Baxter Flo-Gard GSP User manual

Service Manual

Flo-Gard GSP

S Y R I N G E I N F U S I O N P U M P

BS036010EN-P06

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………………………………………….…..4

1.1 General Information……………………………………4

1.2 General Precaution……………………………………..4

1.3 Service Contacts………………………………………..5

2. TECHNICAL DESCRIPTION………………………………..8

2.1 General…………………………………………………8

2.2 Electronic board……………………………………….10

2.3 Drive Unit board …………………………………...13

2.4 Power Supply Unit…………………………………….14

2.5 IRDA/RS232/Nurse Call Interface Specification……...14

2.6 Bootstrap Loader Unit……….………………………...15

3. USER CONFIGURATION MENU…………………………...16

4. SERVICE MENU………………………………………………16

4.1 Maintenance Menu……………………………………..16

4.2 Loading Program…………...…………………………..16

4.3 Calibration……………………………………………...17

4.4 Testing………………………………………………….20

5. RECOMMENDED ROUTINE MAINTENANCE

AND TESTING…………………………………………………22

5.1 AC/Battery Operation Check…………………………...22

5.2 General Cleaning and Inspection for Damage…………22

5.3 Battery Test……………………………………………..23

5.4 Infusion Rate Check……………………………………23

5.5 Occlusion Pressure Level Check……………………….23

6. TROUBLE-SHOOTING……………………………………….24

6.1 Safety WARNINGS…………………………………….24

6.2 Pump has been dropped or damage……………………..24

6.3 Pump has been exposed to fluids………………………..24

6.4 Trouble-shooting by fault symptom……………………..25

6.5 Trouble-shooting by failures codes……………………...28

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7. REPAIR………………………………………………………….33

7.1 Access to the Pump……………………………………...33

7.2 Front Case and Sub-assemblies………………………….33

7.3 Rear Case and Sub-assemblies…………………………..49

7.4 Torque guide…………………………………………….40

8. ELECTRICAL SCHEMATIC DIAGRAMS, COMPONENT

LOCATION DIAGRAMS……………………………………...43

8.1. Electrical Block Diagram of the Pump…………………..43

8.2. Electrical Schematic Diagram of the Pump……………...44

8.3. Electronic Board Schematic Diagram……………………47

8.4. Electronic Board Component Location Diagram………...51

8.5. Drive Unit Board Schematic Diagram …………………..52

8.6. Drive Unit Board Component Location Diagram …….53

8.7. Power Supply Unit Schematic Diagram………………….54

8.8. Power Supply Unit Component Location Diagram………55

8.9. Battery Monitoring Unit Component Location Diagram…56

9. MECHANICAL ASSEMBLY DRAWINGS

AND PART LIST…………………………………..……………..57

9.1. Part List……………………………………………………57

9.2. Front Case Assembly………………………………………59

9.3. Rear Case Assembly……………………………………….71

9.4. Final Assembly…………………………………………….75

10. SPARE PARTS LISTING………………………………………...82

10.1 Spare Accessories…………………………………………77

10.2 Spare Labels/Publications…………………………………77

10.3 Spare Electrical Components……………………………...78

10.4 Spare Mechanical Components……………………………78

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1. INTRODUCTION

1.1.GENERAL INFORMATION

The Flo -Gard GSP syringe pump is designed to accurately control the delivery of solution to the
patient by means of a disposable syringe.

The Flo -Gard GSP syringe pump is compatible with a wide range of standard, single-use,
disposable Luer-lock syringes, ranging from 10ml to 100ml in size.

This SERVICE MANUAL describes the theory of operation, how to check, troubleshoot and
repair Flo -Gard GSP 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 Operating

Instructions carefully prior to using this pump.

This pump contains static- sensitive components. Observe strict precautions

for the protection of static sensitive components when attempting to repair and
service the pump.

An explosion hazard exists if the 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 pump casing is opened or removed.

Refer all servicing to qualified service personnel.

This 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.

If the 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 a qualified service engineer.

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1.3. SERVICE CONTACTS

Baxter Technical Service Centre locations and full addresses:

Argentina

Baxter Immuno SA
Av. Olivos 4140
Tortuguitas-C.P. 1667­ARGENTINA
Tel: [phone]

Austria

Baxter-Immuno Vertriebs GmbH
IZ-Sued Strasse 7 Obj. 58D/Tops2
2355 Wiener Neudorf
AUSTRIA
Tel: [phone]
Fax: [phone]

Brazil

Baxter Hospitalar Ltda
Avenida Santa Catarina 2660
04378-200
Sao Paulo, SP
BRAZIL
Tel: [phone] x5250
Fax: [phone]

Chile

Baxter de Chile, Ltda.
Avenida Mexico #715
Recoleta, Santiago
CHILE
Tel: [phone]
Fax: [phone]

Colombia

Laboratorios Baxter SA
Carrera 99
#46a22
Santafe’de Bogota DC
COLOMBIA
Tel: [phone]
Fax: [phone] x234 or x233

Ecuador

Baxter Ecuador SA
Av. Naciones Unidas #1084
Esquina Amazonas
Edif. Previsora Torre B, Ofic 408
Quito
ECUADOR

Australia

Baxter Healthcare Pty. Ltd.

Baxter Drive, Old Toongabbie
New South Wales 2146
AUSTRALIA
Tel: [phone]

Belgium

N.V. Baxter S.A.

Boulevard R. Branquart 80
B-7860 Lessines
BELGIUM
Tel: [phone]

Canada

Baxter Instrument Services

5055 - Unit 5, Satellite Drive
Mississauga, Ontario
L4W 5K7
CANADA
Tel: [phone]
Fax [phone]

China

Baxter Healthcare Ltd.

Rm 503 China Garments Mansion
99 Jian Guo Road
Beijing 100020,
CHINA
Tel: [phone]
Denmark

Baxter A/S

Gydenvang 43
DK-3450
Allerod
DENMARK
Tel: [phone]
Fax: [phone]
Finland

Baxter OY

Pakkalankuja 6
PO Box 46
FIN-015111 Vantaa
Finland
Tel: [phone]
Fax: [phone]

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France
Baxter S.A.
Avenue Louis Pasteur
Boite Postale 56
78311 Maurepas Cedex
FRANCE
Tel: [phone]
Fax: [phone]

Greece

Baxter (Hellas) EPE
Ethnarhou Makariou 34 & Athinodorou
GR-156341 Illioupolis
Athens
GREECE
Tel: [phone]
Fax: [phone]

Italy
Baxter S.p.a.
Via Lorenzini, 4
20139 Milano
ITALY
Tel: [phone]

Netherlands
Baxter BV
Koblatweg 49
3542 CE Utrecht
THE NETHERLANDS
Tel: [phone]
Fax: [phone]

Panama

Baxter de Panama
Calle 55 Obarrio
Edificio Plaza Obarrio
Primer Piso Suite #105
Panama
REPUBLIC OF PANAMA
Tel: [phone] or 6013
Fax: [phone]

Portugal

Baxter Medico Farmaceutica Lda
Urbanizacao Industrial Cabrafiga
Estrada Nacional 249/4 Lote 3
Cabrafiga
2735 Rio De Mouro
PORTUGAL
Tel: [phone]
Fax: [phone]

Germany

Baxter Deutschland GmbH

Am Wolfsmantel 46
91058 Erlangen
GERMANY
Tel: [phone]

Ireland

Baxter Healthcare Limited

Unit 7, Deansgrange Industrial Estate
Blackrock Co.,Dublin
IRELAND
Tel: [phone]
Fax: [phone]
Northern Ireland
Tel: [phone]

Baxter-SA de CV

Av. Javier Rojo Gomez #709
Col. Guadelupe del Moral CP
09000 MEXICO D.F.
Tel: (52) -56-94-05-20
Fax: (52) -56-94-04-53
Norway

Baxter A/S,

Box 70 Grefsen
0490 Oslo
Gjerdrumsvei 11
NORWAY
Tel: [phone]
Fax: [phone]

Peru

Laboratorios Baxter del Peru SA

Las Camelias 780. Segundo piso
Lima 27
PERU
Tel: [phone]
Fax: [phone]

Puerto Rico

Baxter Sales & Distribution

State Road 24
Rexco Industrial Park
Buchanan
Guaynabo
PUERTO RICO 00968
Tel: [phone]

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Singapore

Baxter Healthcare Asia Pte Ltd
Singapore Technical Services
159 Sin Ming Road
#02-01/02/03 Amtech Building
SINGAPORE 575625
Tel: [phone]
Fax: [phone]
Spain
Baxter S.A.
Poligno Industrial Vara de Quart
Calle Dels Gremis 7
46014 Valencia
SPAIN
Tel: [phone]
Fax: [phone]

Switzerland

Baxter AG
Muellerenstrasse 3
CH-8604 Volketswil
SWITZERLAND
Tel: [phone]

Venezuela

Urb. Industrial Castillito
Centro Comercial Valencia II
Valencia. Edo. Carabobo,
VENEZUELA
Tel: [phone]

South Korea

Baxter International

4, 5/F Jinsung Bldg 996-17
Daechi-dong
Kangnam-ku, Seoul
KOREA
Tel: [phone]
Fax: [phone]
Sweden

Baxter Medical AB

PO Box 63
SE- 164 94 KISTA
Torshamnsgatan 35
Sverige
Tel: [phone]

UK

Baxter Healthcare Limited

UK Nat’l Distribution Centre
Salthouse Road
Brackmills Industrial Estate
Northampton
ENGLAND
NN4 0UF
Tel: [phone]
Fax: [phone]

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2. TECHNICAL DESCRIPTION

2.1. GENERAL

The Block Diagram of the pump is given in the section 8.1. The Electrical Schematic Diagram is
given in the section 8.2. The pump is composed of the following elements:

- Keypads

- Stepper motor

- Stepper motor encoder

- Syringe Force sensor

- Syringe plunger grippers and pusher lever sensor

- Drive engagement sensor

- Syringe size sensor

- Pusher position sensor

- Syringe barrel sensor

- Battery unit

- Electronic board

- Drive Unit board

- Power Supply Unit

- IRDA/RS232/Nurse Call Interface

- Hard bootstrap loader

Below follows a description of these elements, refer the appropriate diagram for full
understanding of the functionality:

2.1.1. Keypads

Keypad K1 comprises of a 4 x 3 key matrix connected to the Electronic board at connector JP1.
The ON/OFF key and BATTERY & MAINS LED’s are also located on the K1 keypad connect
to the Electronic board via JP12.
Keypad K2 comprises of a 4 x 2 key matrix. It is connected to the Electronic board via connector
JP4.

2.1.2. Stepper motor

A two-phase unipolar stepper motor with 7.5º step-angle is used in the pump drive. The motor is
connected to the Drive Unit board via connector P5 and is driven in micro stepping mode. There
are 48 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 5:1; as a result 240 motor steps move the
drive carriage by 1 mm.

2.1.3. Stepper motor encoder

Motor speed and direction is monitored by means of the encoder. It is composed of two photo­interrupters D1, D2 and a 9 slot-encoding disk mounted on the stepper motor shaft. Quadrature
signals (Tax1, Tax2) are transferred to the Drive Unit board via P6 connector.

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2.1.4. Syringe force sensor

Plunger grippers

As a syringe force sensor is used a strain gauge TZ1 mounted on a steel plate within the plunger
retaining mechanism. When this plate is deflected by applied force on the plunger mechanism, 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.

2.1.5. Syringe retainer (plunger grippers and pusher lever) sensors

The plunger grippers and pusher lever sensors are composed of photo interrupters D4, D5, D6.
The LED’s of the photo interrupters are supplied with pulse-modulated current through pin 8 of
JP1 connector of the Drive Unit board.

When the syringe is loaded, the shutters controlling the photo interrupters D4 and D6 are opened.
When the pusher lever is lifted up, the shutter controlling the photo interrupter D5 is opened.
Output signals of these sensors are summed to form syringe retainer output voltage (at pin 7 of
JP1 – Drive Unit board) in accordance with the Table 1.

sensors (D4, D6)

Pusher lever

sensor (D5)

Syr. retainer

output voltage

Off Off <0.3V

On Off

≥0.3V;

≤0.6V

Off On >0.6V;

≤0.95V

On On >0.95V;

≤1.4V

Table 1

2.1.6. Drive engagement sensor

The drive engagement sensor is comprised of photo interrupter D3. Its LED is supplied with
pulse-modulated current. When the half-nuts of drive are closed (engaged), the shutter
controlling the photo interrupter D3 is open and electrical pulses are generated at pin 6 of the
Drive Unit’s board JP1 connector.

2.1.7. Syringe size sensor

The syringe size sensing is achieved using the linear potentiometer R1. The signal from the
potentiometer slider is applied to the Electronic board via pin 2 of JP8 connector.

2.1.8. Pusher position sensor

An optical absolute encoder of pusher position is comprised of a steel encoder ruler and photo
interrupter D7. Ruler is attached to the drive walls, and the photo interrupter is mounted on the
drive carriage and moves along ruler during infusion so that edge of the ruler is inside the gap of
photo interrupter. The edge of the ruler is punched with the slots distributed with various
intervals in certain pattern. Each slot passing the gap generates electrical pulse when the photo
interrupter is moved along the ruler. Microcontroller permanently monitors width of intervals in

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sequence of pulses and determines pusher position basing on combination of passed intervals.
Obviously, certain number of slots should be passed after start of infusion before the pusher
position (and, correspondingly, remaining time and volume) may be determined. Maximum
delay is when the pusher is at the rightmost position (up to 9 mm of pusher travel may be
required).

2.1.9. Syringe barrel sensor

The syringe barrel sensor comprises switch S1. When the syringe is loaded, the switch S1
contacts are closed and a logic “0” is generated at pin 1 of the Electronic board’s JP5 connector.

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 JP7 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.

2.2. ELECTRONIC BOARD

The electrical diagram of the Electronic board is given in section 8.3. It comprises following

main parts:

- Microcontroller circuit

- Display unit

- Display contrast regulator

- RS232 interface

- Watch-dog circuit

- Piezotransducer drive

- Reference voltage source

- LED indicators

2.2.1. Microcontroller circuit

The 16 bit microcontroller U12 (SAB-C167CR-LM) controls and monitors major syringe pump
functions. Clock pulses are generated by the quartz oscillator Q1 at a frequency of 3.686400
MHz and multiplied x 5. Supervisor integrated circuit U9 generates a reset signal for the
microcontroller when the supply voltage changes from 0V to 5V.

Software instructions are stored in 1-Megabyte FLASH memory U10. Device constant
parameters are stored in 8-kilobyte SPI EEPROM, U14. Temporary variables are stored in 128 ­kilobyte SRAM U8 with real time clock and lithium battery.

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The microcontroller functions include:

- Scanning the keypad via the port P8 and the buffers of the U2 and U4 ICs. The

keypad status information is read via other buffers of the U2 and U4 ICs to the
inputs P5.9 (pin 36), P5.10 (pin 39) and P5.11 (pin P40).

- Setting the output P2.10 (pin 59) to ‘0’on switching the pump on. This signal

maintains power supply active. In order to switch power off, the ON/OFF key
shall be kept depressed, thereby setting the P5.7 input (pin 34) to ‘1’. After 3 sec
delay micrcontroller sets the P2.10 output (pin 59) to ‘1’, which switches the
power supply off.

- Detecting pump connection to 100-240VAC mains power or 12VDC by the signal

at the P5.6 input (pin 33) (‘1’ – when connected). At this state transistor T11
opens thereby activating the MAINS indicator on the front panel. When pump is
running on internal battery, microcontroller activates the BATTERY indicator by
setting the P2.0 output (pin 47) to ‘1’.

- Obtaining information from the battery monitoring circuit on the battery voltage,

temperature and capacity via the input P7.6 (pin 25); obtaining battery fast charge
signal via the P5.14 input (pin 43) (‘0’ – fast charge in progress); disabling the
AC mains supply by setting the P7.4 output (pin 23) to ‘1’ in the battery
calibration mode.

- Activating the Nurse Call circuit located at the Supply Unit, by setting the P2.5

output (pin 52) to ‘1’.

- Receiving voltage proportional to syringe size from the syringe size sensor via the

AN0 input (pin 27). Force sensor reference voltage is applied to the AN1 input
(pin 28). Voltage directly proportional to force acting on the syringe pusher, is
applied to the AN2 input (pin 29). Force sensor reference 0 voltage is applied to
the AN3 input (30 pin). Syringe retainer output voltage (see table 1) is applied to
the input AN4 (pin 31). Voltage from piezo transducer current monitor is applied
to the input AN5 (pin 32). The P2.12 output is used for controlling force sensor’s
supply.

- Controlling (pulse modulating) the current through the LEDs of the drive

engaged, gripper and pusher lever sensors via the P2.13 output (pin 62); receiving
signal of engagement of drive half-nuts with lead screw (‘1’ pulses) via the P5.13
input (pin 42) (via the buffer U20); receiving signal that syringe barrel is fitted
(‘0’ level) via the P5.12 input (pin 41) (via the buffer U4E); receiving tachometer
pulses from the Drive Unit board via the P2.15 input (pin 64). Prior to starting
motor rotating backwards and during it microcontroller sets the P2.11 output (pin

60) to ‘0’ to disable motor direction sensor in the Drive Unit board; during normal
infusion this output is set to ‘1’.

- Generating signals for the stepper motor controller/driver which is located in the

Drive Unit board: Data A via the P2.6 output (pin 53), Data B via the P2.7 (pin

54), Strobe A,B via the P2.8 (pin 57), Clock A,B via the P2.9 (pin 58). Signal
controlling magnitude of motor winding current is generated at the POUT0 output
(pin 19) by means of PWM; AC component of this signal is suppressed by means
of the second order low-pass filter (R54, C71, R56, C73), and DC component
having range 0.4 to 2.5 V is transferred via the diode D23 and pin 4 of JP10 to the
Drive Unit board – REF/ENABLE A,B circuit. This circuit is used also for
disabling motor driver by applying +5 V to it. For this sake pin 4 of JP10 is also
connected with the P7.7 output of microcontroller (pin 26) and output of
watchdog via the D21 and D22 correspondingly; logic ‘1’ at any of these two

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outputs sets windings current to zero (e.g. in STOP mode, during pause between
two adjacent steps or when the watchdog is activated).

- Selecting IRDA rate via the P6.4 output (pin 5). Selecting of UART connection

either with the RS232 or IRDA interface via the P6.5 output (pin 6). The P6.7
output is set to ‘1’ when RS232 selected, and ‘0’ is set when IRDA interface
selected.

- Activates Z1 buzzer by setting output P6.7 to ‘1’ when piezotransducer circuit is

interrupted;

- receiving interrupt pulses from the SRAM (U8) Real Time Clock via the T2IN

input (pin 74);

- receiving pulses from the syringe pusher position sensor via T4IN input (pin 70).

2.2.2. Display unit

A 240 x 64 dot blue negative graphic LCD display (MD1) is used in the pump. The backlight is
controlled by means of PWM, using control signal generated at the POUT2 output (pin 21) of the
microcontroller.

2.2.3. Display contrast regulator

Negative voltage adjustable within range of 7.5 to 8.5 V is utilized to control the display
contrast. The negative voltage is generated by means of the DC/DC converter U16, and voltage
regulator U17. Initial voltage value is adjusted by means of trimmer potentiometer R52. The
microcontroller U12 then controls display contrast by means of PWM signal generated at the
POUT3 output (pin 22) and applied to pin6 of the U17 via low-pass filter R50, C60 and diode
D19.

2.2.4. RS232 interface circuit

The RS232 interface circuit is isolated from the pump circuitry by means of the opto-couplers
D8, D9. This isolated part of the circuit is powered from the PC COM port using RTS (+10V)
and DTR (+10V), rectified by means of the D6, D7 diodes signals. Voltage regulator U1 is used
to provide the RS232 interface chip U3 with +5V supply (VDD).
U3 includes a DC/DC converter providing the necessary voltages of +7V and –7V. Integrated
circuit U3 hibernates when no valid receiver level and no receiver or transmitter transient is
detected for 30 seconds, and wake up when a valid receiver level or receiver or transmitter
transient is detected.

2.2.5. Watchdog circuit

The watchdog function is carried out by the uP supervisory circuits with windowed (Min/Max)
watchdog U9. The microcontroller generates clocks at the P2.4 output (pin 51) that are applied to
the WDI input (pin 3 of U9). If the clock period goes outside the permissible range, U9 generates
a short logic ‘0’ pulse at the WDP0 output (pin 5). This pulse sets ‘1’ at the Q output (pin5) of
the flip-flop U6A, which acts as follows:

1) Stops motor (via the D22),

2) Activates red alarm LED D1 (via the D4),

3) Activates the nurse call circuit located in the Supply Unit (via the D16),

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4) Launches the buzzer Z1 (via the D10),

5) Eliminates 3 s delay when switching the pump off (via the input 5 of U11),

6) Indicates to the microcontroller U12 that watchdog is activated (via the P5.8 input – pin 35).
The watchdog circuit is also activated if the motor starts rotating backwards despite forward
rotation commands. In this case the rotation direction sensor in the Drive Unit board sets
“Backwards” circuit (pin 3 of JP9) to ‘0’ which inputs logic “0” to the watchdog (via D18) thus
activating it.
The pump carries out watchdog test each time it is powered up, and if test passes successfully
U6B trigger Q output (pin 9) is set to ‘0’, if test fails – Q output is set to ‘1’. This watchdog
signal is applied to the 67 pin of U12 microcontroller.

2.2.6. Piezotransducer drive

The audible signal is generated by means of PWM at the POUT1 output (pin 20) of the
microcontroller U12. Carrier frequency is suppressed by third order low-pass filter (R58, C75,
R60, C76, R61, C77).
In order to obtain double maximal output voltage a bridge layout of the U18 amplifier is used.
The ratio of R64 and R67 determines audio gain.
R77 monitors current applied on the piezotransducer. Signal from the R77 is amplified by the
U18A amplifier, rectified with the D21, C86 and applied to the AN5 input (pin 32) of the U12
microcontroller.

2.2.7. Reference voltage source

Voltage regulator U7 generates voltage Vref used as reference for the microcontroller’s ADC
and the syringe size sensor. U7 is switched on/off by microcontroller (via the P6.6 output).

2.2.8. LED indicators

The red LED indicator D1 flashes when an ALARM condition is detected or when the watchdog
circuit is activated. It is controlled by the microcontroller U12 via the P2.2 output (pin 49) or by
the watchdog (via the D4). The Green LED D2 flashes during infusion. It is controlled via the
P2.3 output (pin 50) of the microcontroller. The orange LED D3 flashes in ALERT condition. It
is controlled via the P2.1 output (pin 48).

2.3. DRIVE UNIT BOARD

The drive electronics is located on the separate PCB attached to drive mechanical assembly.
Controller-driver U2 is used to operate the stepper motor. It controls current through motor
windings by means of the PWM using control signals from the microcontroller: “Data A” (pin 6
of the U2), “Data B” (pin 17), “Strobe A,B” (pins 2, 13), “Clock A,B” (pins 5, 16),
“REF/ENABLE A,B” (pins 3, 14). Each step of the motor consists of 8 successive micro-steps,
which provide regulation of current through windings closely to sin/cos law, thus ensuring
smooth rotation of the motor shaft. In the case the watchdog is actuated, a high level (+5V)
signal is applied to the “REF/ENABLE A,B” inputs, which removes power from the motor
windings.

Quadrature signals from the motor encoder are processed by means of the decoder built on the
U6, U7, and U8 integrated circuits. 9 square pulses are generated at the TAX output (pin2 of
JP2) during one revolution of motor shaft. The “BACKWARDS” output is used to indicate

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direction of motor rotation. Logic “0” is generated at this output if motor st arts rotating so as to
move syringe pusher backwards while logic “1” is applied to the FWD input (i.e. motor should
not rotate backwards). Logic “0” applied to the FWD input (pin 1 of JP2) disables the direction
sensor and ensures that logic “1” is set at the “BACKWARDS” output regardless of rotation
direction.

The operational amplifier U1 amplifies syringe force sensor’s output signal. Integrated circuit U3
produces precise supply voltage +5V both for the syringe force sensor and amplifier U1. The
trimmer potentiometer R2 is used to balance the force gauge (bridge).
U5A performs buffering of syringe retainer output signal, and U5B performs conditioning of
pusher position sensor’s signal.

2.4. POWER SUPPLY UNIT

The power supply unit includes switching power supply PS1, +5V voltage regulator U2, and
accumulator battery fast-charge controller U1 together with transistor T4. Protective circuits
built using comparators U3, U6 and thyristors D6, D7 are intended to prevent occurrence of
over-voltage and under-voltage at the +5V supply circuit in the case of failure of voltage
regulator or short circuits within pump electronics.

Voltage in the VccNS circuit is approximately +11V when pump is connected to the mains, and
approximately +7V when disconnected (powered from the internal battery). Vcc voltage is +5V
when pump is switched on, and 0 when switched off. The +5V regulator (U2) is switched on
when VccNS voltage is applied to its “ON/OFF” input (pin 2), which occurs when the operator
presses the pump’s ON/OFF key. The regulator is switched off by means of the “SHDN” signal,
which is generated by microcontroller when the operator depresses the ON/OFF key for 3
seconds.

The T8 transistor key is used for switching mains supply off in the course of the accumulator
battery test.

The controller U1 initiates fast charge of accumulator battery each time the pump is connected to
the mains. Detecting a negative battery voltage slope, which occurs when charge is completed,
normally terminates fast charge. For safety reasons termination of the fast charge is provided by
means of the thermistor within the battery pack detecting over-temperature. Additionally,
termination of fast charge is provided on elapsing of established fast charge time. After
termination of fast charge the controller switches to trickle charge mode.

A socket is located on the pump for powering from an external 12VDC source. This circuit
comprises a connector on the rear side of pump and fuses F2, F3, and filter components L1, L2,
C21, C22 mounted on the power supply unit’s PCB. Diode D10 prevents pump from damaging
in case of wrong polarity of external 12 VDC source.

2.5. IRDA/RS232/NURSE CALL INTERFACE

2.5.5. IRDA interface

Serial infrared data communication is operating in accordance with the IRDA standard using
modulator-demodulator U4 and transceiver U5 located on the power supply’s PCB.

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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 IR-transparent plastic.

2.5.6. RS232 interface

The technical specification of the RS232 Interface is listed in table 2 below:

Table 2

Connector D Type –9 Pin, female

TXD Output Voltage Range Minimum: -5V(mark), +5V(space)

Typical: -5.4V(mark), +5.4V(space) with 3kohm load to

ground
RXD Input Voltage Range -25V - +25V maximum
RXD Input Thresholds Low: 0.8V minimum/ High: 2.4V maximum
RXD Input Resistance 3 kohm minimum
Isolation Socket/pump 4 kV
Baud Rate 115 kBaud
Bit Format 1 start, 8 data, no parity, 1 stop

RS232 connections data:

1 - Not used
2 - Transmit Data (TXD) Output
3 - Received Data (RXD) Input
4 - Power Input (DTR)
5 - Ground (GND)
6 - Not used
7 - Power Input (RTS)
8 - Not used
9 - Not used

2.5.7. Nurse Call Interface

Nurse call interface is implemented using relay RL1 located on the power supply’s PCB.
Contacts are rated at 1A at 50VAC or 1 A at 30VDC. Relay contacts are accessible at the
connector on the rear of the pump.
After detecting an alarm condition the microcontroller sets a logic “1” at its P2.5 output (pin 52),
which opens transistor T3 on the power supply’s PCB and the relay is activated. If a failure of
the microcontroller is detected an output signal from the watchdog circuits activated the relay.

2.6. BOOTSTRAP LOADER UNIT

A bootstrap loader unit is used for downloading bootstrap into the Flash memory U10 on the
Electronic board, utilizing microcontroller’s U12 internal bootstrap loader, when the Flash
memory’s software does not contain bootstrap or it does not work. Bootstrap loader unit is
connected to the JP6 connector of the Electronic board. It allows launching the U12
microcontroller by means of manual reset signal, maintains Power Supply Unit active,
commutates UART via the RS232 interface and configures the microcontroller so as to launch its
internal bootstrap lo ader.

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3. USER CONFIGURATION MENU

Depressed the key and turn the pump on. Enter code 237 using the numerical keypad.

Press OK to confirm the code. The User Configuration Menu will be displayed. Use the

softkeys to select the required parameter (see Operator’s Manual).

4. 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

softkeys to select the required parameter.

4.1. MAINTENANCE MENU

Select the MAINTENANCE MENU from the Service menu and press the OK softkey. Use the

softkeys to select the required parameter. Press the OK softkey:

- to modify the NEXT SERVICE DATE

- to view the selected LOG (event, use, key or service)

- to set TIME FORMAT (24h or 12h)

- to set DATE FORMAT (dd-MM-yyyy or MM-dd-yyyy)

- to set DEFAULT PARAMETERS

- to set ALARM PITCH

- to set ALERT PITCH

- to view serial number

- to select INTERFACE type (RS232 or IRDA). (Only one of these interfaces may

be active at a time.)

Press the QUIT softkey to return to Service menu.

4.2. LOADING PROGRAM

4.2.1. Loading program

In order to check the program version, keep the key depressed while turning the pump on.
To perform a programming operation, the following is required:

- Flo -Gard GSP Firmware Upload Utility must be installed and configured on the computer that
is being used.

- Either RS232 extension cable must be connected between the COM port of the computer and
the 9-way ‘D’ connector in the rear of the pump.

Select the LOADING PROGRAM and press the OK softkey. The pump is ready for loading the
program.

Note. When the ERROR: PR02 message (incorrect program CRC) is displayed, the pump also is
ready for loading the program.

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Programming sequence:
Start Flo -Gard GSP Firmware Upload Utility application by clicking on the appropriate icon.
Select which COM port is going to be used.

Click on (Load configuration Set) in order to load program.
Click on Firmware key to start the programming operation.

Note. When the ERROR: OTH01 message is displayed set DEFAULT PARAMETERS.
Having loaded new program it is necessary to execute full testing (see Section 4.4.1).

4.2.2. Loading Bootstrap

In order to perform a programming operation, the following should be in place:

- Flo -Gard GSP Firmware Upload Utility should be installed and configured on the computer
that is being used.

- Having opened the pump housing, Bootstrap Loader Unit should be connected to the Electronic
board connector JP6 (Bootstrap Loader Unit switch should be in ON position).

- RS232 extension cable connected between the COM port of the computer and the 9-way ‘D’
connector in the rear of the pump.

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 Flo -Gard GSP Firmware Upload Utility application by clicking on the appropriate icon.

Select which COM port is going to be used.

Click on (Load configuration Set) 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.

4.3. CALIBRATION

Select the CALIBRATION from the Service menu and press the OK softkey. Select item to be
calibrated using the softkeys and press the OK softkey.

4.3.1. Syringe size sensor calibration

The syringe size detection system stores the characteristics of the syr inge clamp assembly,
including the travel of the linear potentiometer in non-volatile memory.
Equipment:

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- Spacer (gauge) SP1 (B8640037-01) or old (B8640022-01);

- Spacer (gauge) SP2 (B8640037-02) or old (B8640022-02);

- Spacer (gauge) SP3 (B8640037-03) or old (B8640022-03);

- Spacer (gauge) SP4 (B8640023).

Select the Syringe size sensor 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 1 to 4, 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.

4.3.2. Pusher position sensor calibration

Equipment:

- Calibration spacer (gauge) SP1 (B8640037-01) or old (B8640022-01).

Select the Pusher position sensor from calibration menu and press the OK softkey. When
display reads the message Insert spacer SP1, insert the spacer SP1 and slide the drive pusher to
the spacer SP1. Press the OK softkey. Syringe pusher moves backwards and afterwards returns
to the spacer SP1. Following question will be indicated on display:

Is pusher contacting the spacer?

If pusher is not contacting the spacer, press the NO softkey and repeat the calibration. If pusher
is contacting the spacer, press the YES softkey. Following message will be indicated on display:

Offset XX mm,

where XX value shall be (10-13) mm. Press the QUIT softkey to exit.

4.3.3. Force sensor calibration

Equipment:

- Digitron pressure meter, model: 2022P (0-1500 mmHg);

- 50 ml BD PLASTIPAK or 60 ml BD syringe with extension line.

Select the Force sensor from calibration menu and press the OK softkey. The “0 cm Hg
>XXXmV<” message should appear on the screen.

First step is to be performed without loading syringe. Make sure that plunger retainer lever is
released and plunger grippers are in idle position, and pushing surface of the retainer is not in
contact with any part of pump or extraneous object. Leave the pump at rest for at least 15 min,
then press and release the retainer lever a few times. Make sure that actual output value of the
force sensor displayed on the pump screen is (1100±400) mV; if necessary, adjust it by means of
the R2 potentiometer on the Drive Unit board. Press the OK softkey, and the “Insert 60 ml BD
or 50 ml BD PLASTIPAK” message should appear.

Fill syringe with 10-20 ml of water, and fit it to the pump. Connect syringe to the pressure meter
by means of the extension line. Locate the pressure meter at the same height as the syringe. Press
the RUN softkey and keep it depressed, allowing the transmission to run until the pressure meter
reads (148±1.5) cmHg. When approaching the target value, it is recommended to run
transmission in short steps, since if you fail to stop transmission timely and target value is

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overridden, calibration procedure must be repeated from the beginning. When pressure is
adjusted as required, press the OK softkey, then press retainer lever and move the retainer away
from the plunger.

Leave the pump at rest for at least 15 min, then press and release the retainer lever a few times
and check the values displayed on the pump screen to make sure the following:

− difference between actual output value and V1 value is not greater than ±10 mV,

otherwise this calibration procedure shall be repeated from the beginning (a few
times, if necessary),

− difference between V2 and V1 values is within range of 1500-2900 mV. Wrong

readings may indicate malfunction of the force sensor or the Drive Unit.

Press the QUIT softkey to exit.

4.3.4. Battery calibration

Battery calibration cycles the battery through a charge, discharge, re-charge sequence during
which the fuel gauge within 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 to the mains.

Extend the plunger drive arm to the maximum as it will automatically move during the discharge
phase. Select the Battery from calibration menu and press the OK softkey. Leave pump in
calibration mode for up to 14 hours. The cycle should run passing automatically three phases one
by one:

• Initial charge phase – 0 to 3 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 10 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).

While the calibration cycle is active the battery related information is displayed on the pump
screen. At the end of the cycle the screen should show CALIBRATION COMPLETED. Press
the QUIT softkey to exit.

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4.4. TESTING

Select the TESTING from the Service menu and press the OK softkey. Select the item to be
tested using the softkeys and press the OK softkey.

4.4.1. Full testing

This section provides a complete pump test procedure. During test it is possible to review and
modify following parameters: language, date, time, next service date. Follow each stage test and
follow the instructions on the display use the QUIT softkey to move to the other test.

4.4.2. 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 QUIT softkey to return to TESTING menu.

4.4.3. Drive sensors test

This test enables checking of the following sensors: syringe barrel, plunger grippers, push lever
and drive disengaged.
Select Drive Sensors from the testing menu and press the OK softkey. Loading and removing
the syringe will cause the sensors status to changes indicated on the pump display.
Drive engagement sensor can not be activated if nut and lead screw threads come “tooth on
tooth”. In such case slide the syringe pusher to another position and repeat the checking.
Once complete press the QUIT softkey to return to TESTING menu.

4.4.4. Syringe size sensor 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 QUIT softkey to return to TESTING menu.

4.4.5. Pusher position sensor test

This test is enables checking the operation of pusher position sensor. Select Pusher position
sensor from the testing menu and press the OK softkey. Insert the spacer SP1and slide the drive

pusher to the spacer SP1. Press the OK key. Syringe pusher moves backwards and afterwards
returns to the spacer SP1. Pusher position distance (22 ± 0.5)mm should be indicated on the
display. Having finished testing press the QUIT softkey to return to TESTING menu.

4.4.6. Motor test

This test enables checking of the motor operation. During test no syringe should be installed.
Select Motor from the testing menu and press the OK softkey. Having finished testing press the
QUIT softkey to return to TESTING menu.

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4.4.7. Display test

This test checks that all of the display pixels (240x64) illuminate. Select Display from testing
menu and press the OK softkey. Observe “chess- board” structure fields that appear in the
display. All the rectangles should be same shaped and evenly filled. Having finished testing
press the QUIT softkey to return to TESTING menu.

4.4.8. Nurse call test

Equipment:

- Nurse call cable (B6650012);

- 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 3 (com)
and contacts 1 (NO), 5 (NC). The contacts should toggle each time the CHANGE softkey is
pressed, as indicated on the display. Press the QUIT softkey to return to TESTING menu.

4.4.9. Piezotransducer (speaker)/buzzer test

This test checks the piezotransducer (speaker) and buzzer operation. Select Speaker/buzzer
from the testing menu and press the OK softkey. Check for the alternating volume and pitches
sound from the speaker. Check for the sound from the buzzer. Press the QUIT softkey to return
to TESTING menu.

4.4.10. Keyboard test

This test enables checking the keypad operation. Select Keyboard from the testing menu and
press the OK softkey. You will be prompted to press keys on the display (flashing) in sequence.

4.4.11. 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: ALARM, ALERT, INFUS.

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 QUIT softkey to return to TESTING menu.

4.4.12. Watch-dog test

This test enables checking of the watch-dog circuit operation. Select Watch-Dog from testing
menu and press the OK softkey. Initially the watch-dog circuit is applied with an over frequency
signal and later with an under frequency signal. When test completed switch off the pump using
the OFF key.

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5. RECOMMENDED ROUTINE MAINTENANCE AND TESTING

It is recommended that routine maintenance be carried out at least once a year. This should
include:

- AC Mains / Battery operational checks (section 5.1).

- General cleaning and inspection for damage (section 5.2).

- Battery test (section 5.3).

- Infusion rate check (section 5.4).

- Occlusion pressure level check (section 5.5).

- Full test (sections 4.4.1-4.4.12).

5.1. 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.

5.2. 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. Servicing should be performed only by a
qualified service engineer, with reference to this manual. 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 operation of the pole clamp screw. Check it is not loose and that the threads are not
damaged. Check that it folds away correctly.

Inspect the AC power supply inlet and cable for sings of damage.

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5.3. BATTERY TEST

Perform battery calibration in accordance with 4.3.4. When calibration is completed and the
battery is fully charged (at least 2 hours 30 minutes on charge) disconnect the pump from the
mains. Load 50 ml BD Plastipak or 60ml BD 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 2 hours 30 minutes.

5.4. 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 or 60 ml BD syringe with extension set and fill it with distilled
water up to point of 60ml. Program the following infusion parameters:

- VTBI 50 ml;

- 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 and read the volume of water delivered into the test-tube. Calculate the
infusion rate. It shall be 50ml/h ±1ml/h (±2%).

5.5.OCCLUSION PRESSURE LEVEL CHECK

Equipment:

- Digitron pressure meter, model: 2022P (0-1500mmHg).

Fill the 50 ml BD Plastipak or 60 ml BD 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 ma x/min
pressure recording mode.

Set pump occlusion alarm level to L-5 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 (63 - 107) cmHg range.

If recorded value is outside this range, re-calibrate the force sensor in accordance with 4.3.3 and
repeat this test.

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6. TROUBLE-SHOOTING

6.1.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.

- Should further technical assistance be required call your local BAXTER Service

Centre.

6.2. 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, syringe pusher drive, syringe size
sensor.

6.3. 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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