Baxter AP II Pump User manual
TABLE OF CONTENTS
CHAPTER I- INTRODUCTION
1.1
1.2 FACTORY SERVICE/ASSISTANCE
GENERAL ..............................................................................................................
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1.2.1 Technical Assistance, Service, and Repairs
1.2.2 Customer Service Related Business.
1.2.3 Technical Assistance Hotline-
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CHAPTER 2 - THEORY OF OPERATION
2.1 OVERVlEW OFTHE AP II PUMP
2.2 AP II PUMP COMPONENTS
2.2.1 Microprocessor and PROM Subsystem
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
BUS Subsystem
Keypad Subsystem
Supervisory Subsystem (SS)
Power Subsystem (PS)
LCD Subsystem
Buzzer Circuit
Motor Subsystem
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1-I
1-l
2-2
2-3
2-4
2-4
2-5
2-5
2-5
2-6
2-6
2.3
2.3.1
2.3.2
2.3.3
MISCELLANEOUS CIRCUITS
Occlusion Detection Circuits
Backlight Circuit
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Printer Adapter Interface Circuit.
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CHAPTER 3 - INITIAL INSPECTION
3.1 GENERAL
3.2
3.3
INITIAL INSPECTlON AND DAMAGE CHECK
INSPECTIONS
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CHAPTER 4 - FUNCTIONAL TESTS
4.1
4.1.1
4.1.2
4.2
GENERAL
Equipment Required
Optional Equipment
VISUAL INSPECTION
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2-6
2-6
2-6
2-7
3-l
3-l
3-l
4-1
4-1
4-1
4-1
4-2
4.3
4.3.1
4.3.2
FLOW RATE ACCURACY TEST
Procedure using Gravimetric method
Procedure using
Volumetric method
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4-3
4-3
4-4
TABLE OF CONTENTS
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.5
CHAPTER 5 - ROUTINE MAINTENANCE
5.1
5.2
MISCELLANEOUS CHECKS ................................................................................
Tubing Sensor Test ...........................................................................................
Occlusion Switch Test .......................................................................................
PCA Cable Test .................................................................................................
AC Adapter Test ................................................................................................
History Retention Test .......................................................................................
Printer Test (Optional) .......................................................................................
FUNCTIONAL TEST DATA SHEET . . . ..~.............~.................................................
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND DISINFECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 6 - TROUBLESHOOTING AND REPAIR
6.1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-l
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4-6
4-6
4-6
4-7
4-8
4-8
4-8
4-10
5-I
5-1
5-1
6-I
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6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
TROUBLESHOOTING ...........................................................................................
Board Exchange ................................................................................................
Mechanism Exchange .......................................................................................
Tools and Equipment .........................................................................................
Troubleshooting Tips .........................................................................................
System Error Codes (Failure Codes)
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6-l
6-1
6-1
6-2
6-2
6-5
CHAPTER 7 - DISASSEMBLY/ASSEMBLY PROCEDURES .................... ..7- 1
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
GENERAL .............................................................................................................. 7-1
DISASSEMBLY PROCEDURES ............................................................................
Reservoir Assembly ..........................................................................................
Rear Case Half Assembly .................................................................................
Mechanism Assembly and Battery Compartment Removal ..............................
MPU Circuit Board Assembly ............................................................................
3V Backup Battery Replacement ......................................................................
LCD Circuit Board Assembly .............................................................................
7-l
7-2
7-3
7-4
7-5
7-7
7-8
Keypad .............................................................................................................. 7-9
APPENDIX A - SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . ..*.............................. A-l
A.1 GENERAL . . . . . . . . . . . . . . . ..~............................................................................................ A-l
TABLE OF CONTENTS
APPENDlX B - CIRCUIT BOARD ASSEMBLY
B.l GENERAL
APPENDIX C - REPAIR PARTS
C.l
C.2 ASSEMBLY PART USTINGS
c.2.1
c.2.2 Rear Case Half
C.2.3
C.2.4
C.2.5 LCD Circuit Board Assembly and Front Case Half Parts
C.3 ALPHABETICAL PARTS LIST
C.4 NUMERICAL PARTS UST
GENERAL
Reservoir Assembly .......................................................................................... c-2
Mechanism Assembly and Battery Compartment Parts
MPU Board Assembly Parts and ESD Shield
APPENDIX D - PRODUCT UPDATES
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~........................................ C-8
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DRAWINGS
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B-l
C-l
c-1
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C-6
c-7
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D.l GENERAL
APPENDIX E - MANUAL REVISION NOTICES
APPENDIX F - REPAIR HISTORY
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TABLE.OF CONTENTS
7
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INTRODUCTION Chapter I
1 .I GENERAL
This Service Manual has been developed to introduce the Biomedical Technician to the AP II
Pump. This manual will provide a basic understanding of the internal workings of the Pump,
functional test procedures, complete assembly/disassembly instructions, troubleshooting, and
replacement parts list.
NOTE
Except for the procedures and replacement parts included in this
document, no other disassembly or repair should be attempted.
Baxter Healthcare provides a one-year limited warranty for each AP II Pump. If a Pump requires warranty service, call Baxter Healthcare for repair. Unauthorized repairing of a Pump
before the warranty has elapsed voids the warranty.
1.2 FACTORY SERVICE/ASSISTANCE
If factory service is desired, Pumps may be returned to Baxter Healthcare for repair.
To expedite repairs, call for a return authorization number before shipping any Pump to Baxter
Healthcare.
1.2.1 Technical Assistance, Service, and Repairs:
For technical assistance, parts ordering, and service return authorization, contact the Baxter
Healthcare Service Center:
1.2.2 Customer Service Related Business:
1-660-343-6366
Includes: Part orders and return/repair authorizations.
1.2.3 Technical Assistance Hotline:
14004344602
Includes: Parts identification, troubleshooting assistance and technical
training schedules.
l-1
Chapter I INTRODUCTION
THIS PAGE INTENTIONALLY BLANK
1-2
THEORY OF OPERATION Chapter 3
2.1 OVERVIEW OFTHE AP II PUMP
The AP II Pump is a small, lightweight, linear peristaltic Pump that may be operated from
battery or AC power. A uniquely designed, optional pole-mounting clamp allows the Pump to
be unlocked and easily removed for placement into a comfortable carrying case.
The user can program the AP II Pump with prescribed values for the therapy desired. A
combination of security code and keying in prescription parameters from the keyboard is
required to enter a prescription. Once programmed the Pump remains in the programmed
state until the operator turns the Pump off or reenters the programming screens and changes
the prescription. The Pump retains a record of the previous prescription and therapy history
while the Pump is in operation or turned off. The user can choose to review the history by
pressing the “HISTORY” key or clear history by pressing the “CLEAR” key.
A key is required to unlock and open the Pump fluid bag cover as well as enter or change a
prescription. A security code must be entered to access the configuration screens and/or
program the Pump. This security code prevents unauthorized prescription changes.
The Pump can also be configured for specific modes, units, and/or prescription limits. This is
accomplished through the access of the default configuration screens during initial start-up of
the Pump. To access the configuration mode refer to the AP II Pump Configuration Manual
and the Operator’s Manual. Once the Pump has been configured, it will remain in that
configuration until purposely changed.
The remainder of this chapter describes the internal working of the AP II Pump. This information is intended to provide a basic explanation of the Pump’s operation. Refer to the trouble-
shooting section for information on Pump maintenance.
2-1
Chapter 2 THEORY OF OPERATION
2.2 AP II PUMP COMPONENTS
The AP II Pump is divided into modules and subsystems as illustrated by figure 2-1. Figure 2-
1 is a functional block diagram of the system and not intended to illustrate component location.
The modules and subsystems listed below are discussed later in this chapter.
Microprocessor and PROM Subsystem
Bus Subsystem
Keypad Subsystem
Supervisory Subsystem
Power Subsystem
LCD Subsystem
Buzzer Circuit
Motor Subsystem
Miscellaneous Circuits
.
MPU
P%%
BUS
subsystem
T T
Figure 2-1 AP II Functional Block Diagram
THEORY OF OPERATION Chapter 2
2.2. I Microprocessor and PROM Subsystem
The AP II Pump is controlled by a microprocessor executing from an external PROM. The
microprocessor is a 1 S-bit single-chip device with two modes of operation.
single chip mode whenever possible or in memory expansion mode when accessing devices
on the external bus. Running in the single chip mode saves power which is a major factor for
this Pump. The processor has eight input/output (l/O) ports which are used to control or
monitor the following functions:
It will operate in the
.
.
.
.
.
.
.
.
.
.
PROM
LCD Command and Data Register
Motor Drive
Watchdog
KeYPad
Switches
Buzzer Circuit
Real Time Clock Circuit
Occlusion Circuit
Various voltages
If an error is detected, the processor will initiate an error code which will produce an alert
message and audible alarm. A number of power-up tests are performed to ensure that the
Pump is running properly. The power-up tests include testing of the LEDs, beeper, backup
battery, and input voltages.
Included in the processor subsystem is the real time clock (RTC) circuit. The RTC provides
time of day information to the microprocessor. The RTC circuitry keeps track of time when the
Pump is off, through the use of a backup battery mounted to the microprocessor circuit board.
The backup battery is also used to preserve the contents of the microprocessor RAM when
operation power drops below a minimum voltage. The RTC also contains a small amount of
RAM which is used by the system software to determine whether there has been a loss of
backup battery power.
The PROM subsystem supplies data to the bus when addressed by the microprocessor to
identify the operation requested.
2-3
Chapter 2
THEORY OF OPERAnON
2.2.2 BUS Subsystem
The BUS has the capacity to provide for a 24 bit address and 8 bit data path. The micropro-
cessor uses the BUS subsystem to transfer data or instructions to six different functions.
These six functions are:
.
.
.
.
.
.
PROM
LCD Command and Data Register
Motor Drive
Watchdog
Keypad
Switches
2.2.3 Keypad Subsystem
The keypad subsystem enables the user to enter the prescription data which is unique to each
usage, and to start and stop the device. The keypad subsystem is comprised of nine keys on
the membrane keypad and three other switches. The microprocessor samples each of the
keys and switches to determine their status. Each of the keys and switches are described
below:
KEY
START
STOP
ENTER
ON/OFF
CLEAR/SILENCE
HISTORY
Left Arrow Key
Up Arrow Key
Right Arrow Key
Primary Function
Starts operation of the unit.
Stops operation of the unit.
Accepts entered configuration codes, configuration parameters, and lim-
its.
Turns the Pump ON and OFF.
Clears data stored in history and silences the audio alarm.
Access the history screens to allow scrolling through history data.
Move the cursor to the left.
Scrolls a selected digit to the next higher setting.
Moves the cursor to the right.
SWITCH
PCA Jack
Bag Cover Lock
Tubing Sensor
Primary Function
Patient Controlled Analgesia (PCA) switch. The PCA switch is a phono
jack which is monitored by the microprocessor to determine the status of
the PCA button.
Internal switch that detects when the bag cover is locked or unlocked.
Switch that detects when the Pump tubing cover is open or closed with
tubing set properly installed.
2-4
THEORY OF OPERATION Chapter 2
2.2.4 Supervisory Subsystem (SS)
The supervisory subsystem performs a major role in the start-up and shutdown of the Pump.
Monitoring and responding to error situations reported by hardware and software is also a
function of this circuitry. A “well check” is performed by the SS on some of the error detection
hardware circuitry.
The SS also provides the power for the microprocessor and the RTC. As long as the regulated
+5V remains above the backup battery voltage, the SS will produce a +5V source for the
microprocessor and the RTC. If the regulated +5V falls below the backup up battery voltage,
the SS connects the backup battery to the microprocessor and the RTC to preserve the
contents of the microprocessor RAM and provide power for RTC operation.
2.2.5 Power Subsystem (PS)
The power subsystem provides the required DC power for the AP II Pump from a 9 volt battery
or the AC Adapter. The AC Adapter is an external unit, which when plugged into an AC wall
outlet will produce 10 volts DC. The AC Adapter is connected, to the AP II Pump at its AC
Adapter input jack. When power is available from both the battery and AC Adapter, the PS
selects the AC Adapter by default to conserve battery life. The PS automatically switches the
LCD backlight to an increased intensity when the AC Adapter power is present.
The PS provides regulated, partially regulated, and unregulated power. In the event that both
the battery and AC Adapter are not present, the PS, in conjunction with the SS, will switch the
microprocessor and RTC power to the backup battery. This maintains the contents of the
microprocessor RAM and keeps the RTC operational.
The unregulated voltage is used primarily to power the motor that drives the AP II peristaltic
Pump. The partially regulated voltage is used to power the buzzer and the LCD’s backlight
circuit. The unregulated voltage is also used as a monitored voltage for the overvoltage fault
detector. The regulated voltage is supplied to all of the IC chips.
2.2.6 LCD Subsystem
The liquid crystal display (LCD) subsystem serves as a device for the microprocessor to
communicate with the user and facilitate the entry of data from the keypad. The LCD displays
two rows of 16 characters, with each character defined by a selection of dots from a 5 x 7 array
with a cursor underneath the array.
The LCD can be written to by the microprocessor which supplies it with either data or com-
mands. Information in the LCD’s memory is read by the microprocessor. For its functional
operation, the LCD has two memories; the character generator (CG) RAM and the display
data (DD) RAM. The AP II Pump hardware has no need to distinguish between the two RAMS.
This is accomplished by the software running in the microprocessor through the commands it
issues to the LCD.
2-5
Chapter 2
2.2.7 Buzzer Circuit
The buzzer circuit provides an audio output to inform the user of the operational status. The
buzzer is accessible through an I/O port from the microprocessor, external hardware, and
software. Operational status and error conditions reported by the external interface devices
activate the buzzer to produce an audible alarm.
2.2.8 Motor Subsystem
The motor subsystem contains two drive paths to activate the Pump. The paths are known as
the positive and negative drive. The Pump drive paths are controlled very precisely by the
microprocessor with feedback from two independent shaft position encoders. The encoder
information enables precise control over the delivery rate.
To drive the motor, the positive signal must be asserted allowing the motor’s negative signal to
complete the return conduction path through the motor when it is activated. The motor’s posi-
tive and negative drive paths are enabled by the microprocessor through different ports.
THEORY OF OPERATION
2.3 MISCELLANEOUS CIRCUITS
2.3.1 Occlusion Detection Circuits
A check is made for the possibility of blockage (occlusion) during delivery downstream of the
AP II Pump. The elastic section of the tubing set (in the area where the fingers of the peristaltic
Pump operates) will expand slightly if a blockage exists. The expansion causes a switch to
trip enabling the Pump to sense an occlusion. However, before an occlusion is detected, the
Pump will check for a wet switch condition to reduce the occurrence of a false occlusion signal.
2.3.2 Backlight Circuit
The backlight circuit provides power for the light emitting diodes (LEDs) in the LCD unit to
generate the necessary light to read the display. Since these LEDs consume a significant
amount of power, the display is only lit when needed while being powered by the 9 volt battery.
The LEDs are driven at less than the nominal rated current. This provides a dim illumination
of the display to reduce the drain on the battery. When programming the unit on battery
power, the backlight will be on. Piieen seconds after programming is complete, the backlight
will turn off. The backlight will turn on again when a key is pressed.
When the Pump is being powered by the AC adapter, the LEDs are on all the time. The LEDs
are supplied with nominal full rated current giving a bright backlight. As long as the AC adapter
is providing power, the display will remain lit.
2-6
THEORY OF OPERATION
2.3.3 Printer Adapter Intetface Circuit.
The interface to the printer adapter enables the microprocessor to produce a printout of the
history data. The Pump interfaces with the Baxter Printer Adapter, P/N 2L3400, and a printer
(typically a Seiko DPU-411). The printer interface is a serial port that operates on 7TL levels
and provides data at a 600 baud rate.
Chapter 2
2-7
Chapter 2 THEORY OF OPERATION
THIS PAGE INTENTIONALLY BLANK
2-8
INITIAL INSPECTION AND DAMAGE CHECK Chapter 3
3.1 GENERAL
This chapter contains the information necessary to perform an initial inspection and set up of
the AP II Pump. A functional test is included in Chapter 4 to determine if operation is satisfactory.
3.2 INITIAL INSPECTION AND DAMAGE CHECK
The AP II Pump has been thoroughly tested and inspected at the factory prior to shipment
and has been found to comply to Baxter’s electrical and mechanical standards. The API1
Pump has also been designed to reliably withstand normal shipment and usage conditions.
However, abusive handling during shipment may cause either visible or hidden damage.
Follow the instructions in this section before performing operational checks.
If any damage is observed in any of the following inspections, and this damage is related to
shipping, notify the carrier’s agent immediately. Do not return the damaged equipment to the
factory without written authorization.
3.3 INSPECTIONS
1. Carefully inspect the shipping carton before opening it. Note any obvious damage caused
by mishandling and record any such damage.
2. The carton should contain the following:
One AP II Pump with a 250E Fluid Bag Cover
One Patient Control Button
One Pump Carrying Case
One Operator’s Manual
One Quick Programming Guide
One Configuration Manual
Two Keys
One AC Adapter
3. Remove the Pump from the carton. Place the Pump on a flat surface and perform these
visual inspections:
A. Check the entire surface for chips, scratches, dents, or cracks.
B. Check the front keypad panel for damage.
C. Check the Fluid Bag Cover for cracks and check to see that it locks properly.
D. Turn the Pump over and verify that the serial number matches that on the shipping
carton. Refer to the Operator’s Manual for tracking information.
3-l
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