Smiths 3100 User manual

Graseby 3100

Syringe Pump

Technical Service

Manual

Part Number 00SM-0131-7

August 2004

© 2004 Smiths Medical International Ltd.

Smiths Medical International Ltd.

Published by Smiths Medical International Limited.

All possible care has been taken in the preparation of this publication, but Smiths Medical Interna­tional Limited accepts no liability for any inaccuracies that may be found.

Smiths Medical International Limited reserves the right to make changes without notice both to this
publication and to the product which it describes.

© Smiths Medical International Limited 2004

No part of this publication may be reproduced, transmitted, transcribed, or stored in a retrieval
system or translated into any human or computer language in any form by any means without the
prior permission of Smiths Medical International Limited.

SMITHS MEDICAL INTERNATIONAL LTD.,
COLONIAL WAY,
WATFORD,
HERTFORDSHIRE,
UNITED KINGDOM,
WD24 4LG

Address

TEL: (+44) (0)1923 246434
FAX: (+44) (0)1923 231595
WEB: www.smiths-medical.com

REGISTERED IN ENGLAND.
COMPANY No. 362847.

Trademarks and acknowledgements
Graseby and Smiths are registered trademarks of Smiths Group plc.

All other trademarks are acknowledged as the property of their respective owners.

3100 Service Manual

Issue 7 (August 2004)

Page i

Issue Record

Smiths Medical International Ltd.

ISSUE RECORD

Issue No. Reason for change Pages affected Date

1

2

3

4 Reformatted revision All April 3 1995

4.1 Amendment to three pages iii, 6-4 and 8-1 Nov. 24 1995

4.2 Amendment to seven pages Cover, iii, vii, March 1996

4-8, 5-6, 7-8, 7-9

5.0 Reissue of entire Manual All Dec. 1999

6.0 Reissue of entire Manual All July 2000

6.1 Amendment to two pages ii and 5-11 August 2000

7.0 Reissue of entire manual All August 2004

Page ii

Issue 7 (August 2004)

3100 Service Manual

Smiths Medical International Ltd.

Contents

CHAPTER 1 Page

INTRODUCTION, FEATURES and SPECIFICATION

Introduction .......................................................................................................... 1-1

Security cover ...................................................................................................... 1-2

Features .............................................................................................................. 1-2

Specification ........................................................................................................ 1-3

Brief history of Graseby bedside syringe pumps .................................................. 1-4

CHAPTER 2

CONFIGURATION MODE, DIAGNOSTICS MODE and OCCLUSION MEASUREMENT

Configuration mode ............................................................................................ 2-1

Calling up the Configuration mode .............................................................. 2-1

Syringe brand selection.............................................................................. 2-1

Language setting ....................................................................................... 2-2

Setting the AC voltage ......................................................................................... 2-2

Disassembly and assembly of casing ........................................................2-2

AC voltage and fuse adjustment ................................................................ 2-3

Contents

Diagnostic mode .................................................................................................. 2-3

Keying in the diagnostic mode ................................................................... 2-4

Occlusion measurements .................................................................................... 2-4

Thrust measurements ................................................................................ 2-4

Syringe stiction .......................................................................................... 2-4

Thrust checks ............................................................................................ 2-5

Thrust adjustments .................................................................................... 2-6

CHAPTER 3

FUNCTIONAL DESCRIPTIONS

Functional descriptions ....................................................................................... 3-1

Drive system ...................................................................................................... 3-1

Occlusion sensing system ................................................................................... 3-2

Clutch assembly and opto sensor .............................................................. 3-2

Occlusion detection ................................................................................... 3-2

Electro/mech. control system............................................................................... 3-2

Sensing (alarm) systems .................................................................................... 3-3

Syringe nearly empty ................................................................................. 3.3

End of infusion/occlusion ........................................................................... 3-3

AC power failure ........................................................................................ 3-3

Battery voltage low .................................................................................... 3-3

Self tests/pump malfunction ...................................................................... 3-3

Drive disengaged/syringe not fitted ............................................................ 3-3

Syringe size sensors ................................................................................. 3-3

Software ............................................................................................................. 3-4

3100 Service Manual

Issue 7 (August 2004)

Page iii

Contents

Smiths Medical International Ltd.

CHAPTER 4

Page

CIRCUIT DESCRIPTIONS

Circuit descriptions ............................................................................................... 4-1

Main board circuit ................................................................................................. 4-1

Processor core circuit ................................................................................. 4-2

Motor interface circuit ................................................................................. 4-2

Power control circuit.................................................................................... 4-2

Sensors interface circuit ............................................................................. 4-2

Communications processor circuit .............................................................. 4-3

Regulator board circuit .......................................................................................... 4-3

Plug PL11 outputs ...................................................................................... 4-4

Setting RV1 ................................................................................................ 4-4

Syringe size sensors ............................................................................................ 4-5

Opto sensors ........................................................................................................ 4-5

CHAPTER 5

FAULT CODES, MAINTENANCE and REPAIR PROCEDURES

Fault codes ........................................................................................................... 5-1

Faults code, 0 to 92 .................................................................................... 5-1

Faults code, 100 to 112 .............................................................................. 5-2

Maintenance ......................................................................................................... 5-3

Cleaning ..................................................................................................... 5-3

Fuse renewal .............................................................................................. 5-3

Repair procedures ................................................................................................ 5-3

Main board renewal .................................................................................... 5-4

Regulator board renewal ............................................................................ 5-4

Opto sensors board renewal ...................................................................... 5-5

AC transformer renewal .............................................................................. 5-5

Plunger clamp and half nut assembly renewal............................................ 5-6

Pole clamp assembly renewal .................................................................... 5-6

Leadscrew assembly renewal..................................................................... 5-7

Motor and gearbox assembly renewal ........................................................ 5-8

Occlusion clutch and disc assembly renewal.............................................. 5-8

Membrane switch panel renewal ................................................................ 5-9

Super nut renewal .................................................................................... 5-10

Syringe size sensors board renewal ......................................................... 5-10

Plunger clamp repair ................................................................................. 5-11

Batteries. Checks and replacement........................................................... 5-11

Front and/or rear case repair ..................................................................... 5-11

Page iv

Issue 7 (August 2004)

3100 Service Manual

Smiths Medical International Ltd.

CHAPTER 6

FUNCTIONAL TESTS

Functional tests .................................................................................................... 6-1

Plunger clamp alarm checks ................................................................................ 6-4

Ramp check procedures ............................................................................. 6-4

Linear accuracy .................................................................................................... 6-5

Test procedures .......................................................................................... 6-5

Plunger clamp alignment ...................................................................................... 6-5

Test procedures .......................................................................................... 6-5

CHAPTER 7

ILLUSTRATED PARTS LIST

General assembly ................................................................................................ 7-1

Plunger clamp assemblies .................................................................................... 7-6

Pole clamp assembly ........................................................................................... 7-7

Rotating pole clamp assembly .............................................................................. 7-8

Leadscrew assembly ............................................................................................ 7-9

Main board assembly ......................................................................................... 7-10

Regulator board assembly .................................................................................. 7-11

Contents

Page

CHAPTER 8

BRAUN PERFUSOR CONVERSION

Syringe conversion procedures ............................................................................ 8-1

Reselecting ‘various’ syringe brands .................................................................... 8-2

APPENDIX

Fitment of New Modified Size Sensor Flag .......................................................... A-1

Nearly empty flag .......................................................................................8-1

Spacer tube fitment .................................................................................... 8-1

Plunger clamp plate ................................................................................... 8-1

Braun Perfusor selection ............................................................................ 8-1

‘P’ label fitment .......................................................................................... 8-1

Mechanical procedures .............................................................................. 8-2

Programming procedures ..........................................................................8-2

Introduction ............................................................................................... A-2

Fitment of modified SSF ........................................................................... A-2

Final testing .............................................................................................. A-3

Setting the size sensor flag ....................................................................... A-4

3100 Service Manual

Issue 7 (August 2004)

Page v

Figures and Tables

Smiths Medical International Ltd.

LIST OF FIGURES

Figure Page

1.1 General views of the 3100 pump ................................................................................ 1-1

2.1 Rear case screw fixing order ...................................................................................... 2-3

2.2 Thrust measuring set up ............................................................................................ 2-5

4.1 Overall block diagram ................................................................................................ 4-7

4.2 Main board block diagram .......................................................................................... 4-9

4.3 Processor core circuit diagram ................................................................................. 4-10

4.4 Motor interface circuit diagram ................................................................................. 4-11

4.5 Power control circuit diagram ................................................................................... 4-12

4.6 Sensors interface circuit diagram ............................................................................. 4-13

4.7 Communications processor circuit diagram .............................................................. 4-14

4.8 Regulator board circuit diagram ................................................................................ 4-15

4.9 Syringe size sensors circuit ..................................................................................... 4-17

4.10 Opto sensors circuit ................................................................................................. 4-17

4.11 Membrane switch panel circuit ................................................................................. 4-18

5.1 Half nut (obsolete)/ Super nut ................................................................................... 5-10

5.2 Strengthened rear case moulding ............................................................................. 5-11

6.1 Outline of dual ramp gauge ........................................................................................ 6-4

6.2 Size sensor flags ....................................................................................................... 6-4

6.3 Linear accuracy gauge ............................................................................................... 6-5

6.4 Taper gauge ............................................................................................................... 6-5

7.1 General assembly ...................................................................................................... 7-3

7.2 Plunger clamp assemblies ......................................................................................... 7-6

7.3a Pole clamp assembly ................................................................................................. 7-7

7.3b Rotating pole clamp assembly ................................................................................... 7-8

7.4 Leadscrew assembly ................................................................................................. 7-9

7.5 Main board assembly diagram ................................................................................. 7-11

7.6 Regulator board assembly ........................................................................................ 7-12

8.1 Braun Perfusor conversion: parts required .................................................................. 8-2

A.1 New modified Syringe Size Sensor flag...................................................................... A-1

A.2 Case fixing screw tightening order.............................................................................. A-3

A.3 Size Sensor Flag: general details ............................................................................... A-5

LIST OF TABLES

Table Page

4.1 Plug PL11 outputs ..................................................................................................... 4-4

4.1 Temperature/voltage range for setting RV1 ................................................................. 4-5

5.1 Main processor faults code ........................................................................................ 5-1

5.2 Slave processor faults code ....................................................................................... 5-2

5.3 Front case spares kit ............................................................................................... 5-12

5.4 Size Sensor Flag spares kit ..................................................................................... 5-12

5.5 Rear case spares kit ................................................................................................ 5-13

6.1 Functional testing of 3100 .......................................................................................... 6-1

A-1 3100 syringe size sensor gauge ................................................................................. A-5

Page vi

Issue 7 (August 2004)

3100 Service Manual

Smiths Medical International Ltd.

Warnings and cautions

Introduction

This Technical Service Manual for the 3100 together with the Instruction Manual for the pump, contains all the informa­tion that is needed in order to operate, maintain and repair the pump. The contents of this Technical Service Manual
is primarily intended to be read and used by suitably qualified personnel. Only qualified personnel should repair

and maintain the pump.

AC input power connecting socket/cable

The AC input power socket that connects to the rear of the pump has three connections (live, neutral and earth)
provided by a 3-way power cable. As the casing is doubly insulated, the AC input connector situated on the pump
only utilises two connections (live and neutral), there is no third earth pin. This method of AC input enables similar
AC input sockets (if required) to that supplied by Smiths Medical International to be used.

Warnings and cautions

Warnings tell you about dangerous conditions that could lead to death or serious injury to the user or patient that can
occur if you do not obey all of the instructions in this manual.

WARNINGS

1. WARNING: To avoid over- or under- infusion, always verify that the brand and size of the loaded syringe are the
same as the brand and size displayed on the screen before starting an infusion. Failure to do so may result in
an inaccurate delivery of medication, resulting in patient injury or death.

2. WARNING: To avoid incorrect or inappropriate configuration of the pump, the Configuration menu must only be
selected by qualified persons or authorised personnel. Incorrect pump configuration could lead to inappropriate
infusion resulting in patient injury or death.

3. WARNING: This equipment is not suitable for use in the presence of flammable anaesthetics, oxygen-enriched
or explosive atmospheres. The use of the device in such atmospheres may lead to explosion or fire.

not

4. WARNING: To avoid possible malfunction of the pump, do
ionizing radiation, or to the RF interference or strong electric/magnetic fields emitted (for example) by
diathermy equipment or mobile telephones. If the pump is used in the presence of, or in combination with
Magnetic Resonance Imaging (MRI) machines it must be protected from the magnetic field emitted by such
equipment. Malfunction of the pump can cause incorrect infusion or loss of infusion resulting in patient injury or
death.

5. WARNING: Operation of the pump outside the temperature limits defined in the specification may result in
erroneous operation. Ensure that the temperature is within the specified limits. Failure to do so may result in
patient injury or user injury.

6. WARNING: In order to ensure that the intended infusion is performed, data must be entered correctly. Likewise
before confirming any displayed data the user should ensure that it is correct. Failure to do so may result in
compromised function of the product, patient injury or user injury.

7. WARNING: Failure to respond promptly to an alarm may result in patient injury or death.

8. WARNING: Failure to follow the
compromised function of the product and lead to patient injury or death.

9. WARNING: It is essential that clinical staff remain within visual and audible range of the pump so that critical
alarms can be seen or heard and responded to.

10. WARNING: The user should ensure that the performance offered by the pump is fit for the intended purpose.
Failure to do so may result in compromised function of the product, patient injury or user injury.

11. WARNING: When the pump is carrying out an infusion, to ensure that electrical safety is maintained only items
of equipment that conform to EN60950 are to be connected to the RS232 connector situated at the base of the
pump, otherwise patient safety may be compromised.

12. WARNING: Correct management of battery charging is essential to ensure that the pump can operate on
batteries for the time specified. Failure to do so may lead to impaired functioning of the pump, resulting in
patient injury or death.

not

13. WARNING: Do
indicate a FAULT condition and the pump will fail to infuse. Incorrect performance of the pump can cause
complications resulting in patient injury or death.

If the pump develops a fault then it must be referred to a suitably qualified engineer or returned to Smiths
Medical in order to have the fault rectified.

14. WARNING: Failure to use the mains lead clamp means that the pump may be accidentally or erroneously
disconnected from the mains. Although there is battery backup in case this happens, the battery may not be
sufficiently charged. Consequently there is a risk of the pump not functioning, which could lead to patient injury
or death.

use a faulty pump. If the pump develops a fault then an alarm will sound; the display will

Service Manual’s

maintenance schedule recommendations may result in

expose the pump to X- rays, gamma rays or

3100 Service Manual

Issue 7 (August 2004)

Page vii

Warnings and cautions

15. WARNING: If an occlusion alarm occurs, immediately clamp the line to eliminate the possibility of a bolus being
delivered to the patient. Then inspect the fluid pathway for kinks, clogged catheter, etc. in order to remove the
occlusion prior to restarting the infusion. An unintentional bolus of medication can result in patient injury or
death.

16. WARNING: Use only the syringes and administration sets listed in the
Failure to do so may result in an inaccurate delivery. Smiths Medical does not guarantee performance of the
pump if syringes other than those listed are used. Incorrect function or performance of the pump can cause
complications resulting in patient injury or death.

17. WARNING: The volume of fluid contained in the connecting tubing is a residual amount and will
Hence this extra volume of fluid must be allowed for when initially filling the syringe and purging the system.
Under-delivery of medication can cause complications resulting in patient injury or death.

18. WARNING: To avoid patient embolism, ensure that the patient tubing is purged of all air bubbles before
administering any medication. The pump provides a purge facility to assist with this process. The presence of
air within the medication can result in complications leading to patient injury or death.

19. WARNING: To avoid syphoning of the syringe contents (free flow), ensure that the syringe is correctly loaded
into the pump, that the syringe plunger is properly engaged by the pump’s actuator and that the pump is placed
not more than 80cm above the infusion site. Syphoning can result in over-infusion leading to patient injury or
death.

20. WARNING: To avoid over-infusion, do not purge the infusion line when the administration set is connected to the
patient. Over-infusion of medication can result in patient injury or death.

21. WARNING: To avoid the pump becoming detached from an IV pole always make sure that the pump is securely
fixed to the pole. Always check the security and stability of the assembly with the pump mounted.

22. WARNING: Following a significant liquid spill onto the pump, it should be wiped dry and inspected by service
personnel before being returned to service. Failure to do so may result in compromised functioning of the pump,
leading to patient or user injury or death.

23. WARNING: When using a syringe smaller than 50/60 ml the occlusion pressure will increase as the diameter of
the syringe decreases, i.e. the smaller the syringe the higher the pressure.

24. WARNING: The patient history is lost when the clock is reset.

25. WARNING: Only adequately qualified personnel should maintain and repair the pump.

26. WARNING: The pump must be disconnected from the AC power supply before the case is opened.

27. WARNING: The Configuration and Diagnostic mode must only be used by personnel who are adequately
qualified and have previous training in the use of the pump.

28. WARNING: The safety and reliability of the pump may be compromised by the use of parts other than those
specified in this Manual.

29. WARNING: When a new Syringe Size Sensor Flag has been fitted to the pump (see Appendix), then the pump must
be tested using the new syringe size sensor gauges available from Smiths Medical (part number 0131-0202). Page
3 of the Appendix gives details of the Final Testing procedures.

30. WARNING: The pump must be set to display the brand and the size of syringe that is going to be used. Using a
different brand or size of syringe to that being displayed could lead to the incorrect amount of drug being
administered, that could result in injury or death.

31. WARNING: The internal pump batteries must be disposed of in accordance with the manufacturers instructions.
Lead acid batteries must NOT be placed in the normal waste stream.

Smiths Medical International Ltd.

Specification

(Chapter 1).

not

be infused.

Page viii

Issue 7 (August 2004)

3100 Service Manual

Smiths Medical International Ltd.

Warnings and cautions

CAUTIONS

Cautions tell you about dangerous conditions that can occur and cause damage to the pump if you do not obey
all of the instructions in this manual.

1. CAUTION: Refer all service, repair and calibrations only to qualified technical personnel. Unauthorised
modifications to the pump must

2. CAUTION: When turning the pump on if screens similar to those illustrated are not displayed, do
pump. Send the pump to a suitably qualified engineer or return it to Smiths Medical in order to have the fault
rectified.

3. CAUTION: Do not use cleaning and disinfecting agents other than the approved ones specified here.

4. CAUTION: The pump must
spills immediately, and do not allow fluid or residues to remain on the pump. Additionally, the pump is not
designed to be autoclaved, steam-sterilised, ETO-sterilised or subjected to temperatures in excess of 45° C
(113° F). Failure to observe this caution may cause serious damage to the pump.

5. CAUTION: During the removal and replacement of a pump's components, strict observance to Electro Static
Discharge (ESD) rules must be observed at all times, i.e. an earthing strap must be worn. Failure to apply ESD
protection may result in serious damage to the product and possible malfunction. Ensure that any
replacement printed circuit board or other ESD sensitive items are stored in an anti-static container.

not

be carried out.

not

be immersed in any liquids or exposed to strong organic solvents. Wipe off

not

use the

3100 Service Manual

Issue 7 (August 2004)

Page ix

Abbreviations

Smiths Medical International Ltd.

Abbreviations The following list shows the abbreviations that have been used at various places
used throughout this Manual.

Abbreviation Full name

A to D Analogue to digital
AC Alternating current
C Capacitor or Centigrade
COP Computer operating properly
cm Centimetre
cNm Centinewton meter
csk Countersunk
DC Direct current
deg. Degrees
dia. Diameter
µg Micro gramme
Fig. Figure
g Gramme
Hg Mercury symbol
Hz Hertz
IC Integrated circuit
IM Instruction manual
Kg Kilogram
Khz Kilo Hertz
KVO Keep vein open
LCD Liquid crystal display
LED Light emitting diode
mA Milliampere
mg Milligramme
ml Millilitre
mm Millimetre
No. Number
PCA Patient controlled analgesia
PCB Printed circuit board
Pl Plug
R Resistor
RAM Random access memory
ROM Read only memory
V Volts
VFD Vacuum fluorescent display

Page x

Issue 7 (August 2004)

3100 Service Manual

CHAPTER 1

INTRODUCTION, FEATURES and SPECIFICATION

Graseby 3100
Syringe Pump

Smiths Medical International Ltd.

CHAPTER 1

INTRODUCTION, FEATURES and SPECIFICATION

Introduction

Introduction

The 3100 syringe pump is microcomputer controlled and has been purpose developed for
administering sterile liquids. All the controls are clearly marked and easy to use. The
user is provided with a constant indication of the 3100’s operation; the dot matrix
Vacuum Fluorescent Display (VFD) presents the display in any one of seven major

European languages.

The 3100 is a compact robust pump that can operate from a table top or a pole clamp.

The pump can be programmed by the user to work with a range of different makes of
syringe and automatically senses the diameter of the syringe installed and hence its
volume. The syringe sizes that the pump caters for are 20 ml, 30 ml and 50/60 ml.

Figure 1.1 General view of the 3100 pump

3100 Service Manual 1 — 1 Issue 7 (August 2004)

Introduction

Smiths Medical International Ltd.

Introduction

(contd.)

The 3100 is easily configured to dispense liquids at rates between 0.1 ml/hour and 199.9
ml/hour in increments of 0.1 ml. The pump keeps a running total of the volume of
infused liquid even when the infusion has been stopped and then restarted.

The pump can be operated from AC power or from three internally fixed rechargeable
batteries. When running on battery power, the pump gives more than three hours of
continual use. The pump contains a battery recharging circuit and the batteries will be
fully charged when the pump has been connected to the AC power for up to 14 hours
(see Note below) - even when the pump is switched OFF.

Note:

The battery charging period may have to be slightly increased above 14 hours if the
pump is infusing during the charging period.

Safety features have been built into both the software and the hardware. The pump
carries out a self-testing routine each time it is switched on. The user is warned of
incidents such as a power failure or an occlusion by both visual and audible alarms.

Two micro-controllers are installed in the pump and are used to combine the following
facilities:

• non-volatile Random Access Memory (RAM),

• analogue to digital conversion,

• communications circuitry, and

• internal watchdog, COP (Computer Operating Properly).

Security cover

Features

The above facilities are usually provided by up to six separate silicon chips. The use of
highly integrated micro-controllers greatly increases the reliability of the 3100.

The motor within the pump is under the direct control of the primary micro-controller.
For added security, the primary micro-controller’s actions are monitored by the slave
processor.

An optional security cover kit is available (part number 0131-0277). The kit includes all the
items required to modify the pump, including comprehensive fitting instructions.

When fitted, the kit protects the syringe from tampering only; it provides no other security.
It does not lockout the keypad or give audible or visual alarms when opened.

The main features of the 3100 are:

• simple to use,

• ergonomic styling,

• easy to service,

• AC powered or internal battery powered,

• advanced safety features,

• caters for different brands of syringe,

• automatic syringe size sensing,

• clear text display,

• comprehensive range of alarms,

• designed in consultation with users,

• drip proof (IPX1)

• state-of-the-art electronics, and

• numerous Warnings accompanied by an audible and visual alarm, including a
three minute nearly empty syringe warning,

• all materials used in this product are latex free.

1 — 2

Issue 7 (August 2004)

3100 Service Manual

Smiths Medical International Ltd. Features

Specification

Graseby instruments are subject to continual development and may, therefore, differ
from the following specification:

Dimensions: 325 mm (long) x 195 mm (high) x 115 mm (deep), with a pole

clamp, and the plunger clamp closed.

Weight: Not exceeding 3.5 kg including batteries and pole clamp.

Supply 220 V to 240 V AC at 50/60 Hz 15 VA or,
voltage: 100 V to 120 V AC at 50/60 Hz 15 VA.

Battery type: Sealed lead acid, rechargeable (Cyclon, 3 off). The batteries should

be checked at least annually (see page 5-11).

Battery life: More than 3 hours of normal pump operation when the batteries are

fully charged. With the AC supply connected, up to 14 hours will be

required to fully recharge low voltage batteries.

Useable BD Plastipak ... Size 20; 30 or 50/60 ml.
syringes: Braun Omnifix ... Size 20; 30 or 50/60 ml.

Monoject ... Size 20, 30/35 or 50/60 ml.
Terumo ... Size 20; 30/35 or 50/60 ml.
Injectomat 50 ml ... Size 50/60 ml.
Braun Perfusor ... 50 ml (conversion kit required,

refer to Chapter 8).

Flow rate: 0.1 to 199.9 ml/hour in 0.1 ml increments.

Volume 0 to 999.9 ml in 0.1 ml increments.
infused counter:

Adjustable 250 mm Hg to 600 mm Hg.
occlusion pressure:

Temp. range: Operating conditions:

-5° to +40°C, 30 to 75% Rh, 700 to 1060 hPa.

Storage conditions:

-40° to +70°C, 30 to 90% Rh, 700 to 1060 hPa.

Drive +/– 2%.
accuracy:

Design BS 5724 Part 1.
standards: IEC 601 Part 1.

VFG 1046/I984.

Elec. safety: Class II; Type CF; Drip proof.

Language English, Dutch, French, German, Italian, Portugese and Spanish.
versions:

3100 Service Manual 1 — 3 Issue 7 (August 2004)

Specification

Brief history of Graseby bedside syringe pumps

MS2000

The first Graseby bedside syringe pump was the MS2000. This was a basic syringe pump capable of infusions
within the range of 0.1ml/hr to 99.9ml/hr. It had a totaliser, a limited infusion capability, a built in pole clamp and
was designed for vertical operation. The MS2000 was powered by an AC supply or its internal DC batteries.
This pump is no longer manufactured.

PCAS

The PCAS pump was developed from the MS2000 to satisfy the growing interest in Patient Controlled Analgesia
(PCA). The PCAS was very similar to the MS2000 in both appearance and mechanical design, but utilised a
different microprocessor with the capability of running the extra features required for PCA and was eventually
replaced by the 3300 pump. A printer port was also incorporated. This pump is no longer manufactured.

3000

The first pump in the 3000 Series of syringe pumps was the 3000 itself. This pump was designed as a low-cost
alternative to the MS2000 and satisfied the need for a horizontally mounted pump. The 3000 did not have an
internal battery supply. This pump is no longer manufactured.

3100

The 3100 syringe pump was developed from the 3000. It is very similar mechanically but the electronic design is
superior. Dual processors were incorporated along with a vacuum fluorescent text display and internal batteries.
The maximum infusion rate was increased to 199.9 ml/hr and different syringe sizes were able to be used
(automatically sensed). Extra software features, such as the intelligent ‘near end’ alarm, were also incorporated.

3300

The next bedside syringe pump to be developed was the 3300. This was similar in mechanical and electronic
design to the 3100 but the features were specifically for the now more mature PCA market. A lockable syringe
cover was added for security against drug theft, a four line LC display was added, and internal history recording
with printout was also added. With the growth in PCA knowledge in the medical community, many more software
features were incorporated into the 3300 to aid PCA administration.

3400

The 3400 was developed (again from the 3100) to satisfy the need for a high speed infusion pump for intravenous
anaesthesia. Advances in micro-controller technology allowed the use of a single device to control all the pumps
features. The maximum infusion rate was raised to 1200.0 ml/hr and bolusing facilities were also added. Later,
an infusion rate calculation facility was added to the software.

Smiths Medical International Ltd.

A larger liquid crystal display was used on the 3400 with the ability to display text in different sizes, also ‘soft­keys’ were used to make the user interface simpler. The range of syringe sizes that could be used was also
increased. For more advanced applications the pump could be controlled by a computer.

3200

The 3200 was developed as a high end general purpose syringe pump. In-line pressure sensing, intermittent
infusion capabilities and computer interfacing were added. The In-line occlusion pressure monitoring made the
pump particularly suitable for use in intensive care baby units. A large text vacuum fluorescent display was added
and the range of increased syringe sizes of the 3400 remained.

3500

There are two versions of the 3500, as detailed below:

• a Manually Controlled Infusion (MCI)

• a MCI

The 3500 was developed from the 3400 and retains all the 3400 facilities. The ‘MCI
TCI using the Diprivan drug. This version of the 3500 incorporates a Diprifusor module manufactured by Zeneca

Pharmaceuticals. A new main circuit board and new software allows the 3500 to interface with the Diprifusor
module.

3150

The 3150 is very similar to the 3200 general purpose pump. The main difference being that the In-line pressure
sensing system is not available on the 3150, i.e. the pressure transducer is not fitted.

plus

a Target Controlled Infusion (TCI) pump.

only

pump,

plus

TCI’ pump carries out a

1 — 4

Issue 7 (August 2004)

3100 Service Manual

CHAPTER 2

CONFIGURATION MODE, DIAGNOSTIC MODE,

and OCCLUSION MEASUREMENT

Graseby 3100
Syringe Pump

Smiths Medical International Ltd.

CHAPTER 2

CONFIGURATION MODE, DIAGNOSTIC MODE
and OCCLUSION MEASUREMENT

Configuration mode

Configuration
mode

Calling up the
Configuration
mode

Syringe brand
selection

The Configuration mode allows both the syringe brand and the language required to be
displayed and entered before using the pump.

CAUTION
The Configuration mode procedures must only be undertaken by suitably qualified
medical personnel.

1. When in the Set-up mode (refer to the 3100 Instruction Manual), simultaneously
hold down ...
either of the extreme right hand 0.1 arrow buttons ( ▲ or ▼ ) and the PURGE button.

The display will show the following:

CONFIGURATION?

2. Within five seconds, press the START button to confirm that the Configuration mode
is required. If the START button is not pressed within five seconds the pump will
revert back to its Set-up mode.

Note:

The pump has been designed so that the Configuration mode will not be called up
accidentally.

WARNING
The 3100 must be set to operate with the selected syringe. Using the wrong selection
could lead to the incorrect amount of drug being administered.

With the pump in its Configuration mode (as detailed above), complete the following
procedures in order to select the syringe brand required.

1. Use either of the two extreme left hand 100 arrow buttons ( ▲ or ▼ ) to display the
last syringe brand that was used.

2. Use either of the two extreme right hand 0.1 arrow buttons ( ▲ or ▼ ) in order to
scroll to the syringe brand required (see below). The brand of syringe selected will
be retained by the pump until the Configuration mode is called up again and a

different brand is selected.

• BD Plastipak.

• Terumo.

• Braun Omnifix.

• Monoject.

• Injectomat 50 ml.

Note:

The Braun Perfusor 50 ml syringe can only be used when the pump has been
converted to accept this particular syringe (see Chapter 8).

3. Press the STOP button in order to exit the Configuration mode.

3100 Service Manual Issue 7 (August 2004) 2 — 1

Configuration mode

Language setting With the pump in its Configuration mode (as detailed previously), complete the

following procedures to select the required language.

1. Use either of the two extreme left hand 100 arrow buttons ( ▲ or ▼ ) to
scroll and display the last language that was used.

2. Use either of the extreme right hand 0.1 arrow buttons ( ▲ or ▼ ) in order to
scroll and display the language required (see below). The language selected
will be retained by the pump until the Configuration mode is called up again
and a different language is selected:

• English

• Dutch

• French

• German

• Italian

• Portuguese

• Spanish

3. To exit the Configuration mode, press the STOP button.

Smiths Medical International Ltd.

Setting the AC
voltage

Disassembly and
assembly of casing

WARNINGS

1. The following procedures must only be carried out by qualified technicians.

2.

ELECTRIC SHOCK HAZARD.

power supply before opening the casing.

CAUTION
If the AC supply voltage settings are altered the label on the underside of the
pump and also the AC fuse rating must be changed to indicate and cater for the
new AC voltage.

The pump can be set to operate on a 100 to 120 V or a 220 to 240 V AC 50/60 Hz
supply. To change the AC operating voltage settings (as fully detailed in the following
sections) the pump casing has to be opened and two push-on connectors on the
Regulator board have to be adjusted.

The AC supply fuse rating must also be changed.

Each time the case is taken apart, the Syringe size sensor tests (see page 6.1) must
be completed.

1. Disconnect the AC power connector and using a scratch free flat surface, turn
the pump over in order to gain access to its base.

2. Undo and retain the six screws that hold the casing halves together. One of
the six screws is situated in a channel in the rear cover.

3. From the top of the pump carefully ease the casing halves apart, taking care
not to put any strain on the internal connecting cable looms that form a hinge
between the two halves.

The pump must be disconnected from the AC

4. Being careful not to trap any leads, assemble the casing by reversing steps
(2) and (3) above. Ensure that the front and rear mating edges are equal and
parallel. The screws should be tightened to a torque of between 70 and 75
cNm and in the order shown

2 — 2 Issue 7 (August 2004) 3100 Service Manual

Figure 2.1

.

Smiths Medical International Ltd.

Setting the AC voltage

AC voltage and
fuse adjustment

GM0595-B

1

5

3

4

2

6

Rear view of pump

Figure 2.1 Rear case screw fixing order

1. Take the casing apart (see page 2-2).

2. Check/ alter the position of the two push-on connectors situated on the

Regulator board (these connectors are attached to a black and a grey wire).
The alternative settings are as follows:

220-240 V 100-120 V

Grey: PL4 Grey: PL7
Black: PL8 Black: PL3

Diagnostic mode

3. Move the two blank insulated connectors so that they cover the two unused

alternative voltage terminals.

4. Remove the cover that is placed over fuse FS2. If required fit the correct

time delay fuse, as shown below:

• T 50 mA for 220-240 V.

• T 100 mA for 100-120 V.

5. Fit the fuse cover ensuring that the cover goes outside all of the spring

connectors.

6. Assemble the casing (see page 2-2).

7. If necessary stick a new voltage label over the existing label on the underside of

the pump. The new label must correctly specify the pump's present AC voltage.

The pump has a Diagnostic mode which enables the four following parameters to be
checked:

• the version of software that is installed in the Main processor,

• the software Cyclic Redundancy Check (CRC),

• the version of software that is installed in the Slave processor, and

• the voltage from the power supply to the Main board, or with the AC removed will
display the battery voltage.

The pump has been designed so that the Diagnostic mode has to be specifically
keyed in. It will be very unlikely that this mode will appear on the display accidentally.

3100 Service Manual Issue 7 (August 2004) 2 — 3

Voltage and fuse adjustment

Smiths Medical International Ltd.

Keying in the
diagnostic mode

Occlusion
measurements

By carrying out the following procedures the pump will be transferred from its Set-up
mode (refer to the 3100 Instruction Manual) to its Diagnostic mode:

1. Simultaneously press and hold down the following two buttons ... the ALARM

).

▼▼

▼

▼▼

▲ ▲

▲ or

▲ ▲

▼ ▼

▼

▼ ▼

)

in

button and either the right hand up or down arrow button (0.1,

2. Within five seconds press the START button to confirm that the Diagnostic
mode is required. If the START button is not pressed within five seconds the
pump will revert back to its Set-up mode.

3. Press either the extreme left hand up or down arrow button (100,
order to scroll through the four Diagnostic parameters listed above.

4. Press the STOP button to exit the Diagnostic mode.

The two most frequently used methods to measure the point at which an occlusion
occurs are the thrust and pressure methods.

Currently, the occlusion is set at during manufacture by using a thrust measurement
procedure. This method measures the plunger clamp thrust by using a set of weights
(as described on the next page).

The occlusion pressure is obtained by measuring the pressure that occurs in the
infusion line. This in-line method requires the use of a new syringe, infusion line and
pressure gauge. Conversion between the two is achieved using the formulae below,
taking into consideration syringe stiction.

The internal occlusion sensing system within the pump is always active.

▲ ▲

▲ or

▲ ▲

Thrust
measurements

Syringe stiction

The occlusion thrust checks must be carried out whenever the super nut assembly is
dismantled.

Translation of the thrust depends on the syringe diameter and the stiction of the syringe.
The formula for calculating the thrust is given below:

T = P x A +

732

where

: T = the thrust in kg,

P = the delivery pressure in mmHg,
A = the cross sectional area of the syringe in cm2,

and

The occlusion thrust of the pump is factory set to be between two limits (i.e. a minimum
and a maximum tolerance). The customer may reset the thrust for their own particular
requirement. The thrust of a particular pump may, therefore, differ from the original
factory set level.

The occlusion thrust of the 3100 pump is factory set at between

3.5 kg and 4.2 kg (471 mmHg and 565 mmHg).

Stiction for a syringe varies from brand to brand as well as from batch to batch.
Stiction can be as low as 0.1 kg and as high as 2 kg. The stiction of some syringe
brands has been found to be particularly high.

S = the syringe stiction in kg.

S

Stiction can also vary along the plunger travel and is usually lowest in small diameter
syringes. Using a sample syringe and allowing for a safety margin for sticky syringes,
adjustments can be made by measuring the thrust generated. If the stiction
characteristics of a syringe are known then by using the formula given above the
occlusion thrust can be set.

2 — 4 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

Occlusion thrust

Thrust checks

The following thrust checks detailed use the weights that correspond to the factory set
occlusion threshold levels for a 3100 (i.e. 3.5 and 4.2 kg). If a different occlusion level
setting is required, the weights must be adjusted accordingly.

The threshold level adjustment procedures are detailed on page 2-6.

1. Set the pump's plunger clamp to approximately midway along its support tube.

2. Remove the plunger from a BD 60 ml syringe and then saw the end off the

syringe. Place the modified syringe onto the pump so that it acts as a guide for
the weight support rod and also position the size sensor flag (see

Figure 2-2

).

3. With the pump switched ON, set the infusion rate to 200 ml/hr.

4. Place the pump in a vertical position, with its left hand side uppermost (see

Figure 2-2

5. Place the weight support rod through the modified syringe and onto the pump's

plunger clamp.

6. Place a weight of 3.5 kg on top of the weight support and check that the pump

operates for at least 30 seconds and does not occlude (i.e. the alarm does
not sound). Remove the weight.

7. Place a weight of 4.2 kg on top of the weight support and check that within 60

seconds the pump does occlude (i.e. the alarm sounds).

).

GM0241-A

MID-WAY POINT

WORK SURFACE

WEIGHTS

WEIGHT SUPPORT

1
0
.
0

m
l
/
h
r

SYRINGE BODY
(MODIFIED)

SYRINGE BARREL CLAMP

SYRINGE SIZE SENSOR

G

S
y
r

r

in

a

g
e

s
e

P
u

b

m

y

p

2

3

5

0

0

0

m

m

/
6

l

l

0
m
l

SYRINGE PLUNGER CLAMP

Figure 2.2 Thrust measuring set up

3100 Service Manual Issue 7 (August 2004) 2 — 5

Occlusion thrust

Thrust adjustments If the occlusion thrust requires adjustment, the following procedures must be

completed:

1. Switch the pump off and disconnect the AC supply.

2. Take the casing apart (see page 2-2).

3. If necessary rotate the leadscrew to reveal the grub screw that is located on
the occlusion adjusting nut. Loosen the grub screw with a 1.5 mm hexagonal
key.

4. Alter the setting of the occlusion adjusting nut as necessary. One full turn of
the adjusting nut gives approximately 2.73 kg (369 mmHg) of adjustment.

Rotating the adjusting nut in order to decrease the tension on the leadscrew
spring will decrease the pump's occlusion setting.

Rotating the adjusting nut in order to increase the tension on the leadscrew
spring will increase the pump's occlusion setting.

5. Tighten the grub screw to a torque of 15 ± 2 cNm.

6. Temporarily assemble the two halves of the pump, being careful not to trap
any leads.

7. Carry out a thrust check (see page 2-5).

Smiths Medical International Ltd.

8. In order to obtain the thrust required it may be necessary to repeat steps
(2) to (7) above.

9. Finalise the Assembly of the pump casing (refer to page 2-2).

10. Carry out the tests listed below and fully detailed in the functional test
procedures (see page 6-1 onwards):

• Test 4 ... syringe size sensors,

• Test 7 ... accuracy of infusion,

• Test 9 ... plunger clamp alignment, and

• Test 10 ... clamp open.

2 — 6 Issue 7 (August 2004) 3100 Service Manual

CHAPTER 3

FUNCTIONAL DESCRIPTIONS

Graseby 3100
Syringe Pump

Smiths Medical International Ltd.

CHAPTER 3

FUNCTIONAL DESCRIPTIONS

This Chapter explains how the 3100 operates. Reading this chapter will help a
technician to rectify any possible faults that may occur within the pump.

The functional descriptions of the pump may divided into five separate areas, and each
of these functional descriptions have been detailed separately in the descriptions that
follow:

• Drive system,

• Occlusion sensing system,

• Electro/mechanical control system,

• Sensing (alarm) systems,

• Software.

Functional descriptions

Drive system

The drive system comprises a stepper-motor working through a gearbox in order to
rotate a leadscrew. A half nut/ super nut assembly engages onto the leadscrew; the
assembly is also connected to a steel tube. The steel tube is connected to the
plunger clamp. Thus the rotation of the leadscrew will move the plunger clamp and
this movement will push ‘in’ the plunger on the syringe that is being used, as further
described below.

As the stepper-motor spindle rotates the leadscrew rotates and the half nut/ super
nut assembly travels to the left, along the leadscrew. The half nut/ super nut
assembly pulls the outer of two steel tubes to the left. This outer tube travels over
and along a support tube; the support tube is the length of the pump.

The pulses applied to the stepper-motor are derived from a microcomputer. The
microcomputer and its associated software determines the speed of the stepper­motor. To ensure safe operation of the stepper-motor the microcomputer controls the
stepper-motor directly.

A spring-loaded toggle mechanism is attached to the bottom of the half nut. This
toggle mechanism enables the plunger clamp to be physically swung ‘in or out’ thus
rotating the outer metal tube so that the half nut is either fully ‘engaged or disengaged’
(respectively) from the leadscrew.

When the plunger clamp is pushed ‘in’, the half nut/ super nut engages with the
leadscrew and the pump's plunger clamp ‘grabs’ the end of the syringe. The syringe
plunger slots into place behind a slotted pair of lips. These lips prevent the syringe
plunger from moving forward in the event of negative pressure on the syringe.

A small push-button on the edge of the plunger clamp makes contact with the top of
the syringe plunger. This push-button controls the operation of a lever which projects
from the plunger clamp. When the push-button is pressed in, by coming into direct
contact with the top of the syringe, the lever becomes free and is able to retract into
the plunger clamp. This retraction takes place when the plunger clamp is physically
swung into the forward operating position.

(contd.)

3100 Service Manual Issue 7 (August 2004) 3 — 1

Functional descriptions

Smiths Medical International Ltd.

Drive system (contd.)

If the push-button is not pressed ‘in’, the lever remains in its outward position thus
preventing the plunger clamp from being moved. This in turn prevents the half nut
from engaging on the leadscrew. This push-button system prevents the leadscrew
from being engaged unless the top of the syringe is correctly positioned in the
plunger clamp.

If the plunger clamp is accidentally knocked out of place during an infusion it will
automatically and safely shut down and an alarm will sound.

The motor, gearbox, leadscrew and associated components are mounted on a glass
reinforced polycarbonate casing. The strength of this casing enables a precise
mechanical location to be achieved for the components. Both the inner and outer
metal tubes are made of substantial material in order to eliminate all unwanted
flexing.

Occlusion sensing system

Clutch
assembly and
opto-sensor

The occlusion sensing system consists of a clutch, spring mechanism, a rotating
slotted disk and opto OPTO1 (see page 7.10). The clutch and spring mechanism
comprise the back pressure system. The rotating slotted disc and OPTO1 comprise
the rotation detector. The clutch, slotted disc and OPTO1 are located at the left
hand end of the leadscrew, underneath the opto sensor board. The spring is located
at the right hand end of the leadscrew.

Occlusion detection

Electro/mech.
control system

The clutch is held engaged by the spring with a pressure sufficient to overcome any
resistance from the syringe plunger and the normal back pressure from the infusion
line. The rotation detector will generate an output that comprises a continuous set of
pulses when the leadscrew rotates.

If there is an occlusion in the line then the back pressure will rise as the pump
attempts to force fluid through the line. When there is sufficient pressure to
overcome the spring pressure (factory set at 500 mm Hg) then the leadscrew moves
to the right, losing contact with the clutch. The rotation detector no longer generates
an output, which results in an occlusion alarm.

This method of occlusion detection is extremely sensitive as it is the lack of
pressure on the clutch that generates the alarm, rather than the detection of the
movement of the leadscrew as used in traditional designs. UK patent number 2249

497.

The microcomputer produces the pulse train for the stepper-motor in order to
produce a set flow rate. The rotation of the leadscrew slotted disc (described above)
is monitored by the movement of the slots and detected by the opto-sensor. If the
appropriate pulses are ‘not’ detected by the opto-sensor then an alarm signal is
generated.

Brief mechanical characteristics of the system are:

• motor step angle ... 15 degrees,

• gearbox reduction angle ... 210:1,

• number of motor steps per 5,040 at all times,

revolution of leadscrew ...

• leadscrew pitch ... 5 mm, and

• syringe characteristics ... 1 ml/ 1.8 mm (BD 60 ml syringe).

3 — 2 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

Functional descriptions

Sensing (alarm)
systems

Syringe nearly empty

End of infusion/
occlusion

AC power failure

Battery voltage low

In addition to the occlusion sensing system (see page 3-2) the following sensing
systems are also operative within the 3100.

A metal flag protrudes from the left hand side of the half nut (in parallel with the
leadscrew), this is the nearly empty flag. When this flag deactivates OPTO 0 (see

Figures 4.10

slotted disc is still rotating, then the processor makes a calculation that depends on
the infusion rate, and issues an alarm three minutes before the end of the infusion.

Also, when the processor detects that OPTO 0 is deactivated, and the slotted disc
has also stopped rotating, then a OCCLUSION alarm is generated.

Although the above condition has been termed an alarm state, the same conditions
will occur when the syringe reaches the end of its travel at the end of a perfectly
normal infusion.

If the slotted disc stops rotating and the nearly-empty flag has not moved a
sufficient distance to the left to deactivate OPTO 0 then the alarm condition will be
that of occlusion (see page 3-2).

The sensing system is able to detect an AC power failure. The pump will continue to
run after a power failure for a period of three hours or more, by automatically
switching over to its internal battery supply.

The sensing system also monitors the output of the batteries and registers an alarm
if the voltage of the batteries drops below 5.75 V.

and

7.5

) that is situated at the left hand side of the leadscrew, and the

Self tests/
pump malfunction

Drive disengaged/
syringe not fitted

Syringe size sensors

If the voltage falls below 5.4 V the pump will turn itself off after an initial warning
period.

Various ‘self tests’ are carried out on the pump when it is first switched on. In
addition to the self tests the rotation of the slotted disc at the end of the leadscrew is
monitored to ensure that the drive mechanism is operating correctly. The software
continually checks itself for the validity of calculations.

The drive system is designed so that it is only engaged when the top of the syringe
is correctly positioned in the plunger clamp. If the plunger clamp is knocked out of
place during an infusion the drive will automatically stop (the disengagement of the
half nut is detected by an opto-sensor). Also, trying to operate the 3100 without a
syringe or with a syringe incorrectly fitted will cause the pump to go into an alarm
state.

The pump has a syringe size sensor flag which rests on the barrel of the loaded
syringe in order to measure its diameter. This spring retained sensor flag moves up
and down in a bottom case groove. The bottom of the flag moves in-and-out between
two opto sensors (depending upon the diameter of the syringe) and this action results
in four sensor conditions being available:

• top opto sensed ... no syringe,

• neither opto sensed ... 20 ml syringe,

• bottom opto sensed ... 30 ml syringe,

• both opto's sensed ... 50 ml syringe.

3100 Service Manual Issue 7 (August 2004) 3 — 3

Functional descriptions

Smiths Medical International Ltd.

Software

The software has been designed using the latest structured design methods and
incorporates many safety tests and consistency checks. The source code for the
Main processor is written in Modula 2 which is particularly suitable for safety-critical
design. The Slave processor is programmed in Assembler language.

The self tests include the following:

• ROM test (CRC-16),

• RAM test,

• power supply voltage test,

• keyboard test. This test checks for shorted keys,

• stack usage test, and the

• motor windings continuity test.

The Main processor carries out most of the safety critical functions and is solely
responsible for the motor rate calculations.

The Slave processor generates the characters for the display, scans the keyboard
and drives most of the Light Emitting Diodes (LED). The Slave processor also runs
a software watchdog which checks the Main processor.

The Configuration settings are stored in the EEPROM in the Main processor.

3 — 4 Issue 7 (August 2004) 3100 Service Manual

CHAPTER 4

CIRCUIT DESCRIPTIONS

Graseby 3100
Syringe Pump

Smiths Medical International Ltd.

CHAPTER 4

CIRCUIT DESCRIPTIONS

This Chapter describes the action of the circuits that are used to operate the 3100
and also shows the associated circuit diagrams and the associated circuit board
layouts.

The 3100 contains four separate circuit boards:

• Main board,

• Regulator board,

• Syringe size sensors board, and the

• Opto sensors board.

The overall block diagram for the 3100, showing the interconnections between the
various circuits is shown in

Figure 4.1

Circuit descriptions

.

Main board circuit

Processor core
circuit

The Syringe size sensors board (
(

Figures 4.10

points for the sensor outputs.

The Main board circuit is shown in
These sub-circuits are individually described in the sections that follow:

• Processor core,

• Motor interface,

• Power control,

• Sensors interface,

• Communications processor.

The Processor core circuit (
used to process all the ‘operating activities’ of the pump.

The Main microprocessor chip (IC4) has an on-chip EEPROM, which stores the
latest settings. IC4 also incorporates an on-board RAM; an Analogue to Digital
converter (A to D); timing circuitry; communications circuitry and internal watchdog.

The chip IC3 and its associated components C7, C8 and R10 form a reset circuit.
The reset output is fed to pin 17 of the IC4. On power-up this reset circuit holds pin
17

low

in order to reset IC4, and on power-down it also holds pin 17

spurious activity.

X1 and its associated components R11, C9 and C10 form an 8 MHz oscillator circuit
that provides clock pulses for IC4 via pins 6 and 7.

The input to pins 2 and 3 of IC4 controls the mode of operation of IC4. Both pins
are held
IC5.

The EPROM chip IC5 stores the system’s software.

The reference points for IC4’s built-in A to D converter are pin 67 (GRND) and pin 68
(Vcc).

A Non Maskable Interrupt (NMI) signal is generated by the Slave processor (IC7,

Figure 4.7

system fault is detected.

IC4 controls the output to the stepper motor via pins 36 to 39.

D4, D5 and D6 are three LED’s that are used to indicate the syringe size, as
detected from the input on pins 60 and 65 of IC4. The LED’s are controlled by the
outputs from IC4 on pins 25, 26 and 27, which are routed to the circuits associated
with D4, D5 and D6 (i.e. Q4, Q5 and Q6).

and

7.5

) provide a mounting base for the sensors and also junction

high

in order to set the processor ready to address the external EPROM,

) and is routed via pin 18 of IC4. This NMI signal is generated when a

Figures 4.9

Figure 4.2

Figure 4.3

and

7.6

) and the Opto sensors board

and comprises the following sub-circuits.

) forms part of the Main board circuit and is

low

to avoid

(contd.)

3100 Service Manual Issue 7 (August 2004) 4 — 1

Motor interface

Smiths Medical International Ltd.

Motor interface
circuit

Power control
circuit

The stepper motor interface circuit (
the Main processor (IC4), in a set sequence.

Four motor control lines feed to four NOR gates and each NOR gate generates a
pulse. These pulses are used to switch four power MOSFETS (Q7 to Q10) in order
to drive the stepper motor. Diodes D7 to D10 provide a discharge path for the
current that is stored in the motor coils (L3 to L6) when the MOSFETS are switched
off.

R27 and R67 enable the Main processor to detect the current flowing through Q7 and
Q8 (MOTORSENSE 2 signal) and Q9 and Q10 (MOTORSENSE 1 signal).

If the Slave processor (IC7) detects a problem, it sends a DISABLE MOTOR pulse to
the NOR gates, and also sends a Non Masterable Interrupt (NMI) signal to the Main
processor. The output from each NOR gate is forced
pulses from the Main processor) thus disabling the stepper motor.

Power from the Regulator board is routed to the Power control circuit via plug PL1
(

Figure 4.5)

switched ON.

IC1 is a linear regulator which provides a 5 V supply (Vcc) for the logic circuits. C1,
C2 and C3 act as decoupling capacitors.

R7, R8, R9 and Q3 allow the Main processor to detect the presence or absence of
AC power (e.g. if the AC_SENSE line is low it indicates that the AC power is
present).

. D1 is an AC power on LED that is illuminated whenever the AC power is

Figure 4.4

) is controlled by pulses supplied from

high

low

(irrespective of the control

Sensors interface

circuit

IC2B and IC2C form a set/reset latch to operate the power MOSFET Q1. The latch
is triggered by a high pulse from the Main processor (POWER OFF), causing Q1 to
turn off and disconnect the power. Once tripped the latch cannot be reset by the
Main processor but must be reset by a high pulse by pressing the ON button.

Q2, R3, R4 and R6 form a logic level translator to translate 0 to 5 V logic levels into

0 to 7 V logic levels (VDD) for IC2. C4 and C5 overcome the effects of any transients.
D2 prevents C4 from discharging into IC2B.

Connections from plug PL6 and PL7 (
circuit and the Opto sensors circuit, respectively.

When triggered by a SENSOR ENABLE pulse from the Main processor a constant
current circuit (Q18 and Q19) turns on so that V
sensors. The outputs from any of the triggered opto-detectors is read into the Main
processor’s on-board A to D converter.

The sensors interface circuit also contains a battery sensing circuit to detect when the
output voltage of the batteries is low. R55 and R56 act as a potential divider to VIN,
allowing the divided VOLTAGE SENSE output level to be fed to the A to D converter of
the Main processor.

Figure 4.6

) connect to the Size sensors (syringe)

is applied across the LED opto-

IN

4 — 2 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

Communications processor

Communications
processor
circuit

The communications processor circuit (
the display; the ALARM, START and STOP LED’s; the sounder and the membrane
switch panel. This circuit also contains a software watchdog that monitors the operation
of the Main processor, (IC4).

R28, R29 and Q11 act as a buffer circuit such that pin 1 of the Slave processor (IC7) is
able to receive a
reset pulses will be prevented from effecting the Main processor.

X2, R30, C17 and C18 form a 4 MHz oscillator in order to provide clock pulses for IC7.

Outputs from IC7 on pins 9 to 12 are used to strobe the membrane switch panel (active

low

) by using a 4 x 4 matrix circuit. Data from the switch panel is routed via PL6 to pins
5 to 8 of IC7. Diodes D29 to D36 protect the circuit from static discharges induced into
the panel.

Three outputs from pins 24 to 26 of IC7 control the ALARM, START and STOP LED’s.
These three

output

goes

of the three LED’s; D21 (ALARM), D22 (START) or D23 (STOP).

There is a serial link between IC7 and the Main processor which acts as follows. The
Main processor supplies a command every 40 ms. If this command is not received a
DISABLE MOTOR signal appears at pin 31 of IC7, and this signal is used to create a
Non Maskable Interrupt (NMI) signal which is fed to the Main processor.

low

RESET pulse from the reset controller, but internally generated

outputs

high

are fed to three transistors, Q14, Q15 and Q16, and when an

, one of these transistor conducts, causing current to flow through one

Figure 4.7

) is the communications link between

Regulator board
circuit

IC7 also controls the operation of the sounder. When pin 28 goes
and Vcc is applied to the sounder via plug PL4.

Diode D19 allows the NMI signal to immediately turn on the sounder during a fault
condition. D20 protects the circuit against any reverse voltage that might appear from
the sounder.

Pin 13 and 19 of IC7 provide interface connections to the display circuit via plug PL5.

The Regulator board circuit is shown in Fig. 4.8. This power circuit provides 7 V DC
for both the motor and the various LED’s, and is also used to provide the 5 V DC
supply to the logic circuits. The circuit is based around a TL594 chip (IC1) which is a
standard step-down switching regulator chip that operates at 40 K Hz and acts as a
pulse width modulating converter.

The Regulator circuit is protected by an AC power input fuse, FS2 (see page 5-3),
and the AC input is filtered by C1. The two primary windings of the input transformer
are connected in series when the AC supply is 230 V, and in parallel when the AC
supply is 110 V. The primary terminals are PL3, PL4 and PL7 to PL10, and the
secondary terminals are PL5 and PL6 (20 V rms).

PL4 and PL8 are used when the input supply is between 220 V and 240 V, and
terminals PL3 and PL7 are used when the AC supply is between 110 V and 120 V.
VDR1 and L2 suppress all transients.

Diodes D4 to D7 act as a bridge rectifier, and smoothing is accomplished by
capacitor C4. The bridge DC output across C4 is between 25 V and 35 V DC. DC
power (Vcc) is applied to pin 12 of IC1 via protection fuse FS1 (500 mA). The
frequency of IC1’s on-board oscillator is controlled by C6 and R3.

low

, Q12 is turned on

The IC1 outputs at pins 8 and 11 control the operation of transistor Q1. Q1 cycles
on and off such that its mean output voltage is 7 V. As Q1 turns off, the voltage
across the switching inductor L1 charges C3 via flyback diode D2. A feedback
voltage is applied to pin 1 of IC1 via a potential divider comprising R1, TH1, R9, RV1
and R8. TH1 provides a temperature controlled output voltage to compensate for the
varying battery characteristics.

3100 Service Manual Issue 7 (August 2004) 4 — 3

Regulator board

Smiths Medical International Ltd.

C2 acts a decoupling capacitor, and the Zener diode D1 acts as a ‘crowbar’
protection diode for all externally connected circuits, in the event that the Regulator
power circuit malfunctions. Fuse FS3 (1A) acts as a batteries protection fuse. The
three rechargeable batteries, nominally 2 volts per battery, are connected in series
via plug PL12 on the Regulator board.

Plug PL11
outputs

Setting RV1

The outputs at plug PL11 should be as shown in Table 4.1:

T able 4.1 Plug PL11 outputs

Pin Output

1 and 2 Ground.

3 7 V DC, when on AC or battery supply.

4 7 V, when on AC supply.

The procedure for setting RV1 is as follows:

1. Switch off the external AC power, remove the AC power connector and open
the casing (see page 2-3).

2. Remove plug PL11 and PL12 from the Regulator board and connect a 68 ohm, 1
watt resistive load across pins 2 and 3 of plug PL11. Pin 1 of PL11 is the top
pin, as shown on the Regulator component layout diagram,

Note:

A Molex connector (
to be easily connected across PL11.

part number 0053-0658

) will enable the 68 ohm resistor

Figure 7.8

.

3. Connect and switch on the AC power. If necessary, adjust RV1 to give an AC
voltage across the 68 ohm load, dependent on the temperature, as shown in

Table 4.2
Figure 7.8

4. Switch off the AC power; remove the 68 ohm load; reconnect PL11 and PL12
to the Regulator board and assemble the casing as detailed on page 2-3.

. RV1 is located near the top left hand corner of the board (see

).

4 — 4 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

Setting RV1

Table 4.2 Temperature/voltage range for setting RV1

Ambient temperature DC output voltage
(degrees Centigrade) (68 ohm load)

28 7.015

27 7.027

26 7.038

25 7.050

24 7.062

23 7.073

22 7.085

21 7.096

20 7.108

19 7.120

18 7.131

Syringe size
sensors

Opto sensors

17 7.143

16 7.154

15 7.166

The Syringe size sensors board (
of the leadscrew. The sensor moulding houses two infrared emitting diodes and two
photo-transistors.

These two pairs of detection sensors (
has been loaded onto the pump (no syringe then alarm condition). If a syringe has
been loaded then the sensors are able to determine the size of the syringe,

i.e. 20 ml; 30 ml or 50/60 ml.

The sensors are hard-wired from plug PL1 on the Size sensors board via a cable-loom
to plug PL6 on the Main board.

The Opto sensors board (
above the left hand end of the leadscrew. There are three optical interrupt devices
attached to this board.

The three optical senors (opto interrupter 0, 1 and 2;
the status of the three following parameters:

Figure 7.6

Figure 7.5

) is located just in front of the right hand end

Figure 4.9

) is located on the left hand side of the pump just

) are used to determine if a syringe

Figure 4.10

) are used to monitor

• end of syringe travel detection,

• occlusion detection,

• drive engagement/disengagement detection (half nut on/off leadscrew).

The sensors are hard-wired from plug PL1 on the Opto board via a cable-loom to
plug PL7 on the Main board.

3100 Service Manual Issue 7 (August 2004) 4 — 5

Smiths Medical International Ltd.

Overall block diagram

SOUNDER

(Figure 4.7)

DISPLAY

BLK

RED

SYRINGE

SENSOR

PL4

1

PL5

SIZE

BOARD

(Figures 4.9

and 7.6)

PL1

PL6

MAIN BOARD

(Figures 4.2 to 4.7

and Figure 7.5)

OPTO

SENSOR

BOARD

(Figures 4.10

and 7.5)

PL1

PL7

PL2

PL3

OR

YEL

BLK

BRN

GRN

RED

BLU

1

MOTOR

MEMBRANE

SWITCH

PANEL

(Figure 4.11)

TRANSFORMER

NOTE:

Shown connected for 220/240V
(Fuse FS2 T50mA)

For 110/120V move BLK from PL8
to PL3 and move GRY from PL4 to PL7
(Fuse FS2 T100mA)

GM0197-C

AC POWER

20Vrms

SEE NOTE

GRY

YEL

YEL

BLU

BLK

BRN

PL5

PL6

REGULATOR

BOARD

(Figures 4.8

PL10

and 7.6)

PL8

PL3

PL7

PL4

PL9

PL1

PL11

PL12

PL2

PL1

+

RED

2

1

CELL3

PNK

CELL2

PNK

CELL1

-

BLK

RECHARGEABLE

BATTERIES

BLU

BRN

AC INPUT

N

L

POWER

Figure 4.1 Overall block diagram

3100 Service Manual Issue 7 (August 2004) 4 — 7

Smiths Medical International Ltd.

4 — 8 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

Main board block diagram

POWER CONTROL

ON

OFF

(See Fig. 4.5)

AC_SENSE

PROCESSOR CORE

RESET

-NMI

AC_SENSE

VOLTAGE_SENSE

SIZE2_SENSE

SIZE1_SENSE

EMPTY_SENSE

SYRINGE_SENSE

ROTATION_SENSE

SENSOR_ENABLE

(See Fig. 4.3)

COMMUNICATIONS PROCESSOR

RESET

-NMI

(See Fig. 4.7)

MOTORSENSE1

MOTORSENSE2

MOTOR1

MOTOR2

MOTOR3

MOTOR4

-SS

SCK

MISO

MOSI

HANDSHAKE

OFF

HANDSHAKE

MOSI

MISO

MOTOR INTERFACE

MOTORSENSE1

MOTORSENSE2

DISABLEMOTOR

MOTOR1

MOTOR2

MOTOR3

MOTOR4

(See Fig. 4.4)

GM0191-A

DISABLEMOTOR

ON

SCK

-SS

SENSORS

ROTATION_SENSE

SYRINGE_SENSE

EMPTY_SENSE

SIZE1_SENSE

SIZE2_SENSE

VOLTAGE_SENSE

(See Fig. 4.6)

SENSOR_ENABLE

3100 Service Manual 4 — 9 Issue 7 (August 2004)

Figure 4.2 Main board block diagram

Processor core

Smiths Medical International Ltd.

HANDSHAKE
AC_SENSE

C7

100nF

-NMI

GND

VCC

C8

+

0.47uF

1

2

3

7

IC3

VREF

RESIN/

CT

SENSE

TL7705A

RST

RST/

RESET

X1

8MHz

R11 6M8

GND

R12 10K

R13 10K

VCC

GND

C28
10nF

C10

22pF

R14
4K7

C29
10nF

VCC

GND

VCC

C9
22pF

6

VCC

5

R10

4K7

GND

VCC

R15

10K

GND

MAIN PROCESSOR IC4

6

EXTAL

7

XTAL

8

4XOUT

3

MODA/LIR

2

MODB/VSTBY

68

VRH

67

VRL

17

RESET

18

XIRQ

19

IRQ

IC3/PA0
IC2/PA1

IC1/PA2

OC5/IC4/OC1/PA3

OC4/OC1/PA4
OC3/OC1/PA5

OC2/OC1/PA6

PAI/OC1/PA7

PB0/A8

PB1/A9
PB2/A10
PB3/A11

PB4/A12
PB5/A13
PB6/A14
PB7/A15

PC0/D0

PC1/D1

PC2/D2

PC3/D3

PC4/D4

PC5/D5

PC6/D6

PC7/D7

PD0/RXD

PD1/TXD
PD2/MISO
PD3/MOSI

PD4/SCK

PD5/SS

PE0/AN0
PE1/AN1

PE2/AN2
PE3/AN3
PE4/AN4

PE5/AN5
PE6/AN6
PE7/AN7

PF0/A0
PF1/A1
PF2/A2
PF3/A3

PF4/A4
PF5/A5
PF6/A6
PF7/A7

PG0
PG1

PG2
PG3

CSIO2/PG4
CSIO1/PG5

CSGEN/PG6
CSPRG/PG7

R65A 10K#

42
41

40
39

38
37
36
35

A8

50

A9

49
48

A10
A11

47

A12

46

A13

45

A14

44

A15

43

9

D0
D1

10

D2

11

D3

12

D4

13

D5

14

D6

15
16

D7

28
29
30

31
32
33

59
61
63

65
60
62
64

66

58
57
56

55
54
53
52

51

27
26
25
24

23
22
21
20

A0
A1

A2
A3
A4

A5
A6
A7

GND

D4
LED

R19

560

A0
A1
A2
A3

A4
A5
A6
A7

A8
A9
A10

A11
A12
A13
A14

VCC

GND

SYRINGE SIZE INDICATORS

R20

560

12
34

R65B
R65C 10K#

56

R65D 10K#

78

10K#

EPROM IC5

D5
LED

10

A0

9

A1

8

A2

7

A3

6

A4

5

A5

4

A6

3

A7

25

A8

24

A9

21

A10

23

A11

2

A12

26

A13

27

A14

20

CE

22

OE

1

VPP

27C256

R21

560

VIN

O0
O1

O2
O3
O4
O5

O6
O7

D6
LED

11

D0

12

D1

13

D2

15

D3

16

D4

17

D5

18

D6
D7

19

MOTOR1
MOTOR2
MOTOR3

MOTOR4

OFF
MOSI

SCK

-SS

SENSOR_ENABLE

5

GM0193

MISO
MOTORSENSE1

MOTORSENSE2
VOLTAGE_SENSE
SIZE2_SENSE

SIZE1_SENSE
EMPTY_SENSE
SYRINGE_SENSE

ROTATION_SENSE

68HC11F1

R/W

4

E

GND

Figure 4.3 Processor core circuit diagram

4 — 10 3100 Service Manual Issue 7 (August 2004)

R16

10K

Q4

BC184L

R17

10K

Q5

BC184L

R18

10K

Q6

BC184L

VCC

C11 C12 C13

ALL 100nF

GNDGND

Smiths Medical International Ltd.

Motor interface

VIN

MOTOR1

MOTOR2

MOTOR3

MOTOR4

R22

100K

R23

100K

R24

100K

R25

100K

VCC

2

3

5

6

8

9

11

12

IC6A

74HC02

IC6B

74HC02

IC6C

74HC02

IC6D

74HC02

C15

D7

1N4448

1

Q7

4

10

13

VNO300M

VCC

VNO300M

D8

1N4448

Q8

R67

1R2

1N4448

VNO300M

C31
10nF

D9

Q9

1N4448

Q10

VNO300M

D10

R27

1R2

22uF

C32
10nF

C16

+

100nF

L3
TEE

L4
TEE

L5
TEE

L6
TEE

R66 1K

R26 1K

GND

PL2

1
2
3
4
5
6

7

MOTOR

MOTORSENSE1
MOTORSENSE2

DISABLEMOTOR

C14

100nF

GND

GM0195-A

3100 Service Manual 4 — 11 Issue 7 (August 2004)

Figure 4.4 Motor interface circuit diagram

Power control

Smiths Medical International Ltd.

D3

PL1

POWER

L1
TEE

VDD VIN

4
3
2

1

VSS

L2
TEE

VDD

AC

R1

560

D1

LED

C1

100nF

Q1

MTD10N05SE1

1N4448

LM2931AZ-5-0

1

IC1

R7

22K

R8

10K

VCC

R9
47K

Q3
BC184L

GND

AC_SENSE

VCC

3

2

C2

100nF

C3

+

100uF

GND

ON

OFF

GM0192-A

C5

3.3uF

VSS

GND

R2

100K

10K

R3

D2

IC2A

1

2

4093B

+

R6

100K

3

VDD

R4

10K

Q2

BC184L

4093B IS POWERED FROM VDD AND VSS

R5

100K

VSS

1N4448

C4

+

0.47uF

VSS

IC2D

12

13

4093B

11

5

6

8

9

IC2B

4

4093B

IC2C

10

4093B

VDD

C6

100nF

VSS

Figure 4.5 Power control circuit diagram

4 — 12 3100 Service Manual Issue 7 (August 2004)

Smiths Medical International Ltd.

Sensors interface

VIN

R55
11K

1%

VOLTAGE_SENSE

SENSOR_ENABLE

R78
10K

D37

Q18

BC184L

R80
47R

R79

10K

D39

D40D38

Q19

BC184L

R81
47R

GND

C25

VCC

R53

47K

12345

GND

R54

47K

R50

15K

123456

R51

15K

VINVIN

R52

15K

12R68A 10K#
56

R68C 10K#

12

R70A 10K#
R70C 10K#

R58 10K

6

5

C20

1nF

BZX79C6V2

D24

C21

1nF

BZX79C6V2

D25

C22

1nF

BZX79C6V2

C23

1nF

BZX79C6V2

D26

1nF

D27

R56
11K

1%

GND

C24

1nF

BZX79C6V2

D28

34R68B 10K#

R68D 10K#

78
34

R70B 10K#
R70D 10K#

78

R69 10K

SIZE2_SENSE
SIZE1_SENSE

ROTATION_SENSE
SYRINGE_SENSE
EMPTY_SENSE

4 x 1N4148

GND

GM0196-A

PL6

SYRINGE SIZE SENSORS

PL7

OPTO SENSORS

3100 Service Manual 4 — 13 Issue 7 (August 2004)

GND

Figure 4.6 Sensors interface circuit diagram

Communications processor

Smiths Medical International Ltd.

VCC

R29

47K

RESET Q11

MOSI
SCK

-SS

R28

10K

D29

BZX79C6V2

D30

R75D

1K#

GND

D11

2

1

C26
10nF

34567

8

BC184L

D12

GND

D13 D14

D33

BZX79C6V2

D34

BZX79C6V2

D35

GND

1

2

C27
10nF

34567

R76D
10K#

8

VCC

R77D
10K#

-NMI

X2 4MHz

R30

10M

C17
22pF

1234567

8

C18

22pF

GND

VCC

GND

SLAVE
PROCESSOR
IC7

43

OSC1

42

OSC2

1

RESET

2

IRQ

12

PA0

11

PA1

10

PA2

9

PA3

8

PA4

7

PA5

6

PA6

5

PA7

32

PD0/RDI

33

PD1/TDO

34

PD2/MISO

35

PD3/MOSI

36

PD4/SCK

37

PD5/-SS

39

PD7

MC68HC705C8P

NC/VPP

TCMP

TCAP

PB0
PB1
PB2

PB3
PB4
PB5

PB6
PB7

PC0
PC1

PC2
PC3

PC4
PC5

PC6
PC7

38

41

13
14

15
16

17
19

20
21

31
30

29

28
27

26
25

24

4

GND 12R61A 1K#

GND

VCC

R31

10K

Q13

BC184L

GND

34

R61B

56

R61C 1K#

78

R61D 1K#
R63

R62 560

1K#

560

FRONT PANEL LEDs

D21
LED

ALARM

R41

560

START STOP

R42

560

D22
LED

GND

R43

560

VIN

D23
LED

VCC

VIN

PL5

1
2

3
4

5
6

7
8
9

DISPLAY

DISABLEMOTOR

HANDSHAKE

MISO

ON

GM0194-A

GND

BZX79C6V2

D31

BZX79C6V2

BZX79C6V2

GNDD32

BZX79C6V2

D36

BZX79C6V2

VIN

1 2 3 4 5 6 7 8 9 1

PL3

0

MEMBRANE
SWITCH PANEL

R64
10K

VCC

GND

C19

100nF

R40

10K

BC184L

GND

Figure 4.7 Communications processor circuit diagram

4 — 14 3100 Service Manual Issue 7 (August 2004)

Q12

D19

1N4448

D20

1N4448

PL4

VCC

12

SOUNDER

R44

10K

GND

Q14

BC184L

R45
10K

Q15

BC184L

R46

10K

Q16

BC184L

Smiths Medical International Ltd.

Regulator board

ALL RESISTORS +/- 5% UNLESS OTHERWISE STATED

PL1

PL2

15N

Q1

IRF9530

D2

11DQ03

L1

RM6

100UH

C3

+

1000U

10V

R1

1K2

TH1

1K5

D3

R9

1K

RV1

1K

10V

D1

1N5347B

C2

100N

11DQ03

27K

L2

C5

100N

R4

1K2

Q2

BC182L

Q3

BC212L

1uH

R2

100R

12

IC1

NI1

INV1

NI2

INV2

FB

DTC

RT

CT

VREF

Vcc

GND

8

C1

9

E1

11

C2

10

E2

13

OC

7

TL594

1

2

R11
47K

R3

C6

1N

16

15

3

4

6

5

14

C7

100P

R7

680R

FS1

F 500mA

FS2

T 50mA

C1

PL9

PL7

PL8

PL4

PL3

PL10

TRANSFORMER (See Fig. 4-1)

PL6

PL5

D8

VDR

V47ZA1

D6

1N4001D71N4001

D5

1N4001

D4

1N4001

0V

C4

+

220U
50V

R10
2K2

R12

4K99

0.1%

GM0093-A

R13

330R

1%

R5

0R51

1%

R8

3K9

ESD GND

FS3

F 1A

PL11

4

3

2
1

HEADER 4

PL12

2

1

HEADER 2

3100 Service Manual 4 — 15 Issue 7 (August 2004)

Figure 4.8 Regulator board circuit diagram

Smiths Medical International Ltd.

4 — 16 3100 Service Manual Issue 7 (August 2004)

Smiths Medical International Ltd.

OPTO1

B SIZE DETECTOR

OPTO0
A SIZE DETECTOR

Syringe size and Opto sensors

PL1

1

2

3

4

5

6

HEADER 6

GM0094-A

GUARD RAIL

Figure 4.9 Syringe size sensors circuit

OPTO0
END OF TRAVEL DETECTOR

OPTO1
OCCLUSION DETECTOR

OPTO2
DRIVE ENGAGEMENT

DETECTOR

PL1

1
2
3

4
5

6

Note: Cableform is hardwired

L1

CHOKE

GM0095-A

Figure 4.10 Opto sensors circuit diagram

3100 Service Manual Issue 7 (August 2004) 4 — 17

Membrane switch panel

GM0211-A

Smiths Medical International Ltd.

ON

INC0

INC1

INC2

INC3

DEC0

10

DEC1

DEC2

1

2

3

4

5

6

7

8

9

DEC3

START

STOP

DISPLAY

RESET

ALARM

PURGE

OFF

Figure 4.11 Membrane switch panel circuit

4 — 18 Issue 7 (August 2004) 3100 Service Manual

CHAPTER 5

FAULT CODES, MAINTENANCE

and REPAIR PROCEDURES

Graseby 3100
Syringe Pump

Smiths Medical International Ltd.

CHAPTER 5

FAULT CODES, MAINTENANCE and
REPAIR PROCEDURES

Fault codes, maintenance and repairs

Fault codes

Fault codes, 0 to 92

Comprehensive fault codes have been designed into the 3100 so that should a fault
occur it can easily be identified. The fault code numbers that are allocated are used to
indicate the type of fault that has occurred.

Both the Main processor (IC4) and the Slave processor (IC7) in the pump are capable
of recognising faults and generating fault code numbers. The Main processor is able
to generate codes in the range 0 to 99 and the Slave processor in the range 100 to

199. The fault codes are not expected to change for future software versions.

The normal operational ALARMS and WARNINGS are fully detailed in the 3100
Instruction Manual.

Table 5.1 Main processor fault codes

Code Fault description

07 Ram failure (power-on self test).

10 Leadscrew turning too fast (i.e. pulses from sensor via slotted disc

are more than 10% faster than expected).

11 XIRQ interrupt line asserted by Slave processor.

22 Unexpected interrupt asserted.

30 Modula programme returned to start up code.

34 Difference detected between a variable and its duplicate.

35 Variable out of its allowed range.

45 Illegal opcode detected.

46 Internal COP monitor timeout interrupt.

47 Internal clock monitor: reported error interrupt.

54 Motor interrupt operation, without foreground operation.

55 Insufficient processing time detected by task scheduler.

56 Processor CONFIG register not programmed correctly (COP not

enabled and EEPROM not sited correctly).

57 Motor pulse period re-calculations disagree with original calculation.

58 Speed sensor period re-calculation disagrees with original calculation.

61 A node check baton has the wrong value.

70 CPU test failure (power ON self test).

85 Power supply overvoltage during power ON self test.

86 Motor has wrong current during power ON tests.

87 ROM CRC failure during power ON self test.

90 EEPROM index corrupt or, EEPROM expired.

91 A short circuit has occurred on the membrane switch panel during

power ON self test.

92 EEPROM data corrupt.

3100 Service Manual Issue 7 (August 04) 5 — 1

Fault codes

Smiths Medical International Ltd.

Fault codes, 100 to
112

Table 5.2 Slave processor fault codes

Code Fault description

100 Internal COP monitor timeout interrupt .

101 Internal clock monitor interrupt.

102 Main processor resetting software watchdog too frequently.

103 Processor not resetting software watchdog frequently enough.

109 Timeout while waiting for initialisation from Main processor.

110 SPI write collision detected by hardware.

111 Unexpected interrupt asserted.

112 Program checksum failed (power ON self test).

5 — 2 Issue 7 (August 04) 3100 Service Manual

Smiths Medical International Ltd.

Maintenance

Maintenance

Cleaning

Fuse renewal

CAUTION

The 3100 must

Immediately wipe off any liquid that may be accidently spilt on the pump.

The outer surfaces of the pump can be cleaned by wiping them over with a damp
cloth (soapy if necessary).

WARNINGS
The following procedures must only be carried out by a suitably qualified
technician.

The pump must be disconnected from the AC power supply before the case is
opened.

If the AC voltage settings are altered, the label on the underside of the pump
and also the AC fuse rating must be changed to indicate and cater for the new
AC voltage.

The safety and reliability of the pump may be compromised by the use of
parts other than those specified in this Manual.

The pump contains three safety fuses which are located on the Regulator board (see

Figure 7.8

NOT

be immersed in any liquids.

for their location). Details of these fuses are as follows:

Repair procedures

• FS1 is a fuse located in the unregulated DC line and has a 500 mA rating.

• FS2 is an AC supply time delay fuse having the following alternative rating:

— T 50 mA for a 220-240 V AC supply.
— T 100 mA for a 100-120 V AC supply.

• FS3 is a fuse located in the battery supply line and has a 1 ampere rating.

In order to renew a blown fuse the 3100 casing must be disassembled as detailed on
page 2-2, this action will allow access to all three fuses. A blown fuse must only be
replaced by a new fuse of the correct rating. Reassemble the casing as detailed on
page 2-2.

In several of the repair procedures that follow, information has been given on how to
remove and renew the whole of the particular assembly.

If a single component within an associated assembly is faulty and can be individually
repaired, then reference to the appropriate illustrated parts exploded view may enable
the single faulty component to be renewed.

If a leadscrew assembly or a half nut is repaired, then the following checks and if
necessary the associated adjustments must be carried out:

• thrust check (see page 2-5).

• plunger clamp checks (see page 6-3).

Whenever the case is taken apart the Syringe Size Sensors tests detailed on page 6-1
must be carried out.

3100 Service Manual Issue 7 (August 04) 5 — 3

Repair procedures

Smiths Medical International Ltd.

Main board renewal

Regulator board
renewal

1. Open the 3100 casing (see page 2-2).

2. Remove and retain the six pan head self tapping screws that fix the
Main board to the 3100 front casing.

3. Displace and carefully turn the faulty board over. Disconnect the six connectors
from the underside of the board; from the left, plug PL7, 4, 2, 1, 6 and 3
(

Figure 7.7

4. Remove the faulty Main board.

5. Fit a new board by reversing steps (2) and (3) above, and close the casing (see
page 2-2).

1. Open the casing (see page 2-2).

2. Make a note of how the eight spade connectors are mounted on the Regulator
board and then slide and lift the connectors off.

3. Prise open the two nylon retaining clips and release the four wires.

4. Remove and retain the two screws that hold the transformer in place. The left
hand screw is 25 mm long and the right hand screw is 8 mm long. Lift out the
transformer.

).

5. Disconnect the two bottom left hand connectors (PL11 and PL12;
from the Regulator board by prising the side retaining clip from each connector
and then pulling the connector out.

6. Remove and retain the two screws that hold the Regulator board in place and
then remove the faulty board.

7. Fit a new board by reversing steps (2) to (6) detailed above, and then close the
casing (see page 2-2).

Figure 7.8

)

5 — 4 Issue 7 (August 04) 3100 Service Manual

Smiths Medical International Ltd.

Repair procedures

Opto sensors board
renewal

AC transformer
renewal

1. Open the casing (see page 2-2).

2. Remove and retain the six pan head self tapping screws that are used to fix the
Main board to the front casing and turn the board over.

3. Carefully lift up the retaining clip on PL7 (Main board;
PL7.

4. Remove and retain the screw and washer that fixes the ribbon cable clip of PL7
to the chassis.

5. Remove and retain the two fixing screws and washers from the front of the
Opto board.

6. Ease out the plastic flag from the sensors assembly and remove the faulty
Opto sensors board.

7. Fit a new Opto board by reversing steps (2) to (6) detailed above, and then close
the casing (see page 2-2).

1. Open the casing (see page 2-2).

2. Make a note of how the eight transformer spade tags are connected to the
Regulator board and then slide and lift the tags off.

Figure 7.7

) and disconnect

3. Prise open the two nylon retaining clips and release the four transformer wires.

4. Remove and retain the two screws and the spacers that hold the transformer in
place. The left hand screw is 25 mm long and the right hand screw is 8 mm
long.

5. Lift out the faulty transformer.

6. Fit a new transformer by reversing the steps (2) to (4) detailed above and then
close the casing (see page 2-2).

3100 Service Manual Issue 7 (August 04) 5 — 5

Repair procedures

Smiths Medical International Ltd.

Plunger clamp and
half nut assembly
renewal

Pole clamp
assembly renewal

This assembly (
guide tubes, and two clamp brackets that retain the square lay shaft (

7.2)

1. Open the casing (see page 2-2).

2. Unhook the top of the retaining spring (2 mm dia. by 2.5 cm long) from the
syringe size sensor lever arm.

3. Remove and retain the three screws from the two clamp brackets that hold the
lay shaft in place. Remove and retain the two brackets.

4. Lift up the square shaft and toggle mechanism; and carefully ease out the flag
from its housing on the left.

5. Lift the two guide tubes off their respective seating then remove the entire
assembly.

6. Fit the new assembly by reversing steps (2) to (5) detailed above.

7. Close the casing (see page 2-2).

1. Remove and retain the two screws that are inserted into the stainless steel
bracket on the base of the pump.

Figure 7.2)

is held in place by a narrow retaining spring, two circular

Figures 7.1

and

2. Remove the faulty assembly.

3. Fit the new assembly by reversing step (1) detailed above.

5 — 6 Issue 7 (August 04) 3100 Service Manual

Smiths Medical International Ltd.

Repair procedures

Leadscrew assembly
renewal

The leadscrew assembly is held in the rear casing by two bearing clamp plates. It is
also kept under tension by a strong adjustable spring. The keyed coupling bush that
screws into the right hand end of the leadscrew has a ‘left hand’ thread1.

1. Open the 3100 casing (see page 2-2).

2. If necessary, turn the leadscrew in order to reveal the small grub screw situated
in the occlusion nut on the right hand side of the leadscrew. Using a

1.5 mm hexagon key, loosen the grub screw.

3. Ensuring that the leadscrew does not turn, move the occlusion nut counter­clockwise (i.e. towards the left) in order to relax the spring tension.

4. Remove and retain the two pan head self tapping screws that hold the right
hand bearing clamp plate in place; remove and retain the plate.

5. Lift out the leadscrew, complete with the motor and gear box. The motor and
gear box are coupled at the right hand end of the leadscrew.

6. Uncouple the faulty leadscrew from the gearbox by pulling it away from the
gearbox shaft.

7. Fit a new leadscrew assembly (see Note below) by reversing steps (2) to( 6)
detailed above. Tighten the grub screw to 15 ± 2 cNm. Alternatively, renew the
motor and gearbox assembly as detailed in the following section.

Note:

During the fitting of the new leadscrew the spring assembly may have to be
compressed to the left in order to fit it into the appropriate grooves in the rear
casing.

8. Ensure that the groove on the syringe size sensor collar (through which the
larger telescopic tube slides) fits correctly into the concaved rear casing.

9. Assemble the casing (see page 2-2).

10. Complete the thrust checks and plunger clamp checks/adjustments (see page
2-5 and 6-3 respectively).

1

If the LH thread coupling bush is removed, the torque required when refitted

must not exceed 40 cNm.

3100 Service Manual Issue 7 (August 04) 5 — 7

Repair procedures

Smiths Medical International Ltd.

Motor and gear box
assembly renewal

Occlusion clutch
and disc assembly
renewal

There is a small plastic coupling between the leadscrew and the gearbox (
item 2).

1. Open the casing (see page 2-2).

2. Remove the Main board (see page 5-4) and disconnect the motor cable from
the Main board (PL2).

3. Remove the leadscrew assembly (together with the motor and gearbox
assembly) see page 5-7, steps (2) to (5).

4. Pull the faulty motor and gearbox away from the leadscrew.

5. Fit a new motor and gearbox assembly by reversing steps (2) to (4)above, and
then assemble the casing (see page 2-2).

The occlusion clutch and disc assembly is situated on the left hand side of the
leadscrew assembly underneath the Opto sensors board.

1. Open the 3100 casing (see page 2-2).

2. Remove the Opto sensors board (see page 5-5).

Figure 7.4

,

3. Remove the leadscrew assembly (see page 5-7, steps [2] to [5]), complete
with the motor and gearbox assembly.

4. Remove and retain the two screws and the bracket that holds the clutch and
disc assembly in place.

5. Remove the faulty clutch and disc assembly.

6. Fit a new clutch and disc assembly by reversing steps (2) to (4) detailed
above, and then assemble the casing (see page 2-2).

7. Carry out the thrust checks and plunger clamp checks/adjustments (see
pages 2-5 and 6-3 respectively).

5 — 8 Issue 7 (August 04) 3100 Service Manual

Smiths Medical International Ltd.

Repair procedures

Membrane switch
panel renewal

The Membrane switch panel has an adhesive backing that enables it to be fixed to the
top of the front casing. Take care not to unduly bend the new switch panel or its flexible
cable loom.

1. Open the 3100 casing(see page 2-2).

2. Displace the Main board by removing the 6 screws, and disconnect the
switch panel ribbon cable connector PL3 (this is a non-locking connector)
from the right hand underside of the board.

3. Starting by lifting a corner, peel the faulty switch panel away from the case;
pull the loose connector out through the front casing slot, and remove the
faulty switch panel.

4. Remove traces of old adhesive from the front case recess (a cloth lightly
dampened with white spirit may be used).

5. From the top of the new switch panel peel back the protective paper backing
as far as the top of the display window.

6. Push the connector and flexible lead of the new switch panel through the slot
in the case.

7. Align the top edge and sides of the panel with the top and sides of the case
recess. Gently rub the top edge of the switch panel to adhere it lightly to the
case and then remove the remainder of the protective backing paper.

8. Working from the top downwards and using light pressure lay the panel into
the case recess.

9. When the switch panel is positioned correctly into the case recess (i.e. no
over-hanging edges), use a soft cloth to rub the panel down firmly, pushing
out any air bubbles at the same time.

10. Connect PL3 to the Main board and using the six screws that were
previously removed, refit the Main board to the top halve of the casing.

11. Assemble the casing (see page 2-2).

3100 Service Manual Issue 7 (August 04) 5 — 9

Repair procedures

Smiths Medical International Ltd.

Super nut renewal

Early 3100 pumps (pre s/n 56905) were fitted with a half nut. From May 1999, the half
nuts were replaced with a three-quarter super nut. The following procedures refere to the
super nut.

GM1088-A

Half nut Super nut

Figure 5.1 Half nut (obsolete)/Super nut

The super nut casting (
tube by an M4 countersunk screw. This screw is tightened into a recessed hexagonal
nut. It is also attached to the toggle mechanism by a Spirol connecting pin.

1. Open the casing (see page 2-2).

2. Remove and retain the Spirol connecting pin that fixes the super nut to the
toggle mechanism.

3. Unhook the top of the retaining spring (2 mm dia. by 2.5 cm long) from the
syringe size sensor lever arm.

Figure 7.2

) is clamped onto the left hand end of the outer metal

Syringe size sensor
board renewal

4. Lift the two guide tubes off their respective seating and remove the attached
assembly complete with the faulty super nut.

5. Remove and retain the half nut countersunk clamping screw and asssociated nut.

6. Lever the sides of the half nut apart in order to disengage the casting pip from
the locating hole in the guide tube.

7. Fit a new half nut by reversing steps (2) to (6) detailed above.

8. Close the casing (see page 2-2).

9. Carry out the thrust checks and plunger clamp checks/adjustments (see pages
2-5 and 6-3 respectively).

1. Open the casing as detailed on page 2-2.

2. Unscrew the Main board (see page 5-4).

3. Disconnect the flexible cable loom connector, PL6, from the Main board.

4. Remove and retain the two screws that hold the sensor board in place.

5. Remove the faulty sensor board complete with its cable loom and connector.

6. Fit the new sensor board by reversing steps (2) to (5) detailed above.

7. Close the casing as (see page 2-2).

5 — 10 Issue 7 (August 04) 3100 Service Manual

Smiths Medical International Ltd.

Repair procedures

Plunger clamp
repair

Batteries. Checks
and replacement

Checks

The plunger clamp cover must be removed in order to reach the internally located lock
or pin moulding. The outer casing of the clamp is fixed to the right hand end of the
outer tube.

1. Remove and retain the two screws that holds the plunger clamp cover onto the
outer casing and remove the cover.

2. The lock and pin moulding together with the associated spring will become
accessible.

3. As required, fit a new lock and/or pin and assemble the clamp as detailed in
step (1) above.

WARNING
The internal pump batteries must be disposed of in accordance with the manu­facturers instructions. Lead acid batteries must not be placed in the normal waste
stream.

We recommend that the condition of the three internal batteries is checked at least
annually. The batteries will normally last several years, but if they should fail to charge

then all three batteries must be replaced at the same time. The batteries are held in
place in the front casing by three-pronged flexible plastic mouldings.

Connect the pump to AC power; ensure that the pump is switched off and the yellow
AC light is illuminated, this will allow maximum DC charge supply from the regulator
board. Fully charge the batteries for at least 14 hours. Remove the AC power and
run the pump at 100 ml/hr. If the LOW BATTERY alarm appears on the pump’ s
display before 3 hours has elapsed then all three batteries should be replaced, as
detailed below:

Replacement

Front and/or rear
case repair

1. Open the case (see page 2-2).

2. Noting their orientation, prise out the three faulty batteries. Also noting the

connections remove all six spade tags.

3. Reconnect three new fully charged 2 V, 2.5 AH, lead acid D Cell batteries by

reversing the steps detailed in (2) above, ensuring that the two rubber packing
spacers that are attached to the pillars are still in place.

4. Close the casing (see page 2-2).

In March 1999, a new type of strengthened and modified front and rear case moulding
was introduced for the 3000 range of syringe pumps (see

Figure 5.2

GM0983-A

).

CORNERS
ROUNDED
TO MINIMISE
IMPACT

Figure 5.2 Strengthened rear case moulding

If an old style front or rear case becomes damaged and requires replacing then the
appropriate repair kit is available from Smiths Medical. There are two kits (front or rear
case) which each contain all the necessary instructions and parts to carry out a repair.

The contents of the repair kits are shown in Tables 5.3, 5.4 and 5.5 (see page 5-12 and
5-13). The items marked with an asterisk (*) may be obtained individually.

3100 Service Manual Issue 7 (August 04) 5 — 11

Case repairs

Smiths Medical International Ltd.

Table 5.3 Front case spares kit

Description Part No. Remarks

Front case spares kit (English) 0131-0274

Label,front panel (English) 0131-0007

Front case spares kit (other) 0131-0177

Label,front panel (Other) - See

Case front 0131-0150

Syringe clamp assembly* 0131-0149

Button, moulded* 0131-0216 2 off

Instruction leaflet 0131-0156

Size sensor flag spares kit* 0131-0214 See

Foam spacer type 3* 0131-0218 2 off

Case templates* 0131-0235 2 off

Radius gauge,* stainless steel 0131-0234

Case screws, M4x12, pozi pan 5001-0345 6 off

Figure 7.1

Table 5.3

*These items may be obtained individually.
Note:

The Front panel membrane is Country dependent and is supplied,

separately (see

The English front panel mambrane is supplied with the front case

spare kit (part number 0131-0274).

Table 5.4 Size Sensor Flag spares kit

Description Part No. Remarks

Size sensor flag spares kit* 0131-0214

Size Sensor Flag moulding 0131-0135

Size sensor shim (0.6 mm thick)* 0130-0107

Size sensor shim (1.0 mm thick)* 0130-0108

Size sensor shim (1.2 mm thick)* 0130-0190

Size sensor shim (1.4 mm thick)* 0130-0185

Screws, No. 4 x 5/8 ins. Self tap 5017-3410 2 off

Grub screw, M4 x 6, nylon* 0131-0144

Tamper proof protective cap* 0131-0136

Instruction leaflet 0131-0217

Figure 7.1, item 3

).

*These items may be obtained individually.

5 — 12 Issue 7 (August 04) 3100 Service Manual

Smiths Medical International Ltd.

Table 5.5 Rear case spares kit

Description Part No. Remarks

Rear case spares kit* 0131-0185

Case, rear, modified 0131-0276

Foam spacer type 1* 0131-0204

Foam spacer type 2* 0131-0205 3 off

Rubber foot* 0126-0028 2 off

Catch,button 0128-0117

Strip, retaining 0128-0118

Case screws, M4x12, pozi pan 5001-0345 6 off

Screw, M3x10, pozi pan csk 5000-6317

Screw, M3x6, slot pan 5000-6112

Instruction leaflet 0131-0156

.

* These items may be obtained individually

Note:

The Case rear label is Country dependent and can also be supplied,
e.g. 0131-0137, English, 240 V

3100 Service Manual Issue 7 (August 04) 5 — 13

CHAPTER 6

FUNCTIONAL TESTS

Graseby 3100
Syringe Pump

Smiths Medical International Ltd.

Functional tests

CHAPTER 6

FUNCTIONAL TESTS

The functional tests have been designed to verify that the 3100 is safe to use. Com­plete the following tests before putting the pump into service for the first time, and then
as required.

Table 6.1 Functional testing of 3100

Step Test Method Correct result

1 Mechanical Before applying AC power, No visible damage.

inspection check that the case

and exposed mechanical parts
are free from any damage.

2 Electrical safety For routine electrical safety testing, Smiths Medical recommends that units are

test tested in accordance with the UK Medicine and Healthcare products Regulatory Au-

thority (MHRA) guideline document MDA DB9801, supplement 1 (December 1999)
for Class II, Type CF equipment as a minimum.

3 Initial power ON Connect the AC supply. The AC LED lights.

Press the ON button. All LEDs are briefly illuminated, the alarm

briefly sounds and the STOP and AC
LED’s will remain on. The last set up
mode infusion rate will be displayed.
If a syringe is fitted the associated syrin­ge size LED will remain on.

4 Syringe size Perform with plunger clamp 40 mm

sensors from RHS and also at extreme LHS.

Insert the following test rods
(consecutively) in the syringe cradle:

20.50 mm diameter rod. Invalid syringe condition.

21 and 22.9 mm diameter rod. 20ml LED illuminated.

23.70 and 26.2 mm diameter rod. 30ml LED illuminated.

28.5 and 33.1 mm diameter rod. 50/60ml LED illuminated.

Note:

Smiths Medical manufacture a set of Syringe Size gauges,
The Smiths Medical Customer Care Department is able to take orders for these gauges and will supply the
current price. This set of gauges enables test No. 4 to be carried out on all the Graseby 3000 Series of
pumps.

part number 0131-0202

(see Appendix, page A-5).

(contd.)

3100 Service Manual Issue 7 (August 2004) 6 - 1

Functional tests

Table 6.1 Functional testing of 3100 (contd.)

Step Test Method Correct result

5 Operation of With the pump still ON, press The display goes blank, but the AC LED

Membrane the OFF button. remains lit.
switch panel
buttons Press the ON button. As in Step 3 (initial power ON).

Smiths Medical International Ltd.

Check that the pump can be The display alters according to the
programmed by pressing the up ▲
and down rate infusion buttons
(▲ ▼), as described in the
Instruction Manual (IM).

Check that the two totalizer The display button enables the
buttons operate correctly as volume infused since initial START
detailed in the IM. infusion, or reset, to be displayed.

Check that the PURGE button ALARM and START LEDs flash
when pressed twice carries out a and the alarm beeps. The display
purge as detailed in the IM. shows total delivery up to a

Fit a syringe and move the plunger The syringe size is briefly displayed;
clamp to the closed (forward) position. the pump starts the infusion with the
Then press the START button. START LED flashing and the running

Press the STOP button. The pump reverts to its set up mode.

▼

button pressed (see IM).

The reset button resets the displayed
infused volume to zero.

maximum of 2 ml of purge.

indication arrows on the display
also flashing.

(contd.)

Press the START button, then The ALARM sounds intermittently;
move the plunger clamp to the the ALARM LED flashes,
open (back) position. and CLAMP OPEN is displayed.

Press the ALARM button. The alarm is silenced and the

pump reverts to its set up mode.

6 - 2 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

Table 6.1 Functional testing of 3100 (contd.)

Step Test Method Correct result

6 AC power failure With syringe inserted press the The alarm sounds intermittently;

START button to start an infusion, AC MAINS FAIL is displayed
then switch off the AC supply (also intermittently) and the pump
externally. continues running under battery power.

Switch on the AC supply. The AC LED lights.

7 Linear accuracy Set the pump for a 60 ml BD Check that the plunger clamp

syringe to deliver 99.9 ml/hour moved a distance of 18 ±0.3 mm.

Note: Use the linear and close the plunger clamp at See also page 6-5.

accuracy gauge 60 ml position.
(see page 6-5) Run PURGE in order to remove any

backlash, then run an infusion for
exactly six minutes.

8 Occlusion The occlusion thrust is set by Refer to Chapter 2 for the occlusion

thrust applying an opposing force thrust checks and adjustment procedures.

to the plunger clamp. This is
achieved by using weights
(see Chapter 2).

Functional tests

9 Plunger clamp Close the clamp at mid-position. Front edge of clamp must be between 8

alignment Run an infusion of at least 99.9 ml/h. and 10 mm above surface of top cover

After 5 seconds check clamp position. See also page 6-5.

Note:

If this test fails, the super nut must be loosened. This allows the plunger clamp to be manipulated up or down a
small distance, thus enabling the required 8.0 to 10 mm gap to be achieved.

10 Plunger clamp Load a syringe and set an infusion The alarm ...

open, leadscrew rate. Open the plunger clamp. CLAMP OPEN
disengaged Press START. must be activated.

11(i) Syringe Using a BD 60 ml syringe, set the Before the end of travel, check that

NEARLY EMPTY pump for a 199.9 ml/hour infusion, the message...
and syringe set the plunger clamp approx. 5 ml NEARLY EMPTY appears and at end
EMPTY before end of travel; start an infusion of the plunger travel an
warnings and run to end of plunger travel. EMPTY/OCCLUSION alarm

occurs and the pump stops.

11 (ii) Syringe warnings, Set the pump for a 100 ml/hour At about 7 ml before the end of travel

<3 mins to END, infusion; set the plunger clamp check that an intermittent alarm and
END (KVO = .5) approximately 15 ml before end the message... < 3 mins to END

of travel. Start an infusion. appears, and at approx. 2 ml from the

end, a continuous alarm sounds and the
following message appears...

END (KVO = .5)

Note:

When carrying out test No. 11 (ii) on a Perfusor pump, ensure that the syringe is set to a minimum of 18 ml.

12 Plunger clamp If the pump is fitted with the older style half nut (see page 5-10), the Plunger clamp

alarm tests alarm tests should be performed (see page 6-4).

3100 Service Manual Issue 7 (August 2004) 6 - 3

New square style flag

Notch

Old ramp style flag

Plunger clamp alarm checks

Smiths Medical International Ltd.

Plunger
clamp alarm
checks

Ramp check
procedures

The following plunger clamp alarm checks are only required on pumps fitted with the old
style half nut, and not the more recent super nut (see page 5-10).

The dual ramp gauge (

part number 0131-0084

) is used to check that the ...

PLUNGER CLAMP OPEN

alarm is operating correctly when the plunger clamp is set to two alternative infusing
positions, as shown below:

POSITION 2
L.H. RAMP

GM1086-A

POSITION 1
R.H. RAMP

Figure 6.1 Outline of dual ramp gauge

1. Fit the dual ramp gauge onto the pump.

2. Close the plunger clamp at a position that is just clear of the bottom end of the right
hand ramp.

3. Set the pump to infuse at a rate of 199.99 ml/h and press the START button.

4. Check that during the first 30 seconds of travel (as the leadscrew is fully engaged), that
the plunger clamp remains clear of the ramp.

5. Check that as the plunger clamp runs up the right hand ramp a ...

PLUNGER CLAMP OPENED

alarm occurs within 10 minutes of pressing the START button.

6. Repeat the above check with the plunger clamp placed just clear of the left hand ramp.

If the pump fails the ramp gauge checks (on the earlier manufactured pumps) it is
recommended that the half nut is changed for a super nut (see page 5-10). Also ensure that
the three following modified items have been fitted:

1. A new style square shaped flag (

part number 0127-0019

, as shown below) in place of

the old style flag.

2. A new style shaft bracket (

part number 0127-0052

, as shown below). This bracket is

identified by a ‘V’ notch that appears on one of the prongs.

3. Two new thicker washers (

part number 5014-3020

) in place of the previously fitted

thinner washers that are used for fixing the opto sensors board.

Figure 6.2 Size sensor flags

6 - 4 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

20

30

40

60

50

ml

10

GM1209-A

LOCKING SCREWLOCKING SCREW

MODIFIED SYRINGEMODIFIED SYRINGE

METAL ROD

DISTANCE INDICATORDISTANCE INDICATOR

ROTARY ZEROING DIALROTARY ZEROING DIAL

Linear accuracy

Linear accuracy

Test procedures

The linear accuracy gauge (

Figure 6.3, part number 0131-0230

) when placed on the
pump, is able to check that the pump's plunger clamp moves a given distance in a
specified time. Initially, the pump will have been preset to given parameters, then
set to run for a specified time and the distance that the plunger moves being
observed on the measurement dial of the gauge.

Figure 6.3 Linear accuracy gauge

Test No. 7, see page 6-3

1. Place the gauge onto the pump with the syringe plunger almost fully extended.

2. Move the pump's plunger clamp to the left until the gauge plunger is a short

distance away from the metal rod that activates the dial indicator.

Plunger clamp
alignment

Test procedures

3. Turn the pump on and check that the pump shows that the syringe brand and

size is BD 60 ml.

4. Press the PURGE key until the syringe plunger just activates the gauge

indicator. This action will ensure that any pump backlash is removed.

5. Rotate the outer rim of the gauge to set both dial indicators to zero.

6. Set the pump to deliver an infusion at 99.9 ml/hour.

7. Run the pump for exactly 6 minutes and check that the gauge dial records that

the plunger has moved between 17.7 and 18.3 mm.

The taper gauge (

Figure 6.4

) enables the gap between the pump's plunger clamp and
the case to be measured accurately. This measurement is important as it ensures
that the plunger clamp will engage onto the flanges of the smaller sized syringes
correctly.

1098 11 13

GM1210-A

Figure 6.4 Taper gauge

Test No. 9, see page 6-3

1. Switch the pump on and set the rate to at least 99.9 ml/hour.

2. Close the plunger clamp at approximately its mid position.

3100 Service Manual Issue 7 (August 2004) 6 - 5

3. Run the pump for 5 seconds.

4. Using the taper gauge check that the front edge of the plunger clamp is

between 8.0 mm and 10.0 mm above the surface of the case.

CHAPTER 7

ILLUSTRATED PARTS LIST

Graseby 3100

Syringe Pump

Smiths Medical International Ltd.

CHAPTER 7

ILLUSTRATED PARTS LISTS

Figure 7.1 General assembly

Item Description Part number Remarks

1 Front case spares kit, 0131-0177

Kit contains: Front case, Syringe barrel clamp assembly, Moulded buttons (x2),
Foam spacers (x2), Size sensor flag spares kit and Instruction leaflet.

Front case spares kit (English only) 0131-0274

Kit contains: Front case, Syringe barrel clamp assembly, Moulded buttons (x2),
Foam spacers (x2), Size sensor flag spares kit, Front panel label (English),
Instruction leaflet.

2 Rear case spares kit, 0131-0185

Kit contains: Rear case (modified), Foam spacers (x4), Rubber feet (x2), Screw, M3x10,
Screw M3x6, Screw, case M4x12 (x6), Cable clamp, Button catch, Retaining strip,
Instruction leaflet.

Illustrated parts list

3 Membrane switch panel:

- UK, Australian, Dutch 0131-0007

- French 0131-0024

- Italian 0131-0036

- Spanish 0131-0099

- German 0131-0055

- Portuguese 0131-0103

4 Rear panel instruction label: see table below

IMPORTANT: When ordering a CE marked rear label, please supply the serial number
details of the Syringe Pump, if this information is not supplied then a Non-CE marked
label will be issued. It is the responsibility of the owner to ensure that the correct
labels are replaced on the pump.

3100 pump Non CE CE marked CE marked
model number marked Made in UK Made in Malaysia

serial no's serial no's serial no's
below 45643 from 46035 from 90000

to 89999

0131-0001, English 240V 0131-0137 0131-0008 0131-0283

0131-0001, English (euro plug) 0131-0137 0131-0008 0131-0283

0131-0701, English 110V 0131-0194 0131-0023 0131-0284

0131-0703, French 0131-0195 0131-0025 0131-0286

0131-0704, Italian 0131-0196 0131-0037 0131-0287

0131-0705, Spanish 0131-0198 0131-0100 0131-0288

0131-0707, German 0131-0197 0131-0056 0131-0285

0131-0709, Dutch 0131-0199 0131-0097 0131-0289

0131-0714, German (Perfusor) 0131-0197 0131-0056 0131-0285

0131-0719, Portuguese 0131-0200 0131-0104 0131-0290

0131-0721, English without plug 0131-0137 0131-0008 not available

0131-0740, Australian 0131-0137 0131-0008 0131-0283

3100 Service Manual Issue 7 (August 2004) 7 — 1

Illustrated parts list

Figure 7.1 General assembly (contd.)

Item Description Part number Remarks

5 Case screws 5001-0345 6 off

6 Motor and gearbox assembly 0131-0015

7 Leadscrew assembly see

8 Oil shim 0127-0084

9 Occlusion sensing assembly 0131-0067

10 Support tube 0127-0047

11 Plunger clamp assemblies - see

12 Near empty flag kit 0131-0122 2 types of flag

13 Syringe barrel clamp assembly 0131-0149

14 Size sensor flag retainer kit, 0131-0238

Kit contains: Anchor plate assembly and Size sensor spring.

15 Bearing clamp bracket 0127-0053

16 Leadscrew bearing bracket 0127-0051

17 Square shaft bracket 0127-0052

18 Main board assembly 0131-0009 see

19 Regulator board assembly 0128-0013 see

20 Transformer: AC power 0127-0030

21 Opto sensors board:

- Current version: 6 - pin 0128-0090

- Early version: 5 - pin 0127-0015

22 Opto sensor cable:

- Current version: 6 - way 0053-0670

- Early version: 5 - way 0053-0655

23 Size sensors board 0131-0032

24 Pole clamp assembly

- Non-rotating pole clamp 0131-0129 see

- Rotating pole clamp 0131-0083 see

25 Plunger clamp open flag 0127-0019

26 Mains cable assembly, internal: two wire 0053-0646

27 Power cable assembly kit, 0131-0242

Kit contains: Power cable assembly and Header

28 Battery - Cyclon

29 Cable assembly battery A 0053-0647

30 Cable assembly battery B 0053-0648

31 Cable assembly battery C 0053-0649

32 Cable clamp 0127-0043

(was P/N 3420-2120)

Smiths Medical International Ltd.

Figure 7.4

Figure 7. 2

supplied

Figure 7.5
Figure 7.6

Figure 7.3a
Figure 7.3b

0151-0650 3 required

7 — 2 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

General assembly

3100 Service Manual

Issue 7 (August 2004)

Figure 7.1 General assembly

7 — 3

Smiths Medical International Ltd.

Issue 7 (August 2004)

3100 Service Manual7 — 4

Smiths Medical International Ltd.

Illustrated parts list

General assembly of the 3100 (continued)

Item Description Part number Remarks

33 Cordset - AC power:

- UK 3700-0046 UK plug

- 110 V (USA) 3700-0230

- French, Spanish, German, Portuguese 3700-0035

- Italian, UK - without plug 3700-0025

- Dutch 3700-0044

- Australian 3700-0056

34 Instruction Manual: Not illustrated

- English 0131-0018

- French 0131-0050

- Italian 0131-0047

- Spanish 0131-0102

- German 0131-0059

- Dutch 0131-0098

- Portuguese 0131-0106

35 Technical Service Manual 00SM-0131 Not illustrated

36 5/10 ml adaptor plate 0132-0076 Germany only

37 Braun Perfusor 50 ml conversion kit 0131-0048 Not illustrated

Kit contains: Perfusor spacer tube, nearly empty flag for Perfusor,
Plunger clamp plate, ‘P’ label.

38 Size sensor gauge set, 0131-0202 Not illustrated

Kit contains: 18 size sensor gauges and Instruction leaflet for calibration

39 Linear accuracy gauge 0131-0230

40 Taper gauge 0131-0227

41 Dual ramp guage 0131-0084 Not illustrated

42 Security cover kit, 0131-0151 Not illustrated

Kit contains: Pole clamp assembly, Syringe cover, Cover pin bearings (x2),
Cover pins (x2), Compression rings (x2), Circlips (x2), Torx screws (x2),
Retaining strip, Button catch, Drilling template, Loctite 638(3ml),
Screw M3x6 pan slotted, Screw M3x10 csk. pozi and Modification instructions.

Figure 5.1
Figure 5.2

3100 Service Manual Issue 7 (August 2004) 7 — 5

Illustrated parts list

Smiths Medical International Ltd.

Figure 7.2 Plunger clamp assemblies

Item Description Part number Remarks

1 Plunger clamp and tube 0127-0044

2 Plunger clamp cover and internal kit, 0131-0239

Kit contains: Plunger clamp cover, Plunger clamp lock, Plunger clamp pin, Plunger clamp
conical spring and Plunger clamp finger spring.

3 Half nut casting 0131-0042 See

4 Toggle moulding 0127-0026

5 Toggle glide moulding 0127-0027

6 Toggle spring 5752-0010

7 Size sensor flag spares kit, comprising: 0131-0214

Kit contains: Size sensor flag moulding, Protective cap, Grub screw M4 x 6,
Size sensor shim, Size sensor moulding and Instruction leaflet.

8 Square shaft 0127-0048

Figure 7.4

Figure 7.2 Plunger clamp assemblies

7 — 6 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

Figure. 7.3a Pole clamp assembly: Non-rotating

Item Description Part number Remarks

Pole clamp assembly (new version) 0131-0129

1 Pole clamp cap-knob 788098-2890-4

Illustrated parts list

Figure 7.3a Pole clamp assembly

3100 Service Manual Issue 7 (August 2004) 7 — 7

Illustrated parts list

Fig. 7.3b Rotating pole clamp assembly

Item Description Part number Remarks

Rotating pole clamp assembly 0131-0083

1 Securing plate 0131-0074

2 Locating ring 0127-0064

3 Handle 0127-0060

4 Pole clamp body 0131-0061

5 Crescent circlip 5030-5710

6 External circlip, type 7100-010 5030-4010

7 Spirol pin 3 x 26 5028-3408

8 Clamp pad kit, 0131-0052

Kit contains: Clamp bolt, Clamp pad, Spacer, End cap,

Screw M3 x 12, Instruction sheet.

Smiths Medical International Ltd.

Figure 7.3b Rotating pole clamp assembly

7 — 8 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

Figure 7.4 Leadscrew assembly

Item Description Part number Remarks

Leadscrew and half nut kit 0131-0236

Kit contains the following items: Leadscrew assembly, Half nut casting,
Near empty flag, Screw, Nut and Instruction sheet.

1 Half nut casting 0131-0042

2 Leadscrew assembly 0131-0119

3 Leadscrew coupling 0127-0074

Illustrated parts list

Figure 7.4 Leadscrew assembly

3100 Service Manual Issue 7 (August 2004) 7 — 9

Illustrated parts list

Smiths Medical International Ltd.

Figure 7.5 Main board assembly

Item Description Part number Remarks

Main board assembly 0131-0009

1 Sounder PKB5-3BO 3430-1205

2 Sounder restraint kit, comprising: 0131-0240

Nut M3 (x2), screw M3x16 (x2) and Pillar (x2).

3 IC5, Programmed EPROM 0131-0030

4 Display module (LCD) 0131-0011

5 IC7, Slave processor 0131-0016

6 IC4, MC68HC11F1FN (initialised) 0131-0072

7 — 10 Issue 7 (August 2004) 3100 Service Manual

Smiths Medical International Ltd.

Illustrated parts list

131-009 ISS.

R52

PL7

Q18

D37

D20
D19
R40
R22

R23
R24
R25

C14

R80

D38

1

R1

R41
R44

PL4

R78

Q12

1

R51

R50

R58

D24
D25
D26

D21

R69

R55

R70

C20
C21
C22

R56

C25
D3
R7
R8

Q3

R9

S1

D1

Q14

2

IC6

GM0133-B

R65

D40

4

D39

R81

Q19

L6
L3

C3

IC1

C7

+

C11

L1

R10

R18

R79

C31 C32

Q10Q7 Q8 Q9

D10
D9
D8
D7

C15

C16

R61

PL2

Q1

PL1

Q11

C27

L2

R28

C26

PL6

1

IC4

1

PL3

R14

C12

IC3

C8

C29

Q5

R16

R17

R67

R26

R27

R66

R62
R63

PL5

D36
D35

D34
D33
D14
D32
D13

1

D31

L4

D12

L5

D30
D11
D29

R75

C1

C2

1

R29

C19

C13

D5

D6

Q4

Q6

R21

R20

D4

R19

R3
R2
R64
D2

D22

D23

R42

R45

R46
R43

C24

Q15

Q16

R13

D28

C5

R6

Q2

IC2

R4

+

C4

R5

C6

R77
R76

IC7

X2

R30

C17

C23

R12

R31

Q13

C18

C28

R15

C10

C9

R11

X1

5

6

R53

R54

D27

R68

IC5

3

Figure 7.5 Main board assembly diagram

3100 Service Manual Issue 7 (August 2004) 7 — 11

Illustrated parts list

Smiths Medical International Ltd.

Figure 7.6 Regulator board assembly

Item Description Part number Remarks

Regulator board assembly 0128-0013

1 Fuse cover 5346-2010

2 FS1, Fuse 500 mA 5 x 20 mm 3410-3002 UL - Bussmann GMA

3 FS2,

- Fuse 50 mA 5 x 20 mm - 240 V 3410-1305

- Fuse 50 mA 5 x 20 mm - 110V

4 FS3, Fuse 1 A 5 x 20 mm 3410-3703 UL - Bussmann GMA

4

GM0098-B

R8

R1

RV1

R11

C6

D1

PL11

R3

R5

1

2

FS1

L2

R9

R2

R10

IC1

D3

C7

FS3

TH1 PL12

C2

Q3

Q2

C4

R4

1

R13

+

C5

C3

D5

R12

128-013
ISS

R7

L1

Q1

D2

D4

D6

D8

YEL

PL5

YEL

PL6

D7

1, 3

N

PL2

FS2

PL1

L

BLU

BLK

120V

C1

230V

PL8

PL4

GRY

230V

PL10

+

PL3

BRN

120V

PL9

PL7

(120V)T100 mA

(230V)T50 mA

Figure 7.6 Regulator board assembly

7 — 12 Issue 7 (August 2004) 3100 Service Manual

CHAPTER 8

BRAUN PERFUSOR CONVERSION

Graseby 3100
Syringe Pump

Smiths Medical International Ltd.

CHAPTER 8

BRAUN PERFUSOR CONVERSION

Syringe conversion procedures

Braun Perfusor conversion

Introduction

Nearly empty flag

Spacer tube fitment

Plunger clamp
plate

The 3100 can easily be converted, if required, in order to use the Braun Perfusor 50 ml
syringe. The Perfusor conversion kit, p
The conversion procedures are detailed below and shown in

Open the pump case (see page 2-3) and remove the standard flag from the top of the
half nut (retain the standard flag for possible future use). Fit the elongated Perfusor
50 ml nearly empty flag by inserting the flag into the grooves on the half nut (see

Figure 8.1

the direction of the arrow, as shown in

Note:

Carefully lift up the left hand end of the inner metal tube and fit the nylon spacer tube
over the inner tube. The spacer tube acts as an end of travel stop when the half nut
assembly moves to the left.

Fit the self adhesive half-round plunger clamp plate to the left hand side of the plunger
clamp. It must be fitted to the vertical face of the plunger clamp so that it covers both
quadrant vanes (see

). Ensure that the flag is fitted so that the small amount of flag bias is in

If not already biassed, bend/bias the end of the flag in the direction of the arrow
shown in
flag (when it moves to the left) does not touch the left hand post of the rear
case.

Figure 8.1

Figure 8.1

a distance of approximately 2 mm, this will ensure that the

).

art number is 0131-0048

Figure 8.1

Figure 8.1

.

.

.

Braun Perfusor
selection

‘P’ label fitment

Reassemble the case as detailed on page 2-3.

The Braun Perfusor 50 ml syringe is selected for use (on the pump) by using a special
configuration command.

First select the Configuration mode (see page 2-1) and then select the syringe brand
display.

Simultaneously press the following three buttons:

ALARM, PURGE and OFF.

The pump will then switch to the Braun Perfusor syringe mode and other syringe brands
will automatically be disabled The pump syringe display will show:

PERFUSOR 50 ml

and the

Fit the self adhesive ‘P’ label to the front of the pump in the area just above and to the
right of the product name (see
pump must only be used with the Braun Perfusor syringe.

▲▲

▲ adjust button, whilst in this mode will be ineffective.

▲▲

Figure 8.1

). This label acts as a visual reminder that the

3100 Service Manual Issue 7 (August 2004) 8 — 1

Braun Perfusor conversion

3100

Reselecting ‘various’ syringe brands

To reselect the various syringe brands, complete the following mechanical and
programming procedures:

Smiths Medical International Ltd.

Mechanical
procedures

Programming
procedures

1. Take the case apart (see page 2-3).

2. Replace the original standard nearly empty flag.

3. Remove the nylon spacer from the left hand side of the inner metal tube.

4. Remove the adhesive plunger clamp plate.

5. Reassemble the case.

6. Remove the adhesive ‘P’ label from the front of the pump.

1. With the pump switched on and

PERFUSOR 50 ml

displayed within the Configuration mode (see page 2-1), simultaneously press
the following three buttons:

ALARM, PURGE and OFF

in order to set the Configuration mode so that the various brands of syringe may
be selected.

2. Set the pump to the brand of syringe that is going to be used and then press the
STOP button in preparation for the next infusion.

20ml

30ml

P

Graseby

SyringePump

50/60ml

Adhesive
plunger
clamp plate

Adhesive
label

Nearly
empty
flag

Nylon
spacer
tube

Flag
bias

GM0243-B

Figure 8.1 Braun Perfusor conversion: parts required

8 — 2 Issue 7 (August 2004) 3100 Service Manual

APPENDIX

FITTING a MODIFIED SIZE SENSOR FLAG

Graseby 3100
Syringe Pump

Smiths Medical International Ltd.

APPENDIX

FITMENT of NEW MODIFIED SIZE SENSOR FLAG (SSF)

Appendix

INTRODUCTION

In a continual and ongoing programme of improvements Smiths Medical engineers have
recently introduced a modified Syringe Size Flag (SSF, see
that allows the size sensor mechanism to be accurately aligned.

This appendix will enable a qualified Technician to carry out the fitment of the new SSF; the
appropriate sized shim/s, and to carry out the final test procedures.

The SSF and shims required to modify the 3100 pump are supplied in kit form (

0131-0214

The spares kit includes the following:

• SSF,

• 0.6 mm thick shim,

• 1.0 mm thick shim,

• 1.2 mm thick shim,

• 1.4 mm thick shim,

• Screws, No. 4 x 5/8 inch, self-tap, 2 off,

• M4 x 6 nylon grub screw,

• Tamper proof protective cap,

).

part number 0131-0135

part number 0130-0107

part number 0130-0108

part number 0130-0190

part number 0130-0185

part number 0131-0144

(see

Figure A.1

part number 0131-0136

)

part number 5017-3410

Figure A.1

) for the 3100 pump

part number

• Instruction leaflet,

The screws, washers and associated items that are removed during the disassembly of the
pump are required during reassembly.

part number 0131-0217.

Part Number
0131-0135

3100 Service Manual

GM1109-A

Figure A.1 New modified Syringe Size Sensor flag

Issue 7 (August 2004)

Page A-1

Appendix

Smiths Medical International Ltd.

WARNINGS:
When a new SSF has been fitted to a 3100 pump, the pump must be tested using the
Syringe Size Sensor gauges available from Smiths Medical (
Page A-3 gives details of the Final Testing procedures required.

Ensure that the AC mains supply is switched off and the pump's AC connector is
removed before separating the case halves.

CAUTION:
During the removal and replacement of a pump's components, strict observance to
Electro Static Discharge (ESD) rules must be observed at all times, i.e. an earthing
strap must be worn. Failure to apply ESD protection may result in damage to the
pump, resulting in its malfunction.

part number 0131- 0202

).

OPENING THE
CASE

FITMENT OF
MODIFIED SSF

1. Using a scratch-free flat surface, turn the pump over to gain access to the
base of the pump.

2. Undo the six screws that hold the halves of the pump cases together.

3. Place the pump upright and from the top carefully ease the casing halves apart, taking
care not to put any strain on the internal connecting cable looms that form a hinge
between the halves of the case.

1. With the pump case open as detailed above, disconnect the long thin spiral spring
from its slot in the SSF.

2. Remove the large half-nut screw, and then prise the half-nut apart and remove it from
the support tube.

3. Lift the SSF and support tubes assembly up and away from the pump.

4. Remove the existing SSF by sliding it to the left, over and away from the small
diameter support tube. Fit the new modified SSF.

5. Refit the half-nut screw and refit the support tube assembly to the pump.

6. Refit the spiral spring.

7. Displace the size sensor assembly by removing the two screws that hold it in position.

Page A-2

8. Remove any shim/s that were attached to the size sensor opto moulding. If required,
clean the shim area with a suitable solvent. The shim sizes provided in the kit are

0.6, 1.0, 1.2 and 1.4 mm. If necessary, use a combination of shims to obtain the
thickness required, up to a maximum of 2.4 mm. During production a 0.6 mm shim is
initially fitted to the pump.

(continued)

Issue 7 (August 2004)

3100 Service Manual

Smiths Medical International Ltd.

9. Using the two fixing screws, refit the sensor assembly to the pump.

10. Taking care not to trap any leads assemble the casing ensuring that the two case
halves have snapped together and that the front and rear mating edges are equal and
parallel. The six case screws should be tightened to a torque of between 70 and 75
cNm in the order shown below:

Appendix

FINAL TESTING

GM0595-B

1

5

3

4

2

6

Figure A.2 Case fixing screw tightening order

When a new SSF has been fitted, the appropriate Functional Tests given in Chapter 6 must
be completed.

Before starting the syringe size sensor tests, ensure that the pole clamp are correctly fitted
and the six securing screws fully tightened (see

Figure A.2

).

The Syringe Size Sensor tests are performed with the pump's plunger clamp at the following
two positions:

1. 40 mm from the right-hand side of the plunger clamp travel, and

2. at the extreme left-hand side of the plunger clamp travel.

The pump must be configured during the tests to operate with the ‘BD Plastipak’ syringe.

The small grub screw in the SSF must be correctly set (see

Figure A.3

) before carrying out
the Syringe Size Sensor tests. The small anti-tampering cap above the grub screw must
then be fixed into place using a minimal amount of Loctite 414.

3100 Service Manual

Issue 7 (August 2004)

Page A-3

Appendix

Setting the size sensor flag

1. Using the 3100 size sensor test gauges (see page A-5), fit the white 20 ml minimum

2. Depending upon the type of pump being set-up, if either the 20ml LED is illuminated,

3. Turn the grub screw slowly clockwise until the LED/ display illuminates or appears,

Smiths Medical International Ltd.

sensor gauge (
(b) occurs:

a. If the pump indicates that a 20 ml gauge is fitted, complete steps (2) to (5).

b. If no indications are given, complete steps (6) to (8).

or the display shows 20, rotate the grub screw counter-clockwise until the
corresponding LED/ display is extinguished or disappears.

indicating that a 20 ml syringe is fitted.

part number 0131-0170

) into pump's cradle and observe whether (a) or

4. At position X (see
release the SSF several times and ensure that when the SSF returns to it's rest
position, it

Note: It is acceptable that while the SSF is under force, the size of the syringe displayed
alters. However, it must always return to the original 20ml size displayed when the force is
released.

5. If the pump does toggle between different syringe sizes, turn the grub screw
slightly clockwise and complete step (4) again until the 20ml LED/ display is stable.

always

Figure A.3 Size Sensor Flag, general details

displays that a 20ml syringe is present.

), alternately press and

very

Procedures if (b) above occurs

6. Depending upon the type of pump being set-up, if the 20ml LED is not illuminated, or

the display does not show 20, rotate the grub screw slowly clockwise until the LED/
display illuminates or appears indicating that a 20 ml syringe is fitted.

7. At position X (see
release the SSF several times and ensure that when the SSF returns to it's rest
position, it

Note: It is acceptable that while the SSF is under force, the size of the syringe displayed
alters. However, it must always return to the original 20ml size displayed when the force is
released.

8. If the pump does toggle between different syringe sizes, turn the grub screw
slightly clockwise and repeat step (7) until the 20ml LED/ display is stable.

always

Figure A.3 Size Sensor Flag, general details

displays that a 20ml syringe is present.

), alternately press and

very

Page A-4

Apply a small amount of Loctite 414 to the anti-tampering grub screw cap and fit it.

When the grub screw in the SSF has been set, the remaining procedures required to
complete the size sensor testing may be completed. Press and release the SSF each
time a new gauge is placed in the pump's cradle.

Issue 7 (August 2004)

3100 Service Manual

Smiths Medical International Ltd.

Apply a small amount
of loctite 414 to the
security cap

Apply a small amount
of loctite 7400 to the
thread of the grub screw
prior to setting

GM1111-A

Appendix

X

Figure A.3 Size Sensor Flag: general details

The Smiths Medical Size Sensor Gauge set (

part number 0131-0202

), contains the seven
gauges that allow the Size Sensor tests on the 3100 to be carried out. The seven gauges
required are listed in

Table A.1

.

Table A.1 3100 Syringe Size Sensor Gauges (black)

PART No. GAUGE DIA. (mm) CORRECT RESULT

0131-0158 20.50 No LED lit

0131-0159 21.00 - min. 20ml LED lights

0131-0160 22.90 - max. 20ml LED lights

0131-0161 23.70 - min. 30ml LED lights

0131-0162 26.20 - max. 30ml LED lights

0131-0163 28.50 - min. 50ml LED lights

0131-0164 33.10 - max. 50ml LED lights

3100 Service Manual

Issue 7 (August 2004)

Page A-5

The details given in this Manual are correct at the time of going to press. The company, however, reserves the right to improve
the equipment shown.

For further information, please contact your local distributor or Smiths Medical direct on [phone]

Smiths Medical International Ltd.Smiths Medical International Ltd.

Smiths Medical International Ltd.

Smiths Medical International Ltd.Smiths Medical International Ltd.
Colonial Way, Watford, Herts, UK, WD24 4LG
Telephone: [phone], Facsimile: [phone]
http://www.smiths-medical.com

Part No. 00SM-0131 Issue 7

August 2004

© 2004 Smiths Medical International Ltd.

Smiths Medical International - A subsidiary of
Smiths Group plc