Baxter IPump Service manual
Ipump Pain Management System
SERVICE MANUAL
For use with Ipump devices with hardware revision 2 (HW Rev 2).
Disclaimer
The information in this document has been carefully examined, and is believed to be entirely reliable. However,
no responsibility is assumed for inaccuracies. Furthermore, Baxter reserves the right to make changes to any
products herein to improve readability, function, or design. Baxter does not assume any liability arising out of
the applications or use of any product or circuit described herein; neither does it cover any license under its
patent rights nor the rights of others.
Documentation Copyrights
Duplication or distribution of this manual and any information contained within (except for the data sheets), is
strictly prohibited without the express written permission of Baxter. This manual and any information contained
within, may not be reproduced, distributed, or transmitted in any form, or by any means, for any purpose
without the express written permission of Baxter.
Computer Software Copyrights
Copyright 2006, Baxter Healthcare Corporation. All rights reserved.For use only by Baxter Healthcare
Corporation. The software contains proprietary information belonging to Baxter Healthcare Corporation. The
software must not be reproduced or disclosed to others without prior written approval. Any unauthorized use of
this information may subject the user to substantial liability.
Patent Information
This pump is protected under one or more U.S. and Foreign patents.
Trademark Information
Baxter and Ipump are trademarks of Baxter International Inc.
All other trademarks and product names appearing within this manual are the property of their respective
owners.
Copyright 1999 - 2007, Baxter Healthcare Corporation. All rights reserved.
Chapter 1 - Introduction
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Pump Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
Manual Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
Factory Service & Assistance - - - - - - - - - - - - - - - - - - - - - 1-3
Technical Assistance, Service, & Repairs - - - - - - - - - - - - - - - 1-4
Safety Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
Warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Cautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
Labeling Symbol Definitions - - - - - - - - - - - - - - - - - - - - - 1-6
Contents
Chapter 2 - Theory of Operation
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
System Components - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
MPU Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
BUS Subsystem - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
Keypad & Sensors - - - - - - - - - - - - - - - - - - - - - - - - 2-4
PROM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
Supervisory Subsystem (SS) - - - - - - - - - - - - - - - - - - - 2-5
Power Subsystem (PS) - - - - - - - - - - - - - - - - - - - - - - 2-5
LCD Subsystem- - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
Silent Shutdown Circuit - - - - - - - - - - - - - - - - - - - - - - 2-6
Motor Subsystem - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
Occlusion Detection Circuit - - - - - - - - - - - - - - - - - - - - 2-7
Air Sensor Circuit - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
Printer Adapter Interface Circuit - - - - - - - - - - - - - - - - - - 2-7
07-19-A8-092 Ipump Pain Management System Service Manual i
Contents
Chapter 3 - Care & Routine Maintenance
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Cleaning and Disinfecting - - - - - - - - - - - - - - - - - - - - - - - 3-1
Chapter 4 - Troubleshooting
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Reviewing the Alarm Log- - - - - - - - - - - - - - - - - - - - - - - - 4-1
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
System Error Codes - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
Range 10 - 2V -- Peripheral/Sensor Errors - - - - - - - - - - - - - 4-5
Range 30 - 47 -- Motor Control Errors - - - - - - - - - - - - - - - - 4-6
Range 50 - 52 -- RTC Errors - - - - - - - - - - - - - - - - - - - - 4-7
Range 60 - 62 -- Power Supply Errors- - - - - - - - - - - - - - - - 4-7
Range 70 - 74 & L0 -- MPU Errors - - - - - - - - - - - - - - - - - 4-7
Range 75 - 8D -- Processing Errors - - - - - - - - - - - - - - - - - 4-8
Range 90 - 9Z & M0 - P3 -- Data Corruption Errors - - - - - - - - - 4-8
Range A0 - J1 -- Processing Errors - - - - - - - - - - - - - - - - 4-10
Chapter 5 - Functional Tests
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
General Information - - - - - - - - - - - - - - - - - - - - - - - - 5-2
Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Optional Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Exterior Visual Inspection - - - - - - - - - - - - - - - - - - - - - - - 5-3
Configuration Settings - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
Flow Rate Accuracy Test- - - - - - - - - - - - - - - - - - - - - - - - 5-6
Test Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
Procedure Using the Gravimetric Method - - - - - - - - - - - - - - 5-7
Procedure Using the Volumetric Method - - - - - - - - - - - - - - 5-8
Downstream Occlusion Calibration Pressure Test - - - - - - - - - - - 5-8
Operational Checks - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Test Set Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Power-On Self Test (POST) - - - - - - - - - - - - - - - - - - - - 5-9
Keypad Operation Test - - - - - - - - - - - - - - - - - - - - - - 5-10
Bag Cover Lock/Unlock Test - - - - - - - - - - - - - - - - - - - 5-10
ii Ipump Pain Management System Service Manual 07-19-A8-092
Tubing Sensor Test - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Occlusion Sensor Test - Downstream - - - - - - - - - - - - - - - 5-11
Occlusion Sensor Test - Upstream - - - - - - - - - - - - - - - - 5-11
Air Sensor Test - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
PCA Cable & Button Test - - - - - - - - - - - - - - - - - - - - - 5-13
AC Adapter Test (Optional) - - - - - - - - - - - - - - - - - - - - 5-13
History Retention Test (Backup Battery Check) - - - - - - - - - - 5-14
Printer Test (Optional) - - - - - - - - - - - - - - - - - - - - - - - 5-14
Unintended Shutdown Circuit Test - - - - - - - - - - - - - - - - - 5-14
Functional Test Data Sheet - - - - - - - - - - - - - - - - - - - - - - 5-15
Chapter 6 - Disassembly & Reassembly
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-2
Tools & Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-2
Contents
Required Tools & Equipment - - - - - - - - - - - - - - - - - - - 6-2
Consumable Materials - - - - - - - - - - - - - - - - - - - - - - 6-3
Baxter-Created Tools & Equipment - - - - - - - - - - - - - - - - 6-3
Disassembly Procedures - - - - - - - - - - - - - - - - - - - - - - - 6-4
General Disassembly Information - - - - - - - - - - - - - - - - - 6-4
Bag Cover Assembly Removal - - - - - - - - - - - - - - - - - - 6-4
MPU PCBA Handling Guidelines - - - - - - - - - - - - - - - - - 6-5
Rear Case Assembly Removal - - - - - - - - - - - - - - - - - - 6-6
Mechanism Assembly, DDMM PCBA, & Battery Wall Removal - - - 6-7
MPU PCBA Removal - - - - - - - - - - - - - - - - - - - - - - - 6-8
ESD Flex Circuit Removal - - - - - - - - - - - - - - - - - - - - - 6-9
LCD Module Removal - - - - - - - - - - - - - - - - - - - - - - - 6-10
Optional Procedures - - - - - - - - - - - - - - - - - - - - - - - - - 6-11
3V Backup Battery Replacement - - - - - - - - - - - - - - - - - 6-11
Initializing the 3V Backup Battery - - - - - - - - - - - - - - - - - 6-12
Keypad Replacement - - - - - - - - - - - - - - - - - - - - - - - 6-12
Assembly Procedures - - - - - - - - - - - - - - - - - - - - - - - - 6-15
Torque Specifications - - - - - - - - - - - - - - - - - - - - - - - 6-15
Installing the Front Case & Keypad Assembly - - - - - - - - - - - 6-15
Installing the ESD Flex Circuit - - - - - - - - - - - - - - - - - - - 6-15
Installing the Display ESD Shield - - - - - - - - - - - - - - - - - 6-18
Installing the LCD Module - - - - - - - - - - - - - - - - - - - - - 6-18
07-19-A8-092 Ipump Pain Management System Service Manual iii
Contents
MPU PCBA Handling Instructions - - - - - - - - - - - - - - - - - 6-19
Installing the MPU PCBA - - - - - - - - - - - - - - - - - - - - - 6-19
Installing the Battery Wall & DDMM PCBA - - - - - - - - - - - - 6-23
Installing the DDMM PCBA Hold-down Foam - - - - - - - - - - - 6-24
Installing the Mechanism Assembly - - - - - - - - - - - - - - - - 6-24
Installing the Battery Door - - - - - - - - - - - - - - - - - - - - 6-25
Pump Calibration - - - - - - - - - - - - - - - - - - - - - - - - - 6-25
Internal Inspection - - - - - - - - - - - - - - - - - - - - - - - - 6-26
Closing the Case - - - - - - - - - - - - - - - - - - - - - - - - - 6-27
Pump Functional Tests - - - - - - - - - - - - - - - - - - - - - - 6-28
Optional Assembly Procedures - - - - - - - - - - - - - - - - - - - - 6-28
Installing the Bag Cover Assembly - - - - - - - - - - - - - - - - 6-28
Chapter 7 - Internal Tests & Pump Calibration
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
3V Backup Battery Test - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Battery Load Test - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Battery No Load Test - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Calibration Procedure - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - 7-4
Initial Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
Downstream Occlusion Calibration - - - - - - - - - - - - - - - - - 7-5
Upstream Occlusion Calibration- - - - - - - - - - - - - - - - - - - 7-6
Air Sensor Calibration - - - - - - - - - - - - - - - - - - - - - - - 7-8
Downstream Occlusion Calibration Pressure Test - - - - - - - - - - 7-9
Calibration Data Sheet - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Chapter 8 - Electronic Assembly Drawings
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Interconnecting Wiring Diagram - - - - - - - - - - - - - - - - - - - - 8-1
Keypad Cable & Motor Connectors - - - - - - - - - - - - - - - - - - 8-2
Mechanism Assembly Flex Circuit Connector - - - - - - - - - - - - - - 8-2
MPU PCBA Assembly - - - - - - - - - - - - - - - - - - - - - - - - - 8-3
Direction & Drive Motor Module PCBA (DDMM) Daughter Board - - - - 8-4
iv Ipump Pain Management System Service Manual 07-19-A8-092
Chapter 9 - Repair Parts
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1
Assembly Parts List - - - - - - - - - - - - - - - - - - - - - - - - - 9-2
Bag Cover Assembly - - - - - - - - - - - - - - - - - - - - - - - 9-2
Rear Case Assembly - - - - - - - - - - - - - - - - - - - - - - - 9-3
Pump Mechanism & Battery Compartment Assemblies- - - - - - - 9-4
MPU Board Assembly - - - - - - - - - - - - - - - - - - - - - - - 9-5
LCD Circuit Board & Front Case Assemblies - - - - - - - - - - - - 9-6
Alphabetical Parts List - - - - - - - - - - - - - - - - - - - - - - - - 9-7
Numerical Parts List - - - - - - - - - - - - - - - - - - - - - - - - - 9-9
Chapter 10 - Product Updates
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-1
Contents
Limited Warranty
07-19-A8-092 Ipump Pain Management System Service Manual v
Contents
vi Ipump Pain Management System Service Manual 07-19-A8-092
1 - Introduction
In this section Page
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Pump Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Factory Service & Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Technical Assistance, Service, & Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Labeling Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Overview
The Ipump Pain Management System (hereafter referred to as the “pump”) is indicated
for the controlled delivery (continuous, intermittent, and continuous plus intermittent) of
analgesic, sedative, and anesthetic solutions through clinically acceptable routes of
administration including intravenous, subcutaneous, and epidural, and for regional (local)
analgesia applications.
This lightweight, compact pump can be battery o perated for portability or connect ed to an
AC power source for stationary use. A specially designed optional locking pole-mounting
clamp allows the pump to be attached to a standard IV pole. With the pole clamp removed,
the pump can be placed into a comfortable carrying case.
This manual contains service and maintenance information for all Ipump Pain
Management System products (product codes 2L3107, 2L3107R, and 2L3107K) with
hardware revision 2 (HW Rev 2). This information is intended for qualified biomedical
personnel and Baxter authorized service representatives.
This manual provides a basic understanding of the internal workings of the pump,
functional test procedures, troubleshooting, complete assembly/disassembly instructions,
and a replacement parts list.
For complete operational and precautionary information, pump specifications, and
cleaning instructions, refer to the Ipump Pain Management System Operator’s Manual
(p/n 07-19-x4-766). For pump installation and configuration, refer to the Ipump Pain
Management System Configuration Manual (p/n 07-19-x4-768).
Only trained, qualified personnel should perform procedures in this
CAUTION
07-19-A8-092 Ipump Pain Management System Service Manual 1-1
manual. Except for the procedures and replacement parts included in
this document, no other disassembly or repair should be attempted.
1 - Introduction
Baxter Healthcare Corporation provides a one-year limited warranty for new Ipump
devices. If a pump requires warranty service, call Baxter Healthcare Corporation for
repair. Unauthorized repair of a pump before the warranty has elapsed voids the warranty.
Pump Accessories
100 mL Bag Cover 2L3218
250 mL Bag Cover 2L3220
250 mL Extended Bag Cover 2L3217
250 mL Extended Bag Cover, Amber 2L3261
500 mL Bag Cover 2L3221
Printer Adapter 2L3400
Printer Adapter Cable 2L3402
Patient Controlled Analgesia (PCA) Button B069140003RP
Locking Pole Mount Clamp 2L3211
Non-locking Pole Mount Clamp 2L3212
Pump Carrying Case (250 mL) 2L3219
AC Adapter (220-230V) 2L3205K
AC Adapter (100-120V) 2L3210
AC Adapter Holder 2L3214
Configuration Transfer Cable 2L3112
Yellow Face Plate Label 072742210
Description Catalog Number
Manual Layout
This manual is divided into the following sections:
Chapter 1 (Introduction) provides an overview of the contents of this Service Manual
and includes Warnings and Cautions concerning the use and care of this product.
Warnings and Cautions are also located where needed throughout this manual.
Chapter 2 (Theory of Operation) details the functional features of the pump. A general
overview of the pump’s operation and a functional block diagram are provided.
Chapter 3 (Care & Routine Maintenance) includes the routine maintenance and
cleaning procedures with recommended cleaning agents. Battery replacement procedures
are also included.
Chapter 4 (Troubleshooting) contains troubleshooting tables and procedures for
localizing mechanical or electronic faults. A table of System Error Codes is also included.
1-2 Ipump Pain Management System Service Manual 07-19-A8-092
1 - Introduction
Chapter 5 (Functional Tests) provides the tests that are to be used to ensure that the
pump operates properly. Baxter recommends that these tests be performed on an annual
basis as a preventive maintenance procedure. In addition, these tests must be performed
whenever the Mechanism Assembly and/or the MPU PCBA is removed or replaced.
Chapter 6 (Disassembly & Reassembly) provides disassembly, replacement, and
reassembly instructions. Required tools and test equipment are specified. Adjustment
procedures are provided along with the required torques and tolerances. Replacement
procedures for the 3V Backup Battery and the Keypad are also included.
Chapter 7 (Internal Tests & Pump Calibration) contains the procedures required to
test the 3V Backup Battery and to calibrate the pump. The calibration procedures must be
performed after replacement of either the Mechanism Assembly or the MPU PCBA.
Chapter 8 (Electronic Assembly Drawings) contains the assembly drawings for the
interconnecting cables and flex circuits used in the pump.
Chapter 9 (Repair Parts) provides exploded view drawings and parts lists of fieldreplaceable parts and assemblies.
Chapter 10 (Product Updates) contains major updates and additional information for
the pump. This information will be listed by hardware and software revision numbers
and/or product serial number. Product Service Bulletins should also be placed in this
chapter of the manual.
Factory Service & Assistance
Baxter Healthcare Corporation provides a one-year limited warranty for each pump. (See
the inside back cover of this manual for warranty details.) If a pump requires warranty
service, call Baxter Healthcare Corporation for repair. While under Baxter Warranty,
Service Agreement (optional), or Lease Agreement, the pump must not be opened by
unauthorized personnel. Unauthorized repair of a pump before the warranty has elapsed
voids the warranty.
If factory service is desired, pumps may be returned to Baxter Healthcare Corporation for
repair. Always call for a return material authorization number before shipping any pump
to Baxter Healthcare Corporation.
When calling for service, please be prepared to provide the product code and serial
number of the pump. A brief written description of the problem should be attached to the
pump when it is returned for service.
Shipping costs for all pumps returned to Baxter shall be paid for by the customer. The
pump must be packed in its original container or in another container that will provide
adequate protection during shipment. T o ensure prompt return, a Baxter authorized service
representative must be notified before shipping any pump for repair.
Baxter Healthcare Corporation will not be responsible for unauthorized returns or for
pumps damaged in shipment due to improper packing.
07-19-A8-092 Ipump Pain Management System Service Manual 1-3
1 - Introduction
Technical Assistance, Service, & Repairs
For technical assistance, parts ordering, and service return authorization, contact the
Baxter Healthcare Service Center:
Inside the U.S.: Call 1-800-THE-PUMP (843-7867)
Outside the U.S.: Contact your local Baxter representative.
Safety Summary
General precautions to observe while using the pump are shown below. Standards under
which this product is designed, built, and marketed are also included.
• Before operating the pump, carefully read the operator’s manual to fully understand the
pump’s functionality and to ensure safe and proper operation. An operator’s manual is
shipped with each pump.
• Although the pump has been designed and manufactured to exacting specifications, it
is not intended to replace trained personnel in the supervision of infusion therapy.
• Read and understand this manual before attempting to perform service or maintenance
on the pump.
• To ensure that the pump continues to perform within specifications, perform the
Routine Maintenance procedures described in Chapter 3 of this manual when
recommended.
• This manual has been developed with consideration to the requirements in the
International Standard, IEC 60601-2-24 (1998-02) Medical Electrical Equipment —
Part 2-24: Particular Requirements for Safety of Infusion Pumps and Controllers.
• This product is classified by Underwriters Laboratories Inc. with respect to electric
shock, fire and mechanical hazards only in accordance with UL 60601-1 Medical
Electrical Equipment - Part 1: General Requirements for Safety.
Definitions
Certain items in this manual are highlighted by special messages. The definitions of the
various types of message are provided below.
! WARNING !
CAUTION
NOTE: Provides supplemental information to the accompanying text.
1-4 Ipump Pain Management System Service Manual 07-19-A8-092
Indicates a possible hazard which, if ignored, could result in
severe personal injury or death.
Indicates a problem or unsafe practice which, if not avoided, could
result in minor or moderate personal injury, or product or property
damage.
Warnings
1 - Introduction
! WARNING !
! WARNING !
! WARNING !
! WARNING !
! WARNING !
This pump should be repaired only by trained, qualified
personnel using Baxter-recommended parts. There are risks
associated with using anything other than Baxter-recommended
parts and procedures. Baxter will assume no responsibility for
incidents which may occur if the product was not repaired by
qualified Baxter employees.
If the pump has been dropped or appears to be damaged, it
should be taken out of service and inspected by qualified
service personnel.
To ensure safe and proper operation, read the Ipump Pain
Management System Operator’s Manual and any instructions
accompanying disposables or accessories before operating the
pump.
When attaching the pump to an IV pole, ensure it has been
securely clamped and locked.
As with all medical electronic equipment, care must be exercised
to avoid exposing this pump to powerful sources of
electromagnetic interference. Using the pump near operating
equipment which radiates high energy radio frequencies (such
as electrosurgical/cauterizing equipment, two-way radios, or
cellular telephones) may cause false alarm conditions. If this
happens, reposition the pump away from the source of
interference.
Cautions
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
In the U.S., use of this pump is restricted by federal law (USA) to sale
or use by, on the order of, or under the supervision of a physician or
other licensed health care professional.
DO NOT operate this infusion pump in the presence of flammable
anesthetics, ether, oxygen-enriched, or explosive atmospheres.
DO NOT expose the pump to X-rays, gamma rays, or other ionizing
radiation, or to strong electric or magnetic fields.
Wipe off spills immediately. DO NOT allow fluid or residue to remain
on the pump.
Ensure proper maintenance of the pump by following the cleaning
schedule and methods described in this manual.
Do not clean, disinfect, or sterilize any part of the pump by
autoclaving, or with ethylene oxide gas. Doing so may damage the
pump and void the warranty. Only external parts of the pump should
be disinfected.
Refer all service, repair, and calibration to trained, qualified
personnel.
To reduce the risk of electrical shock, only trained, qualified personnel
should disassemble this product.
CAUTION
07-19-A8-092 Ipump Pain Management System Service Manual 1-5
For best performance, routine maintenance procedures must be
performed. (Refer to Chapter 3 of this manual.)
1 - Introduction
Notes
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
Wear a grounding wrist strap when disassembling and reassembling
the pump.
DO NOT lay the pump face down on any surface which could scratch
or damage the keypad or the display.
When troubleshooting the pump, do not inject or apply signals of any
kind. Damage to the pump or its sub-assemblies could result.
Motor and sensor magnets may attract metal debris to motors or
circuit boards. To prevent debris from entering the pump mechanism,
always maintain a clean work area when performing procedures
involving the pump mechanism.
To avoid personal injury, ensure that the IV pole is stable and secure.
Ensure that the pole is able to support the pump, along with any other
devices, without tipping or falling. The pole diameter should be
between 0.5" and 1.25" (1.3 cm and 3.2 cm).
Baxter requests that parties acquiring this pump:
• Promptly report the receipt of this pump to the manufacturer.
• Report the pump’s purchase, receipt in trade, return after sale, loss, destruction, or
retirement.
• If this is an initial purchase from the manufacturer, please return a signed copy of the
packing list to the manufacturer.
Labeling Symbol Definitions
IPX1
Drip-proof equipment: enclosed equipment protected against
dripping fluids.
Connection port for the AC to DC converter/adapter.
CAUTION, Consult Accompanying Documents
Type CF applied part. (The
indicates the level of electric shock protection for the patientcontacting parts such as the PCA button and the IV set.
UL/IEC/EN 60601-1 defines Type CF as providing greater
protection than Type B or Type BF.)
Electrostatic Sensitive Devices
(The pins of the PRINTER/COMM connector are subject to
Electrostatic Discharge and should not be touched. Refer to
page 2-7 for additional information.)
“Type CF Applied Part” symbol
1-6 Ipump Pain Management System Service Manual 07-19-A8-092
1 - Introduction
Recyclable, dispose of properly.
This product is classified by Underwriters Laboratories Inc.
with respect to electric shock, fire, and mechanical hazards
only in accordance with UL 2601-1 (UL 60601-1),
CAN/CSA C22.2 No. 601.1, and IEC 60601-2-24.
Symbol (WEEE 2002/96/EC) Crossed-out wheeled bin
For product disposal, ensure the following:
- Do not dispose of this product as unsorted municipal waste.
- Collect this product separately.
- Use collection and return systems available to you.
Bar below bin
- Product distributed after August 13, 2005.
For more information on return, recovery, or recycling of
this product, please contact your local Baxter representative.
EC REP
REF
SN
Manufacturer
Authorized Representative in the European Community
Catalog Number
Serial Number
07-19-A8-092 Ipump Pain Management System Service Manual 1-7
1 - Introduction
1-8 Ipump Pain Management System Service Manual 07-19-A8-092
2 - Theory of Operation
In this section Page
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Ipump System Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . 2-2
MPU Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
BUS Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Keypad & Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
PROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Supervisory Subsystem (SS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Power Subsystem (PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
LCD Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Silent Shutdown System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Motor Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Occlusion Detection Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Air Sensor Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Printer Adapter Interface Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Overview
The Ipump Pain Management System is a small, lightweight, linear peristaltic pump that
may be operated from battery or AC power. An optional pole-mounting clamp allows the
pump to be unlocked and easily removed for pump placement into a convenient carrying
case. See the list of pump accessories on page 1-2.
The user can program the pump with prescribed values for the therapy desired. A number
of security options are available in order to enter prescription parameters from the keypad.
Once programmed with prescription parameters, the pump operates with these settings
until the operator turns the pump off or re-enters the programming screens and changes the
prescription. A record of the previous prescription and therapy history are retained while
the pump is in operation or turned off. The user can choose to use the previous
prescription, review the history by pressing the
pressing the
The pump can be configured to require a key to unlock and open the pump bag cover to
change a prescription. The pump can also be configured to require either a security code,
or both a key and a security code, to gain applicable access.
The pump can be programmed for specific modes, units, and/or prescription limi ts. This is
accomplished by accessing the configuration screens during initial start-up. To access the
configuration mode refer to the Ipump Pain Management System Configuration Manual
and the Ipump Pain Management System Operator's Manual. Once programmed, the
pump will remain in that configuration until purposely changed.
HISTORY key, or clear the history by
CLEAR key.
07-19-A8-092 Ipump Pain Management System Service Manual 2-1
2 - Theory of Operation
S E N S O R C I R C U I T P R I N T E R A D A P T E R I N T E R F A C E C I R C U I T
C I R C U I T M P U C I R C U I T B U S S U B S Y S T E M M O T O R S U B S Y S T E M P R O M K E Y P A D S U P E R V I S O R Y S U B S Y S T E M L C D S U B S Y S T E M P O W E R S U B S Y S T E M S I L E N T S H U T D O W N
The pump configuration can be transferred between two Ipump devices for the
configuration of multiple pumps. An optional configuration transfer cable, available from
Baxter, is required. See the list of pump accessories on page 1-2.
The remainder of this chapter provides a basic explanation of the pump's internal
operation.
System Components
The pump is divided into modules and subsystems. Figure 2-1 is a functional block
diagram of the system and not intended to illustrate component location. The m odules and
subsystems listed below are discussed later in this chapter.
• MPU Circuit • LCD Subsystem
• Bus Subsystem • Silent Shutdown Circuit
• Keypad • Motor Subsystem
• PROM • Occlusion Detection Circuit
• Supervisory Subsystem • Air Sensor Circuit
• Power Subsystem • Printer Adapter Interface Circuit
A I R
C I R C U I T
O C C L U S I O N
D E T E C T I O N
Figure 2-1. Ipump System Functional Block Diagram
2-2 Ipump Pain Management System Service Manual 07-19-A8-092
2 - Theory of Operation
MPU Circuit
The pump uses a 16-bit micro-controller and an external PROM. The 16-bit microcontroller contains hardware timers, analog to digital converter, RAM and PROM, and
the microprocessor. This application of the micro-controller uses the internal RAM and
PROM whenever possible to save power, which is a major feature of this pump. The
memory expansion mode is only used when accessing functions on the external bus. The
microprocessor has eight input/output (I/O) ports which are used to control or monitor the
following functions:
• PROM • LCD Subsystem
• Motor Subsystem • Watchdog
• Keypad • Switches
• Silent Shutdown Circuit • Real Time Clock Circuit
• Occlusion Detection Circuit • Air Sensor Circuit
• Various voltages
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, memory, display, beeper, backup battery,
and input voltages. If an error is detected, the processor will initiate a 2-character error
code which will produce an alert message and an audible alarm.
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 while 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 operating power drops below a minimum voltage. The
RTC also contains a small amount of RAM that is used by the system software to
determine whether there has been a loss of backup battery power.
BUS Subsystem
The BUS has the capacity to provide for a 24 bit address and 8 bit data path. The
microprocessor uses the BUS subsystem to transfer data or instructions to seven different
functions. These functions are:
• PROM • LCD Command and Data Register
• Motor Drive • Watchdog
• Keypad • Switches
• Real Time Clock (RTC)
07-19-A8-092 Ipump Pain Management System Service Manual 2-3
2 - Theory of Operation
Keypad & Sensors
The Keypad is comprised of nine keys which enable the user to turn the pump Off and On,
enter the prescription data, and START and STOP an infusion. In addition to monitoring
each of these keys, the microprocessor also checks the status of ancillary inputs consisting
of internal switches, sensors, and connectors. Refer to Table 2-1 and Table 2-2 for a
description of the Keypad keys and ancillary inputs.
Key Description
The START key begins the operation of the pump and can also be configured to act as
a PCA button. If all of the required programming values have been entered, the START
key initiates the infusion from any programming screen.
Following the resolution of most alerts or alarms, pressing the START key resumes the
infusion if the condition no longer exists.
The STOP key must be pressed twice within 1 second to stop the operation of the
pump. After the pump is stopped, you can press the ON/OFF key to turn the pump off.
The ENTER key sets the value displayed on the Liquid Crystal Display (LCD) screen.
The ON/OFF key powers up and powers down the pump. If the pump is on, you can
press the key:
• once to deactivate the programmed settings, which can be retrieved.
• twice to power off the pump.
The CLEAR/SILENCE key either clears the data shown on the LCD screen or silences
an alert or alarm signal generated by the pump.
The HISTORY key displays the infusion history on the LCD screen. Pressing this key
again allows you to scroll through the history screens.
The left and right arrow keys move the cursor on the display screen to
the left and right.
The scroll (up arrow) key displays the next available option on the pump’s screen.
Table 2-1. Keypad Keys
2-4 Ipump Pain Management System Service Manual 07-19-A8-092
Feature Primary Function
Patient Controlled Analgesia (PCA) connector. The PCA cable connects
PCA Jack
to the pump via a phono jack and plug style connection which is
monitored by the microprocessor to determine the status of the PCA
button.
2 - Theory of Operation
Printer Jack
Bag Cover Lock
Tubing Sensor
Upstream
Occlusion Sensor
Downstream
Occlusion Sensor
Air Sensor
The printer jack allows the connection of the Baxter Printer Adapter
(p/n 2L3400), and a printer (typically a Seiko DPU-414).
An internal sensor detects when the bag cover is locked or unlocked
when the pump is configured with either security method “key + code” or
“key only.”
An internal sensor that detects when the pump tubing cover is open or
closed with the administration set properly installed.
An internal sensor that detects when an upstream occlusion occurs.
An internal sensor that detects when a downstream occlusion occurs.
An internal sensor that detects when there is air in the tubing segment
inside the pump.
Table 2-2. Ancillary Inputs
PROM
The PROM subsystem supplies data to the bus when addressed by the microprocessor to
identify the operation requested. An EEPROM is also provided in the microprocessor and
PROM subsystem to retain configuration information.
Supervisory Subsystem (SS)
The supervisory subsystem performs a major role in the start-up and shutdown of the
pump. It also monitors and responds to error situations reported by the hardware and
software. A “wellness 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 Real Time Clock (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 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.
Power Subsystem (PS)
The power subsystem provides the required DC power for the pump from either a 9-volt
battery or an optional AC Adapter. The AC Adapter is an external device, which will
provide 10 volts DC when plugged into an AC wall outlet. The AC Adapter is connected
to the pump at its AC Adapter input jack. When power is available from both the battery
07-19-A8-092 Ipump Pain Management System Service Manual 2-5
2 - Theory of Operation
and an AC Adapter, the PS selects the AC Adapter by default to conserve battery life. The
PS automatically switches the LCD backlight on 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 peristaltic
pump. The partially regulated voltage is used to power the buzzer and the LCD's backlight
circuit. The partially regulated supply is monitored for low voltage to shut down the
pump. 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.
LCD Subsystem
The liquid crystal display (LCD) subsystem serves as a module for the microprocessor to
communicate infusion programming information and pump status to the user and facilitate
the entry of data from the keypad. The LCD module 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 module can be written to by the microprocessor which supplies it with either
data or commands. Information in the LCD's memory is read by the microprocessor. For
its functional operation, the LCD module has two memories; the character generator (CG)
RAM and the display data (DD) RAM. The pump hardware has no need to distinguish
between the two types of RAM. This is accomplished by the operating software in the
microprocessor through the commands sent to the LCD module.
The backlight circuit provides power to the light emitting diodes (LEDs) inside the LCD
module to generate the necessary light for reading the display. These LEDs consume a
significant amount of power. Therefoere, when the pump is powered only by the 9-volt
battery, the display is only lit when needed. 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 pump on battery power, the backlight will be on. Fifteen
seconds after programming is complete, the backlight will turn off. The backlight will turn
on again when any 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.
Silent Shutdown Circuit
When both the AC Adapter and 9-volt battery have been accidentally or intentionally
disconnected, the pump will notify the operator by issuing an intermittent “chirping”
sound. The power supply provides a residual voltage which maintains power to the
speaker circuit. Once this voltage has been depleted, the chirping will fade away (no less
than 20 seconds).
2-6 Ipump Pain Management System Service Manual 07-19-A8-092
2 - Theory of Operation
Motor Subsystem
The motor subsystem has the ability to drive the DC motor in a forward or reverse
direction. The pump drive is controlled by the Direction and Drive Motor Module
(DDMM) which receives inputs from two independent shaft position encoders. The
encoder information enables precise control over the motor and therefore the fluid
delivery rate.
T o drive the motor , the microprocessor provides motor drive information using one of two
carrier frequencies. The DDMM uses a frequency discriminator to interrogate the carrier
signal and set the polarity of the voltage to the motor. Once direction is established, the
motor is controlled by the motor drive information directly from the microprocessor.
Occlusion Detection Circuit
A check is made for the possibility of blockage (occlusion) during the delivery
downstream and upstream of the pump. (NOTE: Unless the upstream occlusion alarm is
disabled in the pump’ s configuration.) During downstream occlusion, the elastic section of
the tubing set (in the area where the fingers of the peristaltic pump operate) will expand
slightly if a blockage exists. The expansion causes the deflection of a very sensitive sensor
thereby enabling the pump to sense an occlusion. During upstream occlusion, the elastic
section of the tubing set will contract slightly if a blockage exists upstream thereby
changing the deflection of a second sensor, and allowing the pump to sense the occlusion.
If the motor is operating in the reverse direction, as during the startup upstream occlusion
test, an upstream blockage will cause a slight expansion of the tubing which allows the
pump to sense the occlusion.
Air Sensor Circuit
An ultrasonic sensor is embedded in the plastic housing of the tubing door where the
tubing set is placed. When an air bubble passes through the tubing, the pump will sense
the different properties of fluid versus air and will issue an alarm when a certain amount of
air passes through that section of tubing.
Printer Adapter Interface Circuit
The interface to the printer adapter en ables 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-414). The printer interface is a serial port that operates on
TTL levels and provides data at a 600 baud rate.
A label is normally used to cover the PRINTER/COMM connector at the front of the
pump. This label should only be removed when the printer adapter is connected to the
pump. A second label positioned nearby indicates that this connector is sensitive to
Electrostatic Discharge (ESD).
07-19-A8-092 Ipump Pain Management System Service Manual 2-7
2 - Theory of Operation
2-8 Ipump Pain Management System Service Manual 07-19-A8-092
In this section Page
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Cleaning and Disinfecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Overview
The Ipump device is designed to provide reliable service with only minor routine
maintenance. A periodic functional inspection of the pump should be performed at least
every six months to assure proper operation. The procedures in Chapter 5, “Functional
T ests”, must be used to ensure that the pump operates properly . A review of the Alarm Log
should also be performed to identify system errors encountered by the pump. Refer to
Chapter 4, “Troubleshooting”, for details on reviewing the Alarm Log.
Baxter recommends performing preventive maintenance on an annual basis and cleaning
after every use. For convenience, the pump can be configured to give the operator an alert
whenever maintenance is due. Refer to the Ipump System Configuration Manual for
details.
3 - Care & Routine Maintenance
Cleaning and Disinfecting
The exterior surfaces of the pump may be cleaned with a cloth, sparingly dampened with
any of the cleaners listed in the table below. Follow the manufacturer's instructions for
diluting concentrated cleaners. After use, pumps should be cleaned/disinfected with an
agent from the list below before being used on another patient. Spills and dirt should be
cleaned off the pump as quickly as possible.
Recommended Cleaner Manufacturer Cleaner Disinfectant
Soapy water N/A XXX
A solution of 10% bleach and water N/A XXX XXX
LpH STERIS Corporation XXX XXX
Septisol STERIS Corporation XXX XXX
Super-Edisonite Colgate-Palmolive Co. XXX
TOR or Hi-TOR
Plus
CAUTION
Table 3-1. Approved Cleaners and Disinfectants
The Ipump device and the AC Adapter are not waterproof and should
not be immersed. Avoid getting liquids inside the pump or permanent
damage may result. Do not use alcohol for cleaning. Sterilization via
ETO, steam, etc. should not be attempted.
Huntington Professional Products XXX XXX
07-19-A8-092 Ipump Pain Management System Service Manual 3-1
3 - Care & Routine Maintenance
3-2 Ipump Pain Management System Service Manual 07-19-A8-092
4 - Troubleshooting
In this section Page
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Reviewing the Alarm Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
System Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Range 10 - 2V -- Peripheral/Sensor Errors. . . . . . . . . . . . . . . . . . . . . . . 4-5
Range 30 - 47 -- Motor Control Errors. . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Range 50 - 52 -- RTC Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Range 60 - 62 -- Power Supply Errors . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Range 70 - 74 & L0 -- MPU Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Range 75 - 8D -- Processing Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Range 90 - 9Z & M0 - P3 -- Data Corruption Errors . . . . . . . . . . . . . . . 4-8
Range A0 - J1 -- Processing Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Overview
CAUTION
CAUTION
Pumps under warranty must be returned to the factory for repair. Unauthorized
disassembly/repair will void your warranty. When a pump malfunctions, perform the
following to see if pump operation can be restored. Ensure that the:
• batteries are installed and not depleted.
• batteries are installed correctly (proper polarity).
If this does not restore the pump operation, refer to the Troubleshooting Chart, Table 4-1.
! WARNING !
Only trained, qualified personnel and Baxter authorized service
representatives should perform procedures in this manual.
Contact Baxter Healthcare Corporation to arrange any needed
service support or if you have any questions while servicing the
pump.
The pump must only be serviced by a trained biomedical
engineering technician or Baxter Healthcare personnel.
Reviewing the Alarm Log
Troubleshooting an Ipump device should begin with a review of the alarm log. This
section describes the steps involved for performing this review. For system errors
identified in the alarm log review, refer to the System Error Codes Tables in this chapter to
help determine the component or assembly that may be contributing to the failure.
07-19-A8-092 Ipump Pain Management System Service Manual 4-1
4 - Troubleshooting
1. Unlock the Bag Cover and press the <ON/OFF> key to turn the pump on. The Bag
Cover must be open.
2. If the language option is “None,” the display will read “PRESS ENTER FOR
ENGLISH.” The display will cycle through the choices. Press the <ENTER> key
while the ENGLISH choice is being displayed.
3. If a language has been previously configured, the display will be blank and will automatically continue to the next step.
4. When the display reads “SOFTWARE VERSION XX.XX.XX,” hold down the left
arrow key until “TESTING MEMORY” is displayed. “TESTING MEMORY” will
only be displayed momentarily followed by “CONFIGURATION XXXXX.”
5. The display will then read “000 ENTER CONFIG CODE.” Using the left, right and up
arrow keys, input the code 2-1-5 and press the <ENTER> key.
6. Upon entry to the Configuration Set mode, the display will read “CONFIGURATION
PRESS ENTER.” DO NOT PRESS THE ENTER KEY AT THIS TIME.
7. Press the <HISTORY> key .
8. The display will read “ALARM LOG.”
9. Press the right cursor key to display the first system alarm entry. Each system alarm
log entry will be displayed as follows:
SYSTEM ERROR XX
MM/DD/YY HH:MMXM
10. Record all alarms and their associated dates and times.
11. Continue to press the right cursor key to display the next system alarm log entry. The
display will eventually read “END OF ALARM LOG.”
NOTE: If the Alarm Log is empty, the display will read “END OF ALARM LOG.”
12. At the “END OF ALARM LOG” display, press the <ENTER> key. The pump will
then display “CONFIGURATION PRESS ENTER.” To clear the System Alarm Log,
proceed to the next step. T o reta in the System Alarm Log, press the <ON/OFF> key to
turn the pump off.
13. Press the <CLEAR/SILENCE> key. The display will read “RESET CONFIG?”
14. Choose NO and press the <ENTER> key. The display will read “CLEAR HISTORY?” (if there is a history).
15. Choose NO and press the <ENTER> key. The display will read “CLEAR ALARM
LOG?”
16. Choose YES and press the <ENTER> key. The pump will clear the System Alarm
Log and the display will momentarily read “ALARM LOG CLEARED.”
17. When the display reads “CONFIGURATION PRESS ENTER,” press the <ON/OFF>
key to turn the pump off.
4-2 Ipump Pain Management System Service Manual 07-19-A8-092
Troubleshooting
The information in this chapter is written for repair to the board or module level. Except
for those items listed, circuit board components are not available from Baxter Healthcare.
Refer to Chapter 6 for disassembly procedures and Chapter 9 for repair parts information.
Symptom Possible Cause Solution
No power (9V)
No power (AC)
(No AC Plug icon)
Constant audible alarm –
no display when battery
or AC Adapter plugged in
No audio alarm Defective Buzzer. Replace the Buzzer.
Constant occlusion alarm
No air alarm or constant
Constant alarm, no LCD
display when ON/OFF
key pressed
Dead/Contaminated 9-volt Battery. Check/replace the 9-volt Battery.
Broken battery leads. Replace the Battery Contact Assembly.
Battery installed with wrong polarity. Remove and re-install the 9-volt Battery.
Defective MPU Board.
Poor AC Adapter connection to pump.
Defective AC Adapter.
Defective AC Connector on the Front
Case.
Defective or disconnected AC Power
Connector inside pump.
Defective MPU Board.
Defective MPU Board. Replace the MPU Board.
Defective MPU Board. Replace the MPU Board.
Damaged/disconnected wiring to Flex
Cable.
Defective occlusion sensors. Replace the Mechanism Assembly.
Defective/damaged Flex Cable or
connector on Mechanism Assembly.
Dirty or jammed Occlusion Sensors.
Defective/damaged J14 connector on
MPU Board.
Defective MPU Board. Replace the MPU Board.
Defective Air Sensor. Replace the Mechanism Assembly.
Air Sensor Disabled. Check the pump configuration.
Bent or broken pin on LCD Module. Replace the LCD Module.
Defective LCD Module. Replace the LCD Module.
Defective MPU Board. Replace the MPU Board.
Check for 9-volt line at J10 connector. If it is
present, replace the MPU Board. If not,
replace the battery contact assembly.
Ensure that the red dots are aligned and
the connector is plugged in fully.
Check the output of the AC Adapter for
10 VDC. Replace the AC Adapter.
Replace the Front Case Assembly.
Check for proper installation of the AC
power connector onto the MPU Board at
J4. Replace the front case assembly.
Check for 10 volts at connector J4. If
present, replace the MPU Board. If not,
replace the Front Case Assembly.
Check wiring to the Flex Cable and resolder
as necessary.
Replace the Mechanism Assembly.
Clean the Occlusion Sensors on the
Mechanism Assembly or replace the
assembly.
Replace the MPU Board.
Table 4-1. Troubleshooting Chart
4 - Troubleshooting
07-19-A8-092 Ipump Pain Management System Service Manual 4-3
4 - Troubleshooting
Symptom Possible Cause Solution
LCD not working or
segments missing
No backlighting
“Check Tubing
Placement” screen will
not clear
“Cover Is Unlocked”
alarm will not clear
No input from front panel
keypad
Will not retain memory Low or dead 3V Backup Battery.
Will not accept attempts/
injections from PCA
switch
Will not print
System Error 32 Loose Motor Connector. Tighten the Motor Connector J2 on DDMM.
System Error 33
Defective LCD Module. Replace the LCD Module.
Defective MPU Board. Replace the MPU Board.
Poor connection between J23 and the
LCD Module.
Defective LCD Module. Replace the LCD Module.
Defective MPU Board. Replace the MPU Board.
Tubing segment improperly installed
or not installed.
Dirty or disconnected Flex Cable
Connector to J14 on MPU.
Defective Microswitch.
Defective/damaged Flex Cable. Replace the Mechanism Assembly.
Defective MPU Board. Replace the MPU Board.
Defective Reed Switch on Rear Case. Replace the Rear Case Assembly.
Disconnected Reed Switch.
Missing Magnet (Bag Cover Latch). Repair/replace the Bag Cover.
Defective Lock Assembly. Repair/replace the Bag Cover.
Defective MPU Board. Replace the MPU Board.
Defective Keypad.
Disconnected Keypad Connector. Connect the Keypad Connector.
Bad contact between Keypad Flex
and MPU Board.
Defective MPU Board. Replace the MPU Board.
Defective PCA Cable. Replace the PCA Cable.
Defective PCA Connector on MPU
Board.
Defective MPU Board. Replace the MPU Board.
Defective Printer Connector on MPU
Board.
Defective Motor. Replace the Mechanism Assembly.
Defective/damaged Mechanism
Assembly.
Check to ensure the backlight connector is
properly installed (pins 15 & 16 of J23).
Ensure the tubing set is installed properly.
Refer to the operator’s manual for proper
installation.
Clean and tighten the Flex Cable
Connector.
With a tubing segment properly installed,
check continuity between pins 13 and 14
of the mechanism flex circuit connector
(refer to connector pin-out in Figure 8-3).
If the circuit remains “open,” replace the
Mechanism Assembly.
Connect the Reed Switch Connector to the
MPU Board.
With power removed, check the Keypad for
continuity while pressing the suspected key
(refer to the Keypad pin-out in Figure 8-2).
Check the connector pins and clean/repair
as needed.
Replace the 3V Backup Battery. (Refer to
the 3V Backup Battery Test in Chapter 6.)
Replace the MPU Board.
Check for bent Printer Connector pins.
Replace the Printer Connector if necessary.
Replace the Mechanism Assembly.
Table 4-1. Troubleshooting Chart (Continued)
4-4 Ipump Pain Management System Service Manual 07-19-A8-092
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