BD Plastipak syringe with 20-30 ml of the distilled water and connect it to the
pressure meter using the extension set. Switch on the pressure meter and set the max/min
pressure recording mode.
Set pump occlusion alarm level to L-10 and launch infusion at 5 ml/hr rate (for pump operation
details refer to the Operator’s Manual).
When pump will stop and indicate OCCLUSION read the maximum pressure recorded by
pressure meter. Readings shall be within (73 -117) cmHg range.
If recorded value is outside this range, re-calibrate the force sensor in accordance with 3.3.4 and
repeat this test.
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5. TROUBLE-SHOOTING
5.1. SAFETY WARNINGS
- Use extreme caution when pump whilst it is connected to the AC mains.
Hazardous voltages are present at the mains inlet and on the power supply even the pump is
switched off.
- Disconnect the battery and AC power whenever removing or inserting PCBs or
other connectors.
-
This pump contains static-sensitive components. Wherever the ESD
symbol appears observe strict precaution for the protection of static-sensitive components when
attempting to service and repair the pump.
- Always visually inspect the pump, power cord and plug for damage. If the power
cord or plug is damaged they should be replaced.
5.2. PUMP HAS BEEN DROPPED OR DAMAGED
If the pump is dropped or damaged, the damaged parts should be identified and replaced before
any further troubleshooting is carried out.
During inspection, careful attention should be paid to the front and rear case halves, for signs of
drop damage. Also check the pump drive, syringe pusher and syringe size sensor.
5.3. PUMP HAS BEEN EXPOSED TO FLUIDS
Excessive fluid spills can lead to fluid ingress into the pump. Even if the fluid dries out, deposits
can be left which cause the pump to fail.
If fluid ingress is suspected the pump should be inspected internally.
Clean and dry out the pump.
Take care to ensure dried deposits do not remain on the PCBs or other electrical components.
Replace any damaged PCBs or components.
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5.4. TROUBLE-SHOOTING BY FAULT SYMPTOM
SYMPTOM CHECK CORRECTIVE ACTION
Pump does not operate from
external AC mains (MAINS
LED does not operate).
Pump does not operate from
external 12 VDC (MAINS
LED does not operate).
Check mains cord.
Check switching power
supply.
Check 12VDC & Nurse call
connector unit.
Pump operates from the AC
mains.
One or more keypad key
Perform keypad test. Replace keypad.
presses are not accepted.
Too high or too low contrast
level.
Check contrast setting.
Check the voltage of the
Main Electronics Board test
point TP4. The value should
be (-5.8±0.1)V, when
contrast is set to level 6.
Backlight does not operate
when pump is powered on.
Check backlight setting.
Check backlight circuit
interconnection on Electronic
board.
Check the Display Unit and
its connection to Electronic
board connector JP2.
Second (high pitch) audible
alarm does not sound after
power on.
Check buzzer (Z1) in the
Main Electronic board.
Check backup battery GB1 in
the Main Electronic board.
Grippers do not close when
loading syringe.
Perform drive sensors test
(Pusher).
Check the capacitor C1 and
its connection to Drive Unit
board.
Check the electromagnet
circuit and its connection to
Drive Unit board.
When loading syringe, after
closing grippers the Press
lever prompt is displayed.
Perform drive sensors test
(Unlatch).
Replace mains cord.
Replace switching power
supply if necessary.
Replace 12VDC & Nurse call
connector unit.
Adjust the contrast as
described in Operator’s
Manual.
Adjust voltage by means of
R27, if the problem persists –
replace the Main Electronic
board.
Adjust the backlight as
described in Operator’s
Manual.
Replace Main Electronic
board if necessary.
Replace Display Unit if
necessary.
Replace buzzer (Z1).
Replace backup battery GB1.
Replace syringe pusher if
necessary.
Replace capacitor unit.
Replace syringe pusher if
necessary.
Replace syringe pusher if
necessary.
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Check syringe prompt is
displayed when loading
syringe.
Perform drive sensors test
(Barrel).
Check the syringe barrel
sensor connection to Main
Electronic board.
Pusher home sensors do not
work properly (screen
indicates internal
malfunction after switching
on the pump).
Syringe size sensor does not
determine syringe size
properly.
Perform drive sensors test
(Home).
Check home sensors unit
connection to Main
Electronic board.
Test syringe size sensor (see
section 3.4.4).
Check the syringe size sensor
and its connection to Main
Electronic board.
Occlusion pressure level
incorrect.
Check occlusion pressure
level (see section 4.5).
Check pressure sensor
connection to Drive Unit
board.
Check pressure sensor
amplifier circuit.
Too short operation time on
Test battery (see section 4.3). Replace battery unit if
battery.
Nurse Call does not operate. Perform Nurse Call test.
Check nurse call circuit
interconnection on Power
Supply unit.
USB interface does not
operate.
Check USB connector unit.
Check USB cable.
Check USB circuits on Main
Electronic board.
IrDA interface does not
operate (when link to
AIMS 16 is enabled in user
configuration menu).
Mounting clamp cannot be
Check the connection of
IrDA unit to Main Electronic
board.
Check IrDA circuits.
Check mounting clamp. Replace mounting clamp.
fixed to the pump.
Replace syringe barrel sensor
if necessary.
Replace pusher home sensor
unit if necessary.
Calibrate syringe size sensor
(see section 3.3.1).
Replace syringe size sensor if
necessary.
Calibrate pressure sensor
(see section 3.3.4).
Replace syringe pusher if
necessary.
Replace Drive Unit board if
necessary.
necessary.
Replace 12VDC & Nurse
call connector unit.
Replace Power Supply unit if
necessary.
Replace USB connector unit.
Replace USB cable.
Replace Main Electronic
board if necessary.
Replace IrDA unit if
necessary.
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5.5. TROUBLE-SHOOTING BY FAILURE CODES
CODE DESCRIPTION CORRECTIVE ACTION
AB01 During antibolus motor has exceeded the
step count limit.
Power off then on. If failure code
recurs, replace drive unit board
software. If the problem persists,
replace drive unit board if necessary.
BAR01 Barrel sensor is damaged. Check barrel sensor and replace it if
necessary.
BP00 Corrupted configuration parameters. Set default parameters in Service
menu/Maintenance menu. If failure
code recurs, replace Main electronic
board if necessary.
BP01 Configuration parameters out of limits. Set default parameters in Service
menu/Maintenance menu. If failure
code recurs, replace Main electronic
board if necessary.
BT00 Communications with the battery fuel gauge
has failed.
Inspect cables between Battery unit,
Power supply unit and Main
Electronic board.
BT02 The battery cell voltage is low (less than
1.05V per cell).
BT03 The battery cell voltage is high (greater than
1.75V per cell).
Charge battery, if failure code recurs,
replace Battery Unit if necessary.
Check battery charge circuit and
replace power supply unit if
necessary.
BT04 The battery temperature is high (greater than
60°C).
Check battery charge circuit and
replace power supply unit if
necessary.
BT05 The battery charging current is high (greater
than 1.5A).
Check battery charge circuit and
replace power supply unit if
necessary.
BT06 The battery discharging current is high
(greater than 1.5A).
Disconnect one by one all the
connectors, find current leakage place
and replace faulty unit.
BT07 The battery is discharging whilst the pump is
on the mains.
Inspect cables between battery
Monitoring and Power Supply Unit.
Check battery charge circuit and
replace Power Supply Unit if
necessary.
BVXX Bad variable Power off then on. If failure code
recurs, replace MEB software or
Main electronic board if necessary.
EE00 Cannot read/write data from/to external
EEPROM
Power off then on. If failure code
recurs, replace Main electronic board
if necessary.
FL01 Internal Flash timout Power off then on. If failure code
recurs, replace Main electronic board
if necessary.
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CODE DESCRIPTION CORRECTIVE ACTION
FL03 Internal Flash trap Power off then on. If failure code
recurs, replace Main electronic board
if necessary.
HT01 External NMI activated Power off then on. If failure code
recurs, replace MEB software if
necessary.
HT02 Stack overflow Power off then on. If failure code
recurs, replace MEB software if
necessary.
HT03 Stack upperflow Power off then on. If failure code
recurs, replace MEB software if
necessary.
HT04 Internal microcontroller trap activated (Class
B)
Power off then on. If failure code
recurs, replace MEB software if
necessary.
KY01 Keypad key has been depressed for 5
Replace keypad if necessary.
minutes.
LOG1 Key log has failed Power off then on. If failure code
recurs, replace Main electronic board
if necessary.
LOG2 Error log has failed Power off then on. If failure code
recurs, replace Main electronic board
if necessary.
LOG3 Event log has failed Power off then on. If failure code
recurs, replace Main electronic board
if necessary.
OS01 Operating system timeout Power off then on. If failure code
recurs, replace MEB software if
necessary.
OTHXX Other failures Check log, if necessary replaces MEB
software.
PP01 Pusher position readings out of range for the
inserted syringe.
Calibrate pusher home and syringe
size sensors. If the problem persists,
check and replace pusher home
sensor or syringe size sensor if
necessary.
PP02 Pusher home sensor failure Check and replace pusher home
sensor if necessary.
PP03 Pusher home sensor failure Check and replace pusher home
sensor if necessary.
PR01 Incorrect MEB soft Bootstrap CRC Power off then on. If failure code
recurs, replace MEB Bootstrap
software if necessary.
PR02 Incorrect MEB program CRC Power off then on. If failure code
recurs, replace MEB software if
necessary.
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