Cardinal IVAC-597-598 Service Manual

IVAC® Volumetric Pump

Models 597 & 598

Technical Service Manual

This manual has been prepared for use by qualified service personnel only.

Cardinal Health, Alaris® Products cannot accept any liability for any breakdown or

deterioration in performance of parts or equipment resulting from unauthorised repair or

modification.

t Cardinal Health, 1180 Rolle, Switzerland

IVAC® is a registered trademark of

Cardinal Health, Inc. or one of its subsidiaries

All other trademarks belong to their respective owners.

IVAC® Volumetric Pump (Models 597 & 598) 2/76 1000SM00016 Issue 3

Contents

Chapter 1 Introduction & Start Up 4

Chapter 2 Routine Maintenance & Calibration 12

Chapter 3 Troubleshooting 31

Chapter 4 Circuit Descriptions 37

Chapter 5 Spare Parts Replacement Procedures 41

Appendix A Specifications 57

Appendix B Spare Parts Listing 63

Appendix C Fitting & Replacement Guidelines 69

Appendix D Service Contacts 71

Appendix E Disposal 73

Appendix F Document History 75

Introduction & Start Up

In this chapter

Chapter 1

Introduction 5

General Precautions 6

Views of the IVAC® 597/598 Volumetric Pump 7

Controls and Indicators 8

Flow Sensor 8

Loading the IV Infusion Set 9

Starting the Pump 9

Programming 9

Secondary Infusion (Model 597) 10

Introduction & Start Up

Introduction

The IVAC® Volumetric Pump - Models 597 & 598 automatically regulates the infusion rate of IV solutions using a linear peristaltic, volume displacement mechanism to regulate fluid flow at the prescribed rate. The pump can be operated with a Flow Sensor and is lightweight, compact and robust enough for most patient situations.

The IVAC® 598 Volumetric Pump operates in primary infusion mode only.

The IVAC® 597 Volumetric Pump has a primary and secondary infusion feature.

Product Familiarity

Ensure that you are fully familiar with the pump by carefully studying the Directions for Use (DFU) prior to operation and prior to attempting any repairs or servicing. As part of continuous improvement, product enhancements and changes are introduced from time to time.

Purpose of this Manual

This Technical Service Manual describes how to set up, test and maintain the following volumetric pumps: IVAC® 597 Volumetric Pump IVAC® 598 Volumetric Pump

This manual is intended for use by personnel experienced in medical equipment testing and maintenance procedures .

Conventions Used in this Manual

BOLD

'Single quotes' Used to indicate cross-references made to another section of this manual. For example, see

underline Used to indicate a link to another section within this manual.

Italics

Used for Display names, self-test codes, controls and indicators referenced in this manual, for example, VTBI indicator, test code 08, ON/OFF switch.

Chapter 2, 'Configuration and Calibration'.

Used to refer to other documents or manuals. For example, refer to the relevant Directions for Use

(DFU)

for further information. Also used for emphasis, for example, ...if the gap still measures less

than...

Wherever this symbol is shown a Hints & Tips note is found. These notes provide useful advice or information that may help to perform the task more effectively.

Wherever this symbol is shown a Toolbox note is found. These notes highlight an aspect of test or maintenance that is important to know about. A typical example is drawing attention to a software upgrade that you should check has been installed.

IVAC® Volumetric Pump (Models 597 & 598) 5/76 1000SM00016 Issue 3

General Precautions

Prior to using this pump, carefully read the Operating Precautions described in the Directions for Use

(DFU)

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 anaesthetics. Exercise care to locate the pump away from any such hazardous sources.

Dangerous Voltage. An electrical shock hazard exists if the casing of the pump 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 be fail safe if extremely high levels of interference are encountered. Should false alarm conditions 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 qualified service personnel.

Introduction & Start Up



When connected to an external power source, a three-wire (Live, Neutral, Earth) supply must be used. If the integrity of the external protective conductor in the installation or its arrangement is in doubt, the pump should be operated from the battery.

IVAC® Volumetric Pump (Models 597 & 598) 6/76 1000SM00016 Issue 3

Introduction & Start Up

VOL TO BE INF

READ VOL

CLEAR VOL

VOL

RATEKVO

VTBI

ON / OFF

RUN/ HOLD

ml/hr

Model 598

Volumetric Pump

VOL TO BE INF

READ VOL

CLEAR VOL

PRI

SECKVO

VTBI

ON / OFF

RUN/ HOLD

PRI / SEC

ml/hr

Views of the IVAC® Volumetric Pump (Models 597 & 598)

Front View

Main Display

Display Indicators

Door

Keyboard

(Model 598)

CAM Follower Assembly

Keyboard

(Model 597)

AC power

Indicator

Rear View

Pole Clamp

CAM Follower Assembly Latch

Air-In-Line Sensor

PE Connector (not on XAX* model pumps)

Primary/ Secondary Infusion Switch

Test Connector Cover

AC Power Connector

Flow Sensor Connector (on FSO** pumps)

* XAX refers to pumps with Serial numbers that include XAX, for example, 597XAX01AA.

** Flow Sensor Option.

IVAC® Volumetric Pump (Models 597 & 598) 7/76 1000SM00016 Issue 3

Fuse Holders

Introduction & Start Up

Controls and Indicators

The English keyboard controls and indicators are described below. For information on keyboards in other languages, refer to the relevant DFU. See also Appendix B, 'Spare Parts Listing' for keyboard part numbers.

PRI / SEC

CLEAR VOLUME

READ VOLUME

VOLUME TO BE INFUSED (VTBI)

RUN/HOLD

PRIMARY/ SECONDARY

Resets volume infused value to zero.

Displays volume infused value.

Sets value of Volume To Be Infused.

Starts and stops pump infusions. Silences/cancels alarms.

(Model 597 only). Switches the pump between PRIMARY and SECONDARY infusion modes.

Double chevrons/single chevrons for faster/slower increase or decrease of infusion rate

CHEVRONS

ON/OFF

When any of the following are illuminated:

AC POWER INDICATOR - The pump is connected to an AC power supply and the battery is being charged.

and volume values.

Adjusts user selectable options (in self-test mode).

Switches the pump on and off.

VTBI

KVO

VOL

RATE

PRI

SEC

ml/hr

The value displayed is the Volume To Be Infused.

The pump is infusing at the Keep Vein Open (KVO) rate of 5ml/h (or current rate, whichever is less).

The value displayed is the volume infused.

The value displayed is the current infusion rate.

(Model 597 only). The pump is operating in PRIMARY mode.

(Model 597 only). The pump is operating in SECONDARY mode.

(Millilitres) The value displayed is the VTBI or volume infused value.

(Millilitres / hour) The value displayed is the infusion rate.

Infusion indicator. Three horizontal bars in the left-hand display position flash sequentially when the pump is infusing.

Infusion indicator with Flow Sensor in use. Upper two horizontal bars convert to a square when a drop is detected by the flow sensor in the drip chamber.

Flashing

Display

When the pump is operating on battery power, the Display flashes on/off.

Flow Sensor

A flow sensor is used to detect an empty fluid container. It is connected to the drip chamber and when a drop is detected in the drip chamber the infusion indicator in the top left position of the Display converts to a square character (). See above.

Notes:

1) Use part number 192.

2) A flow sensor can only be used on Flow Sensor Option (FSO) pumps.

IVAC® Volumetric Pump (Models 597 & 598) 8/76 1000SM00016 Issue 3

Introduction & Start Up

Loading the IV Infusion Set

 Follow the Directions for Use supplied with the individual IV infusion set  Only use IV infusion sets that are suitable for use with the IVAC® Volumetric Pumps (Models 597 & 598)

recommended by Cardinal Health

1. Prime the IV infusion set slowly and close the roller clamp.

2. Open the door.

3. Load the primed IV infusion set (see Figure 1):

 Open the latch

 Load the upper tubing segment into the top set retainer

 Insert lower tubing segment into the Air-In-Line Sensor

 Close the latch, ensuring the set is enclosed

4. Close the door.

5. Open the roller clamp.

6. Connect to test equipment as required.

Ensure no fluid flows.

Top set retainer

Primed IV

Infusion Set

Latch (shown open)

Starting the Pump

Without Flow Sensor

1. Load the primed set.

2. Press the

3. Use the chevron switches (I,

ON/OFF switch to power on the pump.

J, L and K) to set

the rate.

4. Press

5. Use the chevron switches (I,

RUN/HOLD to confirm.

J, L and K) to set

VTBI.

6. Clear Volume Infused if required.

7. Press

RUN/HOLD to start infusion.

Programming

Lower Tubing Segment

With Flow Sensor

1. Load the primed set.

2. Connect the flow sensor to the drip chamber.

3. Press the

4. Use the chevron switches (I, the rate.

5. Press

6. Use the chevron switches (I, VTBI.

7. Clear Volume Infused if required.

8. Press

Air-In-Line Sensor

Figure 1. Loading the Set

ON/OFF switch to power on the pump.

J, L and K) to set

VOL TO BE INF if required.

J, L and K) to set

RUN/HOLD to start infusion.

Changing the infusion rate

1. Press the RUN/HOLD switch to place the pump on hold.

2. Adjust rate by using the chevron switches.

3. Restart the pump by pressing the

Clearing total volume infused

RUN/HOLD keys.

1. Press the RUN/HOLD switch to place the pump on hold.

2. Press and hold

CLEAR VOL for 2 seconds, until display

shows 0000.

Changing the Volume To Be Infused

1. Press the RUN/HOLD switch to place the pump on hold.

2. Press the

VOL TO BE INF switch.

3. Set new volume by pressing the chevron switches.

OFF can also be selected when a flow sensor is in

use, see Notes below.

4. Restart the pump by pressing the

RUN/HOLD switch.

Notes:

1) Without a flow sensor in use, a VTBI value

must be

entered, otherwise, the pump displays VTBI when the pump is restarted.

2) With a flow sensor in use, a VTBI value isn't required and

OFF can be selected if required.

IVAC® Volumetric Pump (Models 597 & 598) 9/76 1000SM00016 Issue 3

Introduction & Start Up

Secondary Infusion (Model 597)

Introduction

This mode of operation supports automatic secondary infusions ("piggybacking") in the same pump channel. When the secondary VTBI reaches zero the pump will then automatically switch to the previously set primary rate. Secondary mode can be used where a second, independent VTBI is required, and also when an automatic rate change is required.

When the pump is programmed and delivering in the secondary mode, the primary infusion is temporarily stopped and fluid is drawn from the secondary container. Delivery from the primary container resumes when the fluid level in the secondary line is level with the fluid in the primary container.

Note: The primary fluid container must hang lower than the secondary fluid container to allow the secondary infusion to run. Primary infusion will restart on completion of the secondary infusion.

Starting the Pump with Secondary Infusion

1. Load the primed set. See 'Loading the IV Infusion Set' on the previous page for instructions.

2. Prepare the secondary infusion using a secondary solution container and the IVAC® "59" Series check valve primary set; lower the primary container. See Figure 2.

 Prime the secondary IV infusion set in accordance with the set

Directions for Use

 Attach secondary IV infusion set to the upper Y-site of the primary IV

infusion set

 Fully open the regulating clamp on the secondary IV infusion set.

3. Press the PRIMARY mode.

4. Use the chevron switches to set the primary rate.

5. Press

6. Set primary VTBI if required.

7. Press and hold the and high tone and switch to SECONDARY mode.

8. Use the chevron switches to set the secondary rate.

9. Press the

10. Set secondary VTBI by using the chevron switches.

11. Press

ON/OFF switch to power on the pump. Pump always starts up in

VOL TO BE INF if required.

PRI/SEC switch for one second. Pump will sound low

VOL TO BE INF switch.

RUN/HOLD to start secondary infusion.

Primary container

Regulating

Y-Site

clamp

Back Check valve

Line to patient

Figure 2.

Secondary Infusion Preparation

Secondary container

WARNING:

 Secondary infusion applications using a check valve set must have a VTBI setting equal to the

volume in the secondary container; this will require consideration of such variables as factory overfill, medication additions, etc.

 Underestimating the volume will cause remaining secondary solution to be infused at the primary

rate; overestimating will result in primary solution being infused at the secondary rate.

When using a flow sensor it must be on the primary IV infusion set. Correct placement of a flow sensor is essential for proper operation.

IVAC® Volumetric Pump (Models 597 & 598) 10/76 1000SM00016 Issue 3

Introduction & Start Up

Secondary Infusion (Model 597) continued

Viewing secondary settings when pump is running in primary mode

Display secondary infusion rate - press and hold the PRI/SEC

switch. SEC indicator flashes and secondary infusion rate is displayed as long as the switch is held.

Display secondary volume to be infused - press the PRI/SEC

and VOL TO BE INF switches together. SEC indicator flashes and secondary volume to be infused is displayed while switches are held.

Display secondary volume infused - press the PRI/SEC and READ VOL switches together. SEC indicator flashes and

secondary volume infused is displayed while switches are held.

Entering secondary mode when pump is running in primary mode

Press the

RUN/HOLD switch to set pump on hold. Press and

hold the PRI/SEC switch for one second. Pump will sound low and high tone and go into SECONDARY mode. SEC and

ml/hr indicators light.

Viewing primary settings when pump is running in secondary mode

Display the primary infusion rate - press and hold the PRI/ SEC

switch. PRI indicator flashes and primary infusion rate

is displayed while switch is held.

Display the primary volume to be infused - press the PRI/ SEC

and VOL TO BE INF switches together. PRI indicator flashes and primary volume to be infused is displayed while switches are held.

Display the primary infused volume - press the PRI/SEC and READ VOL switches together. PRI indicator flashes and

primary infused volume is displayed while switches are held.

Exiting secondary mode before dose is complete

Press the

RUN/HOLD switch to set pump on hold. Press

and hold the PRI/SEC switch for one second; pump sounds low and high tone and goes into PRIMARY mode. OR, press the ON/OFF switch and close secondary set roller clamp.

IVAC® Volumetric Pump (Models 597 & 598) 11/76 1000SM00016 Issue 3

Routine Maintenance &

Calibration

In this chapter

Chapter 2

Routine Maintenance 13

Self-Test Mode 13

Test Codes 14

Test Connector 20

Upgrading Software 20

Cam Follower Gap Check 21

Functionality Checks 22

Occlusion Verification Test 23

Rate Accuracy Verification Test (Code 13) 23

Physical Inspection and Clean 24

Calibration Procedures 26

Performance Verification Procedure 30

Routine Maintenance & Calibration

Routine Maintenance

For routine maintenance, the following tests and Performance Verification Procedures (PVP) should be performed in addition to the tasks described in the section 'Physical Inspection and Clean'.

Refer to the relevant

DFU for the recommended routine maintenance period.

Self-Test Mode

Self-test mode is used to access a number of test routines which are designed to test and verify many of the pump functions, defaults and calibrations without requiring internal inspection. Configuration settings are also enabled or disabled via self-test mode.

Each test can be run in a single pass or in a continuous loop mode. See 'Test Execution' below for further details. Some tests require a test jumper (part number 134646), see 'Test Connector' for further details.

Test Pass/Fail

The PRI & SEC (Model 597) or RATE & VOL (Model 598) indicator lights on the front panel of the pump are used to signal whether the pump passes or fails a test as follows:

If the yellow PRI (Model 597) or VOL (Model 598) indicator light comes on, the pump has passed the test in progress. If the red SEC (Model 597) or RATE (Model 598) indicator light comes on, the pump has failed the test in progress.

Most test procedures display data, such as numeric codes to indicate a test failure reason. See 'Test Procedure' table for further details.

Entering Self-Test Mode

 Press the CLEAR VOL and ON/OFF switches simultaneously until the display turns on. The pump then performs power-

on self-tests. Initially, the current software revision level is displayed, followed by the battery voltage.

 When the battery voltage is displayed, press the RUN/HOLD switch to display t=00 which means the pump is ready to

start test 00.

Note: To bypass the display of the software revision level and the battery voltage and advance directly to t=00, hold

the CLEAR VOL switch until the power-on display test completes.

 Use the chevron switches (I, J, L and K) to select the test code required.

 To exit self-test mode, turn the pump off.

Test Execution

Single Pass Mode

After selecting the test number (see 'Entering Self-Test Mode' above), press the RUN/HOLD switch to start the test for one pass. The display changes to show the test number for example, t=13. If there is data to display, it can be viewed after the test by pressing the READ VOL switch.

Continuous Loop Mode

Certain tests can be run in a continuous loop mode (see tables below). After selecting the test number, press the RUN/

HOLD

switch twice within one second to enter the test loop. The display will change as in the single pass mode then the

test will be repeated continuously until the RUN/HOLD switch is pressed again.

To display the test data while the test continues, press the

To exit the loop, press the

Exiting Self-Test Mode

RUN/HOLD switch.

Self-mode can be exited at any time turning off the pump.

READ VOL switch.

IVAC® Volumetric Pump (Models 597 & 598) 13/76 1000SM00016 Issue 3

Test Codes

Summary

Routine Maintenance & Calibration

Code Test Name

00 Self-Test (01 to 08)

01 Speaker and Speaker Drive Circuit Test

02 Motor and Drive Circuitry Test

03 Pressure Sensor Test

04 Air-in-line Test

05 Safety Switch and Driving Circuitry Test

06 Front Panel LED Test

07 External RAM Test

08 Tach/Volume Flag Test

09 Drop Discriminator Circuitry, Simulated Drop Test

Code Test Name

19 EEPROM Test

20 Rate Calibration Number Read

21 Total Pump Life "On" Time Read/Clear

22 Total Battery "On" Time Read/Clear

23 Error/Alarm Stack Read/Clear

Pressure Calibration Read/Set

See 'Pressure Calibration' section for details of test.

25 Language Code Read/Set

26 CRIS Configuration

27 Air Bubble Length Read

28 FLO Alarm Threshold Read

10 Drop Detector LED Drive Current Test

11 Door Sensor Test

12 Dried Spillage Alarm Parameters Read

Rate Accuracy Test

See 'Rate Accuracy Verification Test' section for details of test.

14 Switch Test

15 Burn-In Test

16 Battery Voltage Test

17 Seven-Segment Display Test

Factory Use Only

Door Calibration Read/Set

See 'Door Calibration' section for details of test.

30 Auxiliary Front Panel Display Enable/Disable

31 Secondary Mode Setting On/Off

Production/Quick Configuration Test

Factory Use Only. Test not available.

33 Pump Identification Number Read/Set

34 Hospital or Alternate Site Configuration Set

35 Secondary Mode Enable/Disable (Model 597 only)

36 Flow Sensor Optional/Mandatory

IVAC® Volumetric Pump (Models 597 & 598) 14/76 1000SM00016 Issue 3

Routine Maintenance & Calibration

Test Codes (continued)

Test Procedures

Code Test Action/Data Displayed Loop

The pump cycles through tests 01 through 08 sequentially, displaying the test

00 Self-Test (01 to 08)

Speaker and Speaker

Drive Circuit Test

Motor and Drive

Circuitry Test

03 Pressure Sensor Test

04 Air-in-line Test

Safety Switch and

Driving Circuitry Test

06 Front Panel LED Test

07 External RAM Test

08 Tach/Volume Flag Test

Drop Discriminator

Circuitry, Simulated Drop Test

number in progress, in the format t0.01 through t0.08. If a test fails, the red SEC (or RATE) indicator lights, the current test stops and the test number is displayed. Press the RUN/HOLD switch once to continue to the next test (or twice to exit the test).

Test fail codes: 1=speaker senses as not turning on 2=speaker senses as not turning off

Test fail codes: 1=motor would not turn on (or shorted coil) 2=motor would not turn off

Data displayed: D/A trim level is displayed at end of test. Test fail codes: 1 = amplifier output stuck high 2 = amplifier output stuck low 3 = amplifier cannot attain 4.6 volts 4 = amplifier cannot go below 0.2 volts 5 = bridge will not trim (D/A bits bad) 6 = trim/amplifier gain > 4.4 7 = trim/amplifier gain < 3.6

To run the test:

 Load an air or fluid-filled IV infusion set.  Press the READ VOL switch to display the output code.

Test fail codes: 0 = fluid detected in IV infusion set 1 = air detected in IV infusion set 2 = output stuck high 3 = test line could not force air indication

Test fail codes: 1 = safety logic line would not go low 2 = safety logic line would not turn off 3 = safety switch would not turn on 4 = safety switch would not turn off 5 = both safety switch and motor drive stuck on

All front panel LEDs are lit until the

RUN/HOLD switch is pressed.

Inspect LEDs. Note that the AC charge LED only lights on AC power. Test fail: display shows the first address failed, hexadecimal. Note that the highest

address is tested first. Data displayed: tt.vv where tt equals the last two digits of the number of tach flags,

and vv equals the number of volume flags. Normal display is 20.28, and the tt may vary by +/- one count. This test is designed to assist in aligning the encoder disk optics and is intended to be used in the loop mode. When running test, if there is excessive noise, loosen retaining screws as required and adjust the cam follower assembly as far as possible towards the bottom of the pump. Tighten retaining screws then turn the pump off.

Note: The flow sensor must be connected to the pump. Data displayed: output voltage in A/D counts. Ideal value is 205 counts = 4.00 volts Test fail codes: 1 = no drop detected 2 = value too high, max = 4.257 V, 218 counts 3 = value too low, min = 3.750 V 192 counts 4 = simulated drop detected as multiple drops 5 = simulated drop detected as long or small drop

Loop

only

Ye s

IVAC® Volumetric Pump (Models 597 & 598) 15/76 1000SM00016 Issue 3

Routine Maintenance & Calibration

Test Codes (continued)

Test Procedures (continued)

Code Test Action/Data Displayed Loop

Drop Detector LED

Drive Current Test

11 Door Sensor Test

Dried Spillage Alarm

Parameters Read

13 Rate Accuracy Test See 'Rate Accuracy Verification Test' section for details of test. -

Note: The flow sensor must be connected to the pump. Data displayed: LED current, in mA Test fails if the current exceeds 126 mA or falls below 2 mA.

OPEN = door sensed as open CLOS = door sensed as closed

READ VOL switch to display the A/D value.

Press See 'Door Calibration' for instructions on how to read and set door calibration value.

See 'Read Parameter/Values' table on the next page. -

Press each switch and check the corresponding code is displayed:

Ye s

I 0 E 5

J 1 C 6

14 Switch Test

K 2

B 7

L 3 F 8 (hidden switch on Model 598)

D 4 Note: the ON/OFF switch does not have a code.

To exit this test, press both the RUN/HOLD switch and PRI/SEC (hidden switch on Model 598) switch simultaneously, or turn the pump off.

All front panel LEDs light continuously (except for run indicator which behaves as if in normal mode). Pump runs at 125 ml/h, all FLO, OCCL, and Air alarms are ignored.

15 Burn-In Test

16 Battery Voltage Test Data displayed: battery voltage, in volts. Test passes with value above 5.7 volts . Yes

Seven-Segment

Display Test

Data displayed: All detected errors. Door alarm is also active. Note: It is not possible to run this test if any errors have been detected since entering self-test mode.

Test fail codes (LED segment assembly number): 0 = far left, 1 = 2nd from left, 3 = 2nd from right, 4 = far right

18 Factory Use Only Factory Use Only -

19 EEPROM Test Data displayed: number of first registration to fail. No

Read Parameters/Values

Code Test Action/Data Displayed Loop

Read parameters by pressing the RUN/HOLD switch four times:

Dried Spillage

Alarm Parameters Read

13 through 19 See 'Test Procedures' table on the previous page. -

Rate Calibration

Number Read

IVAC® Volumetric Pump (Models 597 & 598) 16/76 1000SM00016 Issue 3

1st press displays the dried spillage scan start volume flag number. 2nd press displays the scan stop volume flag number. 3rd press displays the alarm threshold value. 4th press exits the test.

Read the factory-set calibration number. If the Cam Follower Assembly is replaced and the number is not "0033" change as follows:

 Use the chevron switches until the display reads "0033"  Press the RUN/HOLD switch and verify "Cal Done" is displayed

Routine Maintenance & Calibration

Test Codes (continued)

Read Parameters/Values (continued)

Code Test Action/Data Displayed Loop

Read the total pump "on" time, displayed in 10-hour increments. For example, 0037 =

Total Pump Life

"On" Time Read/ Clear

Total Battery "On"

Time Read/Clear

Error/Alarm Stack

Read and Clear

Pressure Calibration

Read/Set Language Code

Read/Set

370 hours. To clear the total pump "on" time:

 Install a test jumper. See 'Test Connector' for instructions.  Press the CLEAR VOL and PRI/SEC (hidden switch on Model 598) switches until the

display shows 0000. Read the total total time the pump has been running on battery power, displayed in

10-hour increments. For example. 0048 = 480 hours. To clear the total battery "on" time:

 Install a test jumper. See 'Test Connector' for instructions.  Press the CLEAR VOL and PRI/SEC (hidden switch on Model 598) switches until the

display shows 0000. Read the last 16 error or alarm codes.

The most recent alarm or error is always displayed first. Pressing the K switch displays the previous error/alarm and cycles through the error or alarm codes. ---denotes the end of the alarm stack. Notes:

1) All error and alarm messages will be displayed in English regardless of the Language Code setting (Test 25).

2) The stack of alarms/error codes will be lost if the battery is removed and the information will be unreliable until filled with new alarm messages or cleared. To clear the alarm stack:

 Install a test jumper. See 'Test Connector' for instructions.  Press the CLEAR VOL and PRI/SEC (hidden switch on Model 598) switches until the

display reads ----.

See 'Pressure Calibration' section for details of test. -

See 'Configuration Settings' table on the next page. -

26 CRIS Configuration See 'Configuration Settings' table on the next page. -

Air Bubble Length

Read

Read the air-in-line alarm threshold value, displayed in microlitres. This value is the nominal air bubble alarm threshold in microlitres used for air-in-line detection and is originally set at the factory.

Read the FLO alarm threshold value in psi. This value is the upstream occlusion alarm threshold pressure in psi and is originally set at the factory.

When upgrading software from V9.xx to V10.05, the flow alarm threshold setting must be changed from 008 to 006. To do this:

FLO Alarm

Threshold Read

 Install a test jumper. See 'Test Connector' for instructions.

 Change the display to 006 by pressing the chevrons switches.  Press the RUN/HOLD switch. The pump should beep then display CAL

DONE followed by t=28.

 Turn the pump off/on.

IVAC® Volumetric Pump (Models 597 & 598) 17/76 1000SM00016 Issue 3

Routine Maintenance & Calibration

Test Codes (continued)

Configuration Settings

Code Setting Action Loop

Read and/or set how error and alarm messages are displayed.

Language Code

Read/Set

26 CRIS Configuration

27 Air Bubble Length Read See 'Read Parameter/Values' table on the previous page. -

FLO Alarm Threshold

Read Door Calibration Read/

Set

Auxiliary Front Panel

Display Enable/Disable

Secondary Mode Setting

On/Off

Pump Identification

Number Read/Set

E = English text, for example door, Err6. C = Codes or International, for example, P1, E1. For non-English language users. To change the setting, press the PRI/SEC (hidden switch on Model 598) switch and any chevron switch simultaneously for two seconds.

Setting not in use. CRIS=CRIS enabled, OFF=CRIS disabled. Ensure the setting is OFF.

See 'Read Parameter/Values' table on the previous page. -

See 'Door Calibration' section for details of test. -

Enable or disable Auxiliary Front Panel Display feature, used to display calibration data. on.05 = feature enabled, where 05 equals the number of times remaining that the pump can be powered on/off with Auxiliary Front Panel Display enabled (five maximum). OFF = feature disabled. To enable the feature:

 Press the PRI/SEC (hidden switch on Model 598) switch and any chevron switch

simultaneously for two seconds. The display will read on.05.

 Turn the pump off then on. The pump is now in normal operating mode with

this feature enabled. To disable the feature:

 Enter test 30 and press the CLEAR VOL switch. The display will show OFF.

Alternatively, turn the pump off/on five times. Warning: Ensure that this feature is OFF before returning the pump into service.

Enable or disable the Secondary Mode setting (code 35). SC.On = Secondary mode setting enabled (Model 597 only) SC.OF = Secondary mode setting disabled (Model 598) Defaults to Model 598, the setting must be changed to

SC.On when the EPROM is first installed. If an EPROM is installed on a

SC.OF (secondary off).

To change the setting:

 Install a test jumper. See 'Test Connector' for instructions.  Load a set segment into the cam follower assembly.  Press the PRI/SEC (hidden switch on Model 598) switch and any chevron switch

simultaneously for two seconds. Read and/or set the pump identification number (ID).

To set a new ID, use the chevron switches to select a desired value, then hold

PRI/SEC switch and press the RUN/HOLD switch to exit the test. Press RUN/

the

HOLD

again to display and verify the new pump ID.

IVAC® Volumetric Pump (Models 597 & 598) 18/76 1000SM00016 Issue 3

Routine Maintenance & Calibration

Test Codes (continued)

Configuration Settings (continued)

Code Setting Action Loop

HOSP = Hospital Configuration ASC = Alternate Site Configuration See Note below. To change the setting:

 Press the PRI/SEC switch and any chevron switch for 2 seconds to toggle the

Hospital or Alternate Site Configuration Set

Note: This setting is unavailable on pumps with software version

10.03 or below.

Secondary Mode Enable/Disable (Model 597 only)

Note: This setting is unavailable on pumps with software version

10.03 or below.

Flow Sensor Optional/Mandatory (FSO pumps only

selection. The new configuration choice is displayed.

 Turn off the pump to exit the test and set the new configuration in memory.

Note: when set to ASC, note the following:

1) These test codes are not available, and cannot be changed: 25-Language Code set to E=English 26-CRIS setting is OFF=Disabled 30-Auxiliary Front Panel Display feature is OFF=Disabled 31-Secondary Mode Setting is SC.OF = Disabled

2) While the pump is running, the AIL alarm value is 500 microlitres. See test 27.

3) Any previous HOSP configuration values are stored while set to ASC. HOSP values are restored when the HOSP setting is selected again.

Read and/or enable or disable Secondary Mode on the Model 597 pump. SC.ON = Secondary mode enabled SC.OF = Secondary mode disabled When software is first installed, this setting may not be enabled when pump is powered on. Ensure the setting is enabled. To change the setting:

 Load a set segment into the cam follower assembly.  Enter self-test mode and select test code 35.  Press the RUN/HOLD switch to enter the test. Press the PRI/SEC switch and any

chevron switch simultaneously to toggle the selection and select the mode.

 Press the RUN/HOLD switch, then turn the pump off.

Note: This setting must be enabled via test code 31. Set Flow Sensor usage to optional or mandatory.

FS.OP = Use of a flow sensor is optional when running an infusion FS.On = A flow sensor is mandatory (must be fitted) in order to run an infusion To change the setting:

 Install a test jumper. See 'Test Connector' for instructions.  Press the PRI/SEC switch (the hidden switch on the Model 598) and any

chevron switch simultaneously for two seconds.

 Release the switches when the required setting is displayed.

* On non-FSO pumps, when replacing the Logic PCB (139046-

100), ensure this setting is changed to FS.OP (flow sensor optional).

IVAC® Volumetric Pump (Models 597 & 598) 19/76 1000SM00016 Issue 3

Routine Maintenance & Calibration

Test Connector

In order to perform certain tests and to change any pump settings, a test jumper or a low value resistor of 1K5Ω or less, connecting test connector pin 9 to pin 23 must be installed.

Procedure:

1. With the pump off, remove the test connector cover from the back of the rear case.

2. Using a test jumper (part number 134646), a wire, or a low-value resistor (1k5Ω or less), connect pin 9 to pin 23 on the external test connector. See Figure 2-1 below. Take care not to short any pins adjacent to pin 9 or 23 as this may result in a blown fuse.

Pin 2

Figure 2-1 External Test Connector (J3)

3. Place the pump in self-test mode then select and carry out the test(s) as required.

4. When the test is complete, remove the test jumper from the test connector.

5. Refit the test connector cover.

Pin 1

Pin 9

Pin 23

Upgrading Software

 Upgrade of Model 597/598 (FSO) volumetric pump software to V1.10 or greater is recommended

when serviced

 Upgrade of Model 597/598 (non-FSO) volumetric pump software to V10.03 or greater is

recommended when serviced. See 'Notes (non-FSO pumps)' below.

Perform upgrades by acquiring the software upgrade kits specified in spare parts listings.

Equipment required: Software upgrade kit (includes EPROM fitting and removal instructions)

Software Upgrade Kits Available

Pump Model Part Number Software Version

597/598 (FSO) 143053 1.10

597/598 (non-FSO) 136814 10.05

Notes (non-FSO pumps):

1) The latest non-FSO software available is V10.05.

2) When upgrading software from V9.xx to V10.05, the flow alarm threshold setting must be changed from 008 to 006. See test 28.

3) V10.05 software includes test

4) When replacing the Logic PCB (part number 139046-100) on a non-FSO pump, the latest software is fitted on the PCB. Ensure that test

36 is set to FS.OP (flow sensor optional).

35 Seconday Mode Enable/Disable (Model 597).

IVAC® Volumetric Pump (Models 597 & 598) 20/76 1000SM00016 Issue 3

Routine Maintenance & Calibration

Cam Follower Gap Check

Equipment required:

 0.160" pin gauge (part number 305601), 0.160" block gauge or calibrated calipers

 Indelible marker

Procedure:

1. Open the orange cam follower assembly latch.

2. Position the topmost follower closer to the pressure pad than the other followers. To do this:

Enter self-test mode and select test

the RUN/HOLD switch twice within one second to enter the test in loop mode, then press RUN/HOLD switch again to exit the loop. Repeat this step until the topmost follower is positioned closest to the pressure pad.

3. Using the pin gauge, check the gap between the pressure pad and the end of the followers (while it is still positioned closest to the pad). See Figure 2-2 below.

4. If the gap measures less than 0.160", check that the Cam Housing Assembly and the Cam Follower Assembly are correctly seated.

5. If the gap

 replace the Cam Follower Assembly

 OR, replace the Cam Housing Assembly

 OR, replace the Front Case

still measures less than 0.160":

08 (alternatively, select test 02). See 'Entering Self-Test Mode' for instructions. Press

0.160" minimum

Top Follower

Pressure Pad

Orange Cam Follower Assembly Latch

Figure 2-2 Follower/Pressure Pad Gap

IMPORTANT: Failure to maintain the appropriate gap width may result in a set being incorrectly loaded into the pump. If this situation arises, there is a risk that an undetected over-infusion may occur. Refer to MHRA Hazard Notice 2002 (09) for more information.

IVAC® Volumetric Pump (Models 597 & 598) 21/76 1000SM00016 Issue 3

Functionality Checks

Alarms

Alarm Action

Open the door at least ¼ inch. Verify that the pump stops running, an alarm sounds, and the

Door (P1)

FLO (P2)

Hold (P3)

Air (P5)

Reload ---- Air (P5)

Reload (P6)

OCCL (P7)

KVO

display shows door (P1). Close the door. Press the RUN/HOLD switch momentarily to verify that the alarm stops and the display alternates between the set rate and hold (P3)

Set rate to 200 ml/h. Press the RUN/HOLD switch. Verify that the pump starts. Close the set regulating clamp and verify that a FLO (P2) alarm occurs within approximately 15 seconds. Open the set regulating clamp. Note: If you are not using a flow sensor and the pump fails to alarm, perform the 'Pressure Calibration' procedure.

Press the RUN/HOLD switch. Verify that the pump starts. Press the RUN/HOLD switch to put pump on hold. Verify audible bleep and hold (P3) alarm displayed after two minutes.

Load an air-filled IV infusion set (no fluid) into the pump. Press the ON/OFF switch to turn the pump on. Set the rate and the VTBI. Press the RUN/HOLD switch to start the pump. Verify that the pump alarms and displays Air (P5).

With pump displaying Air (P5)—see above—press RUN/HOLD to put pump on hold, then press the RUN/HOLD switch again and verify that the pump alarms and displays Reload ---- Air (P5) alternating with Air (P5).

Start pump without an IV infusion set loaded. Verify that the pump alarms and displays Reload (P6).

Set rate to 200 ml/h. Press the RUN/HOLD switch. Verify that the pump starts. Occlude the set at approximately 2.5 cm from the exit of the pump. Verify an OCCL (P7) alarm occurs within approximately 15 seconds. If the pump fails to alarm, perform the 'Pressure Calibration' procedure. Important: Run the 'Occlusion Verification Test' to verify that the pump occludes between 5.5 and 11 psi (nominal 6 to 8 psi). See below for instructions.

Set rate to 200 ml/h. Press switches. Press RUN/HOLD switch to start pump. Verify that a KVO alarm occurs within approximately 18 seconds.

Routine Maintenance & Calibration

RUN/HOLD or VTBI. Set VTBI to 0001 ml by pressing the chevron

Verify Volume Infused and Rate Retention

1. Press the READ VOL switch and note the infused volume.

2. Press the seconds, then press the the pump on.

3. Verify the infused volume and the rate displayed are the same as before.

ON/OFF switch to turn pump off. Wait 15

ON/OFF switch again to turn

Battery Power Check

1. Remove power cord from the AC power socket.

2. Press the bleep.

3. Verify that the pump operates and the display flashes on and off. Verify that the moving horizontal bars in the left-hand display position are sequencing as before.

4. Plug the power cord back in to AC power socket.

RUN/HOLD switch and verify an audible

Flow Sensor Check

See 'Physical Inspection and Clean' for instructions.

IVAC® Volumetric Pump (Models 597 & 598) 22/76 1000SM00016 Issue 3

Routine Maintenance & Calibration

Occlusion Verification Test

Equipment Set Up:

 Set up equipment as per ' Pressure Calibration Equipment Set Up', with the pressure gauge connected and three-way

stopcock closed.

Procedure:

1. Set rate to 200 ml/h.

2. Press the

RUN/HOLD switch. Verify that the pump starts.

3. Verify that an OCCL (P7) alarm between 5.5 and 11 psi (nominal 6 to 8 psi).

If the pump fails to alarm, perform the 'Pressure Calibration' procedure.

Rate Accuracy Verification Test (Code 13)

Equipment Set Up:

 Set up the pump as shown in Figure 2-3 below.

 Close the set roller clamp.

 Plug the pump into AC mains.

Burette

Water Source

Ensure flow sensor is removed.

30 2 inches (76 ± 5 cm)

Burette Clamp

Equipment Stand

Middle of Follower Assembly/Door Latch

Table

Tubing

Three-way Stopcock

or Bench

IV Tubing

Used Fluid

Figure 2-3 Rate Accuracy Verification

Receptacle

Test Equipment Set Up

Procedure:

1. Using a Class A burette, adjust the fluid level so that the meniscus is level with the zero mark.

2. Enter self-test mode and select test

13. See 'Entering Self-Test Mode' for instructions.

3. Press the RUN/HOLD switch; the default rate of 300 ml/h will be displayed.

4. Press the

RUN/HOLD switch; the default test time of 300 seconds (5 minutes) will be displayed.

5. Press the RUN/HOLD switch to start the test. The display will show the test time remaining in seconds. A click will sound as each second is decremented.

6. When the display reaches zero seconds, the display shows

STOP to indicate the end of the test. The PRI indicator will

also be lit.

7. Press the

RUN/HOLD switch to display the volume infused and verify that the infused volume in the burette is 25 ±1.25

ml.

Due to variations between IV infusion sets, the reading may not fall within the stated parameters. If this occurs, retest

using another IV infusion set. If the variance still exceeds ±5% after retesting with another IV infusion set, replace the Cam Follower Assembly.

Note: During the test run, operational alarms can be cleared by pressing the

RUN/HOLD switch. The test must be rerun.

Error alarms are cleared by turning the pump off and back on. The test must be rerun.

IVAC® Volumetric Pump (Models 597 & 598) 23/76 1000SM00016 Issue 3

+ 53 hidden pages

Cardinal IVAC-597-598 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual