Graseby 3200
In-line Pressure
Syringe Pump
INFUSION RATE=
200.0 ml/h
Technical Service
Manual
0473
Part Number 00SM-0130-5
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 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 LIMITED,
COLONIAL WAY,
WATFORD,
HERTFORDSHIRE,
UNITED KINGDOM,
WD24 4LG
Copyright and address
TEL: (+44) (0)1923 246434
FAX: (+44) (0)1923 231595
http/www.smiths-medical.com
Registered in England. Company number 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.
3200 Service Manual
Issue 5 (August 2004)
Page i
Issue record
Smiths Medical International Ltd.
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Page ii
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
LIST OF CONTENTS
Copyright and address ...................................................................................... i
Warnings and cautions ..................................................................................... x
Abbreviations used ......................................................................................... xiii
CHAPTER 1
INTRODUCTION, FEATURES AND SPECIFICATION
Introduction ................................................................................................... 1-1
Security cover ....................................................................................... 1-1
Features .................................................................................................... 1-3
Micro-controller ............................................................................................. 1-3
Specification .................................................................................................. 1-4
AC power supply ................................................................................... 1-4
Battery type ........................................................................................... 1-4
Battery life ............................................................................................. 1-4
DC input operation ................................................................................. 1-4
Syringe brands and sizes ...................................................................... 1-4
Infusion rates and increments................................................................ 1-4
Mass unit programming range ................................................................ 1-4
Volume infused counter ......................................................................... 1-4
In-line occlusion pressure range ............................................................ 1-5
Internally adjustable occlusion pressure ................................................ 1-5
Factory set occlusion ............................................................................ 1-5
Display languages available................................................................... 1-5
Dimensions ........................................................................................... 1-5
Weight ................................................................................................... 1-5
Temperature range ................................................................................. 1-5
Drive accuracy ...................................................................................... 1-5
History ................................................................................................... 1-5
Electrical safety .................................................................................... 1-5
Design standards ................................................................................... 1-5
UK patent number.................................................................................. 1-5
Printer protocol ...................................................................................... 1-5
Brief history of the Smiths Medical bedside syringe pumps ...................... 1-6
Contents
Page
CHAPTER 2
CONFIGURATION, DIAGNOSTICS and OCCLUSION THRUST
Configuration mode ....................................................................................... 2-1
Entry into the Configuration mode ............................................................... 2-2
Available Configuration mode parameters and settings ............................. 2-3
3200 Service Manual
Introduction ............................................................................................ 2-1
Changing a setting ................................................................................. 2-2
Moving to the next parameter ................................................................ 2-2
Syringe brands ....................................................................................... 2-3
Syringe size ...........................................................................................2-3
Lock progam values ...............................................................................2-3
Issue 5 (August 2004)
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Contents
Smiths Medical International Ltd.
CHAPTER 2 (contd.)
Page
Max infusion rate ................................................................................... 2-3
Select pump modes ............................................................................... 2-4
Preset volume mode with time ............................................................... 2-4
KVO rate ................................................................................................ 2-4
Allow mass units option ......................................................................... 2-4
Infusion units ......................................................................................... 2-4
Show rate in ml/h while infusing ............................................................. 2-4
Use pressure transducer ........................................................................ 2-5
Display pressure bar graph .................................................................... 2-5
Allow bolus while running ....................................................................... 2-5
Allow rate change while running ............................................................. 2-5
Intermittent mode start delay ................................................................. 2-5
RS232 Baud rate ................................................................................... 2-5
Communication mode ............................................................................ 2-6
Pump ID ................................................................................................ 2-6
Set key beep volume .............................................................................2-6
Pressure units ....................................................................................... 2-6
End of menu .......................................................................................... 2-6
Diagnostic mode ............................................................................................ 2-7
Introduction ........................................................................................... 2-7
Entry into the Diagnostic mode .............................................................. 2-7
Moving to the next display ..................................................................... 2-7
Diagnostic displays ........................................................................................ 2-8
Software ................................................................................................ 2-8
Calibrate transducer ............................................................................... 2-8
Transducer alarm ................................................................................... 2-9
Battery voltage ...................................................................................... 2-9
Language ............................................................................................... 2-9
Number of faults .................................................................................... 2-9
Volume infused ...................................................................................... 2-9
Hours of use .......................................................................................... 2-9
Setting the clock .......................................................................................... 2-10
Entering the clock display ................................................................... 2-10
Disassembly and assembly of casing ......................................................... 2-11
Taking the casing apart ....................................................................... 2-11
Assembly ............................................................................................ 2-11
Occlusion measurements ............................................................................ 2-12
Thrust measurements .......................................................................... 2-12
Syringe stiction.................................................................................... 2-12
Thrust checks ..................................................................................... 2-13
Thrust adjustments .............................................................................. 2-14
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(contd.)
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Smiths Medical International Ltd.
CHAPTER 3
FUNCTIONAL DESCRIPTIONS
Introduction ................................................................................................... 3-1
Drive system .................................................................................................. 3-1
Introduction ........................................................................................... 3-1
Stepper motor and leadscrew ................................................................ 3-1
Microcomputer ....................................................................................... 3-1
Toggle mechanism ................................................................................. 3-1
Plunger clamp ....................................................................................... 3-2
Internal occlusion system ............................................................................. 3-2
In-line occlusion system ............................................................................... 3-2
Electro/mech control system ........................................................................ 3-3
Sensing (alarm) systems ............................................................................... 3-3
Introduction ........................................................................................... 3-3
End of infusion ...................................................................................... 3-3
Syringe nearly empty ............................................................................. 3-3
AC power failure .................................................................................... 3-3
Battery voltage low ................................................................................ 3-4
Self tests/pump malfunction .................................................................. 3-4
Drive disengaged or syringe not fitted .................................................... 3-4
Syringe sizing system ........................................................................... 3-4
Rate setting ........................................................................................... 3-4
Cannot zero extension set ..................................................................... 3-5
Cannot calibrate extension set .............................................................. 3-5
Communications (RS232) failure............................................................ 3-5
Software .................................................................................................... 3-5
Self tests ............................................................................................... 3-5
Design ................................................................................................... 3-5
Contents
CHAPTER 4
CIRCUIT DESCRIPTIONS
Introduction ................................................................................................... 4-1
Main board ................................................................................................... 4-1
Processor core ...................................................................................... 4-1
Motor interface ...................................................................................... 4-3
Power control ......................................................................................... 4-3
Sensors interface .................................................................................. 4-4
RS232 serial interface ........................................................................... 4-5
Umbilical connector ............................................................................... 4-5
Input/output serial interface ................................................................... 4-5
(contd.)
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Contents
CHAPTER 4 (contd.)
Status sensors ................................................................................................ 4-6
Syringe size sensors ..................................................................................... 4-9
Status sensors ................................................................................................ 4-9
Distribution board .......................................................................................... 4-9
Pressure sensing board ................................................................................. 4-9
Main board components ................................................................................ 4-9
Regulator board components ........................................................................ 4-9
Membrane switch panel ................................................................................. 4-9
‘D’ connector .................................................................................................. 4-9
CHAPTER 5
Smiths Medical International Ltd.
Page
PL 11 output .......................................................................................... 4-7
PL 12 output .......................................................................................... 4-7
Setting RV1 ........................................................................................... 4-8
FAULT CODES, CLEANING, RENEWAL of FUSES AND REPAIRS
Fault codes .................................................................................................... 5-1
Cleaning .................................................................................................... 5-4
Repairs .................................................................................................... 5-4
Renewal of fuses ................................................................................... 5-4
Access to fuses .................................................................................... 5-4
Main board renewal ................................................................................ 5-5
Regulator board renewal ........................................................................ 5-5
Status sensors board renewal ................................................................ 5-5
Plunger clamp and super nut assembly renewal .................................... 5-6
Pole clamp assembly renewal ................................................................ 5-6
Leadscrew assembly renewal ................................................................ 5-6
Motor and gearbox assembly renewal .................................................... 5-7
Occlusion clutch and disc assembly renewal......................................... 5-7
Membrane switch panel renewal ............................................................ 5-8
Super nut renewal .................................................................................. 5-8
Syringe size sensors assembly renewal ................................................ 5-9
Plunger clamp repair .............................................................................. 5-9
ACAM pressure sensing assembly renewal ........................................... 5-9
Batteries. Checks and replacement ............................................................ 5-10
Checks ................................................................................................ 5-10
Replacement ....................................................................................... 5-10
Front and/or rear case repairs .................................................................... 5-10
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(contd.)
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Smiths Medical International Ltd.
CHAPTER 6
FUNCTIONAL TESTS and MANUFACTURING SETTINGS
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
Manufacturing settings .................................................................................. 6-6
CHAPTER 7
ILLUSTRATED PARTS LISTS
General assembly .......................................................................................... 7-1
Contents
Page
Plunger clamp and half nut assembly ......................................................... 7-7
Pole clamp assembly: non-rotating .............................................................. 7-8
Pole clamp assembly: Rotating .................................................................... 7-9
Leadscrew assembly ................................................................................... 7-10
Main board assembly .................................................................................. 7-11
Regulator board assembly - AC Power ....................................................... 7-13
CHAPTER 8
BRAUN PERFUSOR CONVERSION
Syringe conversion procedures ................................................................... 8-1
Introduction .......................................................................................... 8-1
Nearly empty flag conversion ...............................................................8-1
Spacer tube fitment ............................................................................. 8-1
Plunger clamp fitment plate ................................................................. 8-1
Braun Perfusor selection ...................................................................... 8-1
‘P’ label fitment .................................................................................... 8-1
Reselecting ‘various’ syringe brands ...........................................................8-2
Mechanical procedures ........................................................................ 8-2
Programming procedures ..................................................................... 8-2
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(contd.)
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Contents
Smiths Medical International Ltd.
CHAPTER 9
Page
DC INPUT VERSION of 3200
Introduction ........................................................................................................... 9-1
DC electrical input supply ..................................................................................... 9-1
APPENDIX
FITTING a MODIFIED SIZE SENSOR FLAG
Introduction .................................................................................................. A-1
Opening the case .......................................................................................... A-2
Removal of old SSF ...................................................................................... A-2
Reassembly ...................................................................................................A-3
Final testing .................................................................................................. A-3
Setting the Size Sensor Flag ....................................................................... A-4
LIST OF TABLES
Table Page
4.1 RS232 D connector ......................................................................................... 4-5
4.2 PL11 connections ........................................................................................... 4-7
4.3 Temperature/voltage range for setting RV ........................................................ 4-8
5.1 Main processor fault codes ............................................................................. 5-1
5.2 Fault causes and actions ................................................................................ 5-3
5.3 Front case spares kit....................................................................................... 5-11
5.4 Size Sensor Flag spares kit ............................................................................ 5-11
5.5 Rear case spares kit ....................................................................................... 5-12
6.1 Functional tests .............................................................................................. 6-1
6.2 Manufacturing settings .................................................................................... 6-6
A.1 3200 Syringe Size Sensor Gauges (white) ...................................................... A-5
LIST OF FIGURES
Figure Page
1.1 Itemised front view of the pump...................................................................... 1-2
2.1 Case fixing screw tightening order ................................................................. 2-11
2.2 Thrust measuring set up ................................................................................ 2-13
4.1 Overall block diagram of the 3200 system ..................................................... 4-10
4.2 Main board block diagram .............................................................................. 4-11
4.3 Processor core circuit diagram ...................................................................... 4-12
4.4 Motor interface circuit diagram....................................................................... 4-13
4.5 Power control circuit diagram ......................................................................... 4-14
4.6 Sensors and pressure sensing interface ........................................................ 4-15
4.7 Pressure sensing interface circuit diagram .................................................... 4-16
4.8 RS232 interface circuit diagram ..................................................................... 4-17
4.9 Umbilical cable connections .......................................................................... 4-18
4.10 Input/output serial interface circuit diagram .................................................... 4-19
4.11 Overview of the regulator ............................................................................... 4-20
(contd.)
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LIST OF FIGURES (contd.)
Figure Page
4.12 Regulator live (primary) circuit diagram .......................................................... 4-21
4.13 Regulator isolated (secondary) circuit diagram ............................................... 4-22
4.14 Syringe size sensors circuit diagram ............................................................. 4-23
4.15 Status sensors circuit diagram ...................................................................... 4-23
4.16 Distribution board connections ....................................................................... 4-24
4.17 Pressure sensing circuit diagram ................................................................... 4-25
4.18 Membrane switch panel circuit ....................................................................... 4-26
4.19 Internal ribbon cable and ‘D’ connector connections ....................................... 4-26
5.1 Half nut (obsolete)/Super nut ........................................................................... 5-8
5.2 Strengthened front and rear case mouldings .................................................. 5-10
6.1 Outline of dual ramp gauge .............................................................................. 6-4
6.2 Ramp check - Square/Ramp style flags........................................................... 6-4
6.3 Linear accuracy gauge ..................................................................................... 6-5
6.4 Taper gauge .................................................................................................... 6-5
Contents
7.1 General assembly ............................................................................................ 7-3
7.2 Plunger clamp and half nut assembly .............................................................. 7-6
7.3a Pole clamp assembly diagram - Non-rotating ................................................... 7-7
7.3b Pole clamp assembly diagram - Rotating ......................................................... 7-8
7.4 Leadscrew assembly ....................................................................................... 7-9
7.5 Main board assembly..................................................................................... 7-12
7.6 Regulator board assembly - AC Power ........................................................... 7-13
8.1 Braun Perfusor conversion: parts required ....................................................... 8-2
9.1 Diagram of pump chassis connector ................................................................ 9-1
9.2 Power supply circuit diagram ........................................................................... 9-2
9.3 Layout of components on the power supply board ........................................... 9-2
A.1 New modified Syringe Size Sensor Flag .......................................................... A-1
A.2 Order for tightening the case screws................................................................ A-3
A.3 Size Sensor Flag: general details ..................................................................... A-5
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Warnings and cautions
Smiths Medical International Ltd.
Introduction
This Technical Service Manual together with the Instruction Manual, contains all the information that is needed in order
to maintain, repair and operate the Graseby 3200 pump. The contents of this Manual are intended to be read and used
by suitably qualified personnel.
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 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.
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 Graseby
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.
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.
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
not
expose the pump to X- rays, gamma rays or
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Issue 5 (August 2004)
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Smiths Medical International Ltd.
Warnings and cautions
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: For high risk or critical infusions, the use of the dedicated 3200 Extension set incorporating the
pressure sensing disc is recommended in order that occlusion pressure can be appropriately set and
monitored during an infusion.
25. WARNING: The patient history is lost when the clock is reset.
26. WARNING: Only adequately qualified personnel should maintain and repair the pump.
27. WARNING: The pump must be disconnected from the AC power supply before the case is opened.
28. 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.
29. WARNING: The safety and reliability of the pump may be compromised by the use of parts other than those specified
in this Manual.
30. 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.
31. 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.
32. 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.
Specification
(Chapter 1).
not
be infused.
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Warnings and cautions
Smiths Medical International Ltd.
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
not
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
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
use the
be immersed in any liquids or exposed to strong organic solvents. Wipe off spills
Page xii
Issue 5 (August 2004)
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Abbreviations
used
The following list shows the abbreviations that have been used at various
places throughout this Manual.
Abbreviation Full name
AC Alternating current
A-to-D Analogue-to-digital
C Capacitor or Centigrade
CMOS Complimentary metal oxide silicone
cNm Centinewton metre
COP Computer operating properly
DC Direct current
D Diode
EEPROM Electrically erasable and programmable read
only memory
EPROM Erasable program
Fig Figure
Hz Hertz (cycles per second)
IC Integrated circuit
ID IDentification
kbyte Kilo byte
kg Kilo gram
KVO Keep vein open
LC Liquid crystal
LED Light emitting diode
MCI Manually controlled infusion
MHz Mega Hertz
ml/h Millilitre per hour
ml Millilitre
mm Millimetre
PSI Pounds per square inch
PWM Pulse width modulated
R Resistance
RAM Random access memory
TCI Target controlled infusion
V Volts
VF Vacuum fluorescent
W Watts
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CHAPTER 1
INTRODUCTION, FEATURES and SPECIFICATION
3200
In-line Pressure Syringe Pump
Smiths Medical International Ltd.
CHAPTER 1
INTRODUCTION, FEATURES and SPECIFICATION
Introduction
Introduction
The 3200 is a microcomputer controlled syringe pump that has primarily been developed for
the neonatal infusion of sterile liquids.
The pump has an In-line (wet-side) pressure sensing system for accurate occlusion detection.
The pump is capable of operating in any one of three different infusion modes, as follows:
• continuous,
• preset, or
• intermittent.
And is able to carry out an infusion using a 5, 10, 20, 30, 50/60 ml size syringe.
The pump incorporates a dot matrix vacuum fluorescent display that provides a constant
indication of the pump’s operation. A choice of any one of the following languages is available (with the appropriate software) via the diagnostic options mode:
English, Dutch, French, German, Italian, Norwegian and Spanish.
The pump can be Configured by the user to work with one of a range of brands of syringe.
It automatically senses the size of the syringe fitted to the pump. The rate of the pump can
be set to operate with either mass units or ml/hour.
The pump is able to dispense liquids at rates of between 0.05 and 200 ml/hour.
The pump keeps the running total of the volume infused, and a history of events as they
occur. About 1,500 events can be logged, complete with the date and time of each.
This compact and robust pump can be used on either a table top or mounted via its pole
clamp to an IV (Intravenous) pole. The pump’s history can either be viewed on the screen or
output to a printer.
Security cover
An RS232 interface link connects the pump to either a printer or a computer. This allows the
pump’s history to be printed or externally monitored.
Safety features are built into the pump and its software. This includes a set of self test
routines which are run when the pump is switched on.
Users are warned of such incidents as occlusion or power failure by both visible and audible
alarms.
The pump can be powered from either an AC supply or internal rechargeable batteries.
The batteries can power the pump for at least two and a half hours from a fully charged
condition.
A DC version of the 3200 also exists, that requires an input supply of 10 V to 28 V DC (see
Chapter 9).
This Manual refers to pumps that have software Version 2.20 installed. Software versions
other than 2.30 may show slight deviations from certain features described in this Manual.
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.
3200 Service Manual 1 — 1
Issue 5 (August 2004)
Introduction
Smiths Medical International Ltd.
1 — 2
Figure 1.1 Itemised front view of the pump
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Features
Features
Microcontroller
The key features of the 3200 are as follows:
• In-line (wet-side) pressure sensing,
• automatic syringe size sensing,
• up to 1500 History events storage,
• universal AC supply powered or battery powered,
• can be Configured to work with a range of syringe brands,
• advanced safety features,
• state-of-the-art electronics,
• clear text display,
• comprehensive range of alarms,
• RS232 interface,
• simple to use and service,
• all materials used in this product are latex free.
The pump makes use of a sophisticated micro-controller which combines microprocessor
facilities with the following:
• 0n-board non-volatile memory,
• RAM,
• ROM,
• an analogue-to-digital converter,
• communications circuitry,
• four 8-bit pulse-width modulated outputs,
• an internal watchdog (COP).
These facilities are usually provided by many separate silicon chips, the use of a single
micro-controller greatly increases the pump’s reliability.
3200 Service Manual 1 — 3
Issue 5 (August 2004)
Specification
Specification
Smiths Medical International Ltd.
AC power
supply:
Battery type:
Battery life:
DC input
operation:
Syringe brands
and sizes:
100 V to 240 V at 50/60 Hertz, 40 VA.
The power supply uses primary switching in order to utilise the AC supplies of most
countries.
Sealed lead acid, rechargeable (Cyclon, 3 off). Smiths Medical recommend that the
batteries are checked at least annually (see page 5-10).
More than 2.5 hours of normal pump operation when the batteries are fully charged.
With the AC supply connected, up to 14 hours are required to fully recharge low voltage
batteries.
3200 DC variant pump.
10 V to 28 V DC at a maximum of 4 amps input supply (see Chapter 9).
BD Plastipak... 5, 10, 20, 30/50 and 50/60 ml.
Injectomat... 10 ml and 50 ml.
IMS Pumpjet... 30 ml, prefilled.
Monoject... 5, 10, 20, 30/35 and 50/60 ml.
Braun Omnifix... 5, 10, 20, 30 and 50/60 ml.
Terumo... 5, 10, 20, 30/35 and 50/60 ml.
Infusion rates
and increments:
Mass unit
programming
range:
BD Plastipak (A)... 5, 10, 20, 30/35 and 50/60 ml.
The BD Plastipak (A) syringe accommodates the American manufactured 10 ml syringe,
which differs slightly in length to the European version. All other syringe sizes in the BD
Plastipak selection are identical to the standard BD Plastipak syringes.
Braun Perfusor... Optional (see Chapter 8).
Rates Increments
0.05 to 1.0 ml/h... 0.01 ml/h
1 to 200 ml/h... 0.1 ml/h
0.01 to 999 mg/kg/h
0.01 to 999 mg/kg/min
0.01 to 999 µg/kg/h
0.01 to 999 µg/kg/min
0.01 to 999 mg/h
0.01 to 999 µg/h.
Patient weight... 0.4 to 200 kg.
Drug mass... 1 µg to 999 mg.
Drug volume... 1 ml to 60 ml.
Volume infused
counter:
1 — 4
0 to 999.9 ml in 0.1 ml increments.
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Specification (contd.)
In-line occlusion
pressure range:
Using a 30 ml sized syringe:
0 to 7.42 kg (1000 mmHg).
0 to 1355 cmH2O.
0 to 133.3 kPa.
0 to 1316 mBar.
0 to 19.34 psi.
Using a 50 ml syringe, 0 to 4.83 kg (0 to 650 mmHg).
Specification
Internally adjustable
occlusion pressure:
Factory set occlusion:
Display languages
available:
Dimensions:
Weight:
Temperature
range:
Drive accuracy:
Using a 50 ml syringe, 1.85 kg (250 mmHg) to 4.83 kg (650 mmHg).
3.5 kg (471 mmHg) to 4.2 kg (565 mmHg).
Dutch.
English.
French.
German.
Italian.
Norwegian.
Spanish.
350 x 195 x 115 mm, with pole clamp fitted and plunger clamp closed.
Not exceeding 3.5 kg including the batteries and pole clamp.
Operating conditions:
+5°C to +40°C, 30 to 75% Rh, 700 to 1060 hPa.
Storage conditions:
-40°C to +70°C, 30 to 90% Rh, 700 to 1060 hPa.
±2%.
History:
Electrical safety:
Design standards:
UK patent number:
Printer protocol:
1500 events can be stored.
Class II
Type CF
Drip proof IPX1.
BS5724 Part 1
IEC601 Part 1
VFG1046/1984.
2229497.
Serial, 8 bits, no parity, 1 stop bit.
3200 Service Manual 1 — 5
Issue 5 (August 2004)
Development of 3000 series
Smiths Medical International Ltd.
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 0.1 ml/hr to 99.9 ml/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 used a different
microprocessor with the capability of running the extra features required for PCA. It 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. This pump was 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 with improved electronics.
Dual processors were incorporated, 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 (1500 events)
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. An infusion
rate calculation facility was later added to the software.
A larger liquid crystal display was used on the 3400 with the ability to display text in different sizes, also ‘soft-keys’
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 general purpose syringe pump. Wet-side pressure sensing, intermittent infusion
capabilities, and computer interfacing were added. The wet-side 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
increased syringe size range of the 3400 remained.
A DC input supply (10 V to 28 V DC) version of the 3200 is also manufactured by Smiths Medical. This variant is
primarily intended for use in an aviation environment, but may be utilised in an environment where the required DC
voltage exists.
3500
There are two versions of the 3500, as follows:
1. A Manually Controlled Infusion (MCI)
2. An MCI
The 3500 was developed from the 3400 and retains all the 3400 facilities.
The ‘MCI
module manufactured by Zeneca Pharmaceuticals. A new main circuit board and new software allows the 3500 to
interface with the Diprifusor module. A 3500 non-TCI pump can be converted to become a 3500 plus TCI pump.
3150
The 3150 is very similar to the 3200 general purpose pump. The main difference being that the In-line (wet-side) pressure
sensing system in not available on the 3150, i.e. the pressure transducer is not fitted.
1 — 6
plus
a Target Controlled Infusion (TCI) pump.
plus
TCI’ pump carries out a TCI using the Diprivan drug. This version of the 3500 incorporates a Diprifusor
only
pump.
Issue 5 (August 2004)
3200 Service Manual
CHAPTER 2
CONFIGURATION, DIAGNOSTICS
and OCCLUSION THRUST
3200
In-line Pressure Syringe Pump
Smiths Medical International Ltd.
CHAPTER 2
CONFIGURATION, DIAGNOSTICS and OCCLUSION THRUST
Configuration mode
WARNING
The Configuration mode must only be used by personnel who are
adequately qualified and have had previous training in the use of the 3200.
Configuration mode
Introduction
The Configuration mode allows the various different pump parameters to be displayed, which
in turn allows various settings within these parameters to be set to the values required for the
infusion.
The full list of Configuration parameters is shown below, but the availability of some parameters
depends upon the setting of other parameters. Each parameter is further detailed in the
sections that follow this list:
1. Syringe brand.
2. Syringe size.
3. Lock program values.
4. Max infusion rate.
5. Select pump modes.
6. Preset volume mode with time.
7. KVO rate.
8. Allow mass unit.
9. Infusion units, mg/kg/h.
10. Infusion units, µg/kg/h.
11. Infusion units, mg/kg/min.
12. Infusion units, µg/kg/min.
13. Infusion units, mg/h.
14. Infusion units, µg/h.
15. Show rate in ml/h while infusing.
16. Use pressure transducer.
17. Display pressure bar graph.
18. Allow bolus while running.
19. Allow rate change while running.
20. Intermittent mode start delay.
21. RS232 Baud rate.
22. Communication mode.
23. Pump ID.
24. Set key beep volume.
25. Pressure units.
26. End of menu.
3200 Service Manual 2 — 1
Issue 5 (August 2004)
Configuration mode
Entry into the Configuration mode
With the pump switched on and in the set-up mode, complete the following procedures to
enter the Configuration mode.
Press and hold down the PURGE button. Press either the ▲ or ▼ button. The following is
displayed:
CONFIGURATION MODE ?
(USE WITH CARE)
Within six seconds of pressing the buttons, press the START button to confirm the
configuration mode.
Note:
If the START button is not pressed within six seconds, the pump returns to
its set-up mode.
A display similar to the following will be shown:
Smiths Medical International Ltd.
Changing a
setting
Moving to the next
parameter
SYRINGE TYPE=
BD PLASTIPAK
Press the ▲ or ▼ button sequentially to scroll through the settings available within each
parameter. The setting required must be displayed.
The various settings are retained by the pump until the Configuration mode is re-entered
and the setting reset.
Press the ENTER button to move to the next parameter. If a new choice is required,
repeat the above. Sequentially pressing the ENTER button scrolls through the available
Configuration parameters.
To exit the Configuration mode and return to the set-up mode press the STOP button at
any time.
2 — 2
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Available Configuration mode parameters and settings
Configuration mode
Syringe brands
Syringe size
Lock program
values
1.
2.
3.
WARNING
The pump must be set to operate with the brand and size of syringe that
is going to be used. Using a different brand to that selected could lead
to the incorrect amount of drug being administered, resulting in injury or
death.
The syringe parameter allows a choice of any one of eight different syringe brands to
be pre-selected and used during an infusion.
Choice: BD PLASTIPAK
INJECTOMAT
IMS PUMPJET 30
MONOJECT
BRAUN OMNIFIX
TERUMO
BD PLASTIPAK (A), see page 1-4.
BRAUN PERFUSOR, optional syringe. See Chapter 8.
This parameter allows the five syringe sizes that are available to be locked to any one
size, thus excluding the other four settings, or NOT LOCKED in order to accept all five choices.
Choice: 5 ml ONLY
10 ml ONLY
20 ml ONLY
30 ml ONLY
50/60 ml ONLY
NOT LOCKED
After the required infusion program values have been set into the pump (i.e. during the
set-up mode) this parameter allows these set-up program infusion values to be temporarily locked in. This prevents tampering and is useful for home treatment.
Max infusion
rate
The lock must be turned off (i.e. the lock program value set to NO) to change the set-up
infusion mode.
Choice: YES or NO
This parameter allows the maximum infusion rate to be set. Above the set rate, an
4.
alarm message is displayed; the pump will not infuse.
The infusion rate that is initially entered into the pump in the set-up mode acts
independently of the maximum infusion rate that can be entered in the configuration
mode.
The configuration mode maximum rate setting takes priority with respect to the
maximum infusion rate that can be used.
The Instruction Manual details the maximum infusion rates for the five different syringe
sizes that are available.
Choice: 10 to 200.0 ml/h in 0.1 ml steps.
(contd.)
3200 Service Manual 2 — 3
Issue 5 (August 2004)
Configuration mode
Smiths Medical International Ltd.
Select pump
modes
Preset volume
mode with
time
KVO rate
Allow mass
units option
7.
8.
5.
This parameter shows the versatility of the 3200 by allowing five different combinations of the three modes of infusions to be pre-selected.
Choice: ALL MODES AVAILABLE
CONTINUOUS & PRESET
INTERMITTENT ONLY
PRESET VOLUME ONLY
CONTINUOUS ONLY
6.
This parameter allows either a preset volume with time (YES selected) or a preset
volume with rate (NO selected).
Choice: YES or NO.
This parameter allows either a KVO rate of 0.50 ml/h or 0.05 ml/h to be chosen.
Choice: 0.5 ml/h or 0.05 ml/h.
When YES is chosen this parameter allows any one of the six mass units to be
selected [see parameters (9) to (14)].
When NO is chosen this parameter allows only ml/h to be selected.
Choice: YES or NO
Infusion units
9.
10.
11.
12.
13.
14.
Show rate in 15.
ml/h while
infusing
When YES is chosen from parameter (8), parameters (9) to (14) allow any combination
of mass units from the following list:
mg/kg/h.
µg/kg/h.
mg/kg/min.
µg/kg/min.
mg/h.
µg/h.
Choice: YES or NO for each parameter.
This parameter allows the infusion rate, when set to mass units, i.e. YES, to also be
displayed in ml/h when infusing.
Choice: YES/NO
(contd.)
2 — 4
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Configuration mode
Use pressure 16.
transducer
Display 17.
pressure
bar graph
This parameter allows a selection of in-line pressure sensing options.
If YES is chosen, the pump senses the presence of a syringe extension set and shows
the in-line pressure on the display.
If the extension set is not being used, choosing YES causes the following prompt to
appear when the START button is pressed...
Press START to run without disposable
This display serves as a warning that the extension set is not being used. Pressing the
START button a second time runs the pump without the extension set.
Choosing NO also allows the pump to run without the extension set.
Choice: YES or NO
This parameter allows the pressure bar graph to be displayed when YES is chosen.
If NO is chosen, the display will be similar to the following:
Allow bolus 18.
while running
Allow rate 19.
change while
running
Intermittent 20.
mode start
delay
RS232 Baud 21.
rate
10 mmHg (75)
Choice: YES or NO
If YES is chosen this parameter allows the PURGE button to infuse a bolus when the
pump is running.
Choice: YES or NO
If YES is chosen, this parameter allows the infusion rate to be changed during the actual
infusion.
The infusion can thus be titrated to the physiological response of the patient.
Choice: YES or NO
In the Intermittent mode, this parameter allows a start delay between 0 and 24 hours to
be chosen before the intermittent regime is started.
Choice: YES or NO
This parameter allows a choice of Baud rates when the pump is connected to a PC or a
printer.
Choice: 9600
4800
2400
1200
600
300
(contd.)
3200 Service Manual 2 — 5
Issue 5 (August 2004)
Configuration mode
Smiths Medical International Ltd.
Commun- 22.
ication mode
Pump ID 23.
This parameter allows a computer to interrogate both the information stored in the pump
and the pumps status.
Choice: MONITOR this choice allows an external computer or a printer to
ONLY.. be connected to the pump.
NONE... this choice ensures that a computer cannot be used to
monitor the pump.
Contact Smiths Medical (Customer Support) for information on setting up a computer
link.
The identification (ID) of the pump appears on the initial power up display. It also
appears on the printout.
This parameter allows an ID of up to 12 alphanumeric characters to be chosen.
To change the pump’s ID use the START, ▲ or ▼ and ENTER buttons, and press STOP
when finished.
A typical ID display is shown below:
GRASEBY-3200
Set key 24.
beep
volume
Pressure units 25.
End of menu 26.
The pump ID accepts 12 characters exactly. A blank space is not provided.
This parameter allows the sound of the key beep to be adjusted so that it is at an
appropriate level for the existing environment.
Choice: 1 to 10.
1 is quiet.
10 is loud.
As the choice is altered from 1 to 10, the sound level increases.
This parameter allows any one of five choices to be made for the in-line pressure
sensor display, as shown below:
Choice: mmHg.
mbar.
cmH2O.
psi.
kPa.
Press the STOP button to exit from the configuration mode.
2 — 6
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Diagnostic mode
Diagnostic
mode
Introduction
Entry into the
Diagnostic mode
WARNING
The Diagnostic mode must only be used by personnel who are adequately
qualified and have been trained in the use of the 3200.
The Diagnostic mode has seven available options which can be used to view, select and
complete the procedures detailed in the following sections.
The Diagnostic options are:
• Software version.
• Calibrate transducer.
• Battery voltage.
• Language.
• Number of faults.
• Total volume infused.
• Total hours of use.
To enter the Diagnostic mode, complete the following procedures with the pump switched
on:
Press and hold down the ALARM button and press either the ▲ or ▼ button. The following is displayed:
Moving to the
next display
DIAGNOSTIC MODE ?
(USE WITH CARE)
Within six seconds of pressing the buttons, press the START button to confirm the Diag-
nostic mode is required:
Note:
If the START button is not pressed within six seconds of the display
appearing, the pump will return to its set-up mode.
A display similar to the one shown below appears:
SOFTWARE VERSION=
2.30
Press the ENTER button to move to the next display. Sequentially pressing the ENTER
button scrolls through the available Diagnostic displays.
Press the STOP button at any time in order to exit the Diagnostic mode and return to the
set-up mode.
3200 Service Manual 2 — 7
Issue 5 (August 2004)
Diagnostic mode
Diagnostic displays
Smiths Medical International Ltd.
Software 1.
Calibrate 2.
transducer
The software display shows the version of software installed in the pump. It is similar to
the following display:
SOFTWARE VERSION=
2.30
To calibrate the transducer, both a syringe extension set and a mercurial sphygmomanometer
(or a similar pressure reading device) are used.
Insert the pressure sensing disc into the pump’s sensor housing and attach the disc to the
pressure reading device.
In the Diagnostic mode, scroll through the displays until the following display appears:
PRESS START TO
CALIBRATE TRANSDUCER
Press the START button and the following display is shown:
SET ZERO mmHg
AND PRESS START
Set the pressure reading device to zero mmHg and then press the START button.
The following two displays automatically appears:
ZEROING
PLEASE WAIT
SET 300 mmHg
AND PRESS START
Set the pressure reading device to 300 mmHg and press the START button.
The following three displays automatically appear:
CALIBRATING
PLEASE WAIT
CALIBRATION
COMPLETE
2 — 8
PRESS START TO
CALIBRATE TRANSDUCER
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
After carrying out the previous display request (i.e. pressing START), press STOP to return
the pump to its set-up mode.
Diagnostic mode
Transducer
alarm
Battery 3.
voltage
Language 4.
If a fault occurs within the transducer set-up system, a pulsing loud alarm (silenceable)
occurs and the following alarm display appears:
WARNING: CANNOT
CALIBRATE TRANSDUCER
The battery voltage display is similar to the following:
BATTERY VOLTAGE=
6.9 V
Various languages may be selected and used for display purposes. The English display
selection is shown below:
LANGUAGE=
ENGLISH
The other language displays are:
Number of 5.
faults
Volume 6.
infused
Hours of use 7.
• SPRÅK = SVENSKA
• TAAL = NEDERLANDS.
• LINGUA = ITALIANO.
• SPRACHE = DEUTSCH.
• LANGUE = FRANCAIS.
The total number of faults that may have occurred to the pump since manufacture is
displayed when in this parameter:
NUMBER OF FAULTS=
1
The total volume of liquid that has been infused since the pump was manufactured is
displayed when in this parameter:
TOTAL VOLUME INFUSED
0.06 litre
The total number of hours that the pump has been switched on is displayed when in this
parameter is selected:
TOTAL HOURS OF USE=
9.0 hours
3200 Service Manual 2 — 9
Issue 5 (August 2004)
Setting the clock
Setting the clock
Smiths Medical International Ltd.
The time and date may be viewed; if required, both may be reset. The procedures for
entering and setting the clock are detailed below.
Entering the
clock display
Simultaneously press the...
ALARM, ENTER and DISPLAY button,
and a display similar to the one shown below appears:
SET CLOCK ?
15:19:22 31-AUG-2003
Within six seconds of pressing the buttons, press the START button to amend the time
and/or date.
Note:
If the START button is not pressed within six seconds of the display appearing
the pump returns to its set-up mode.
A display similar to the one shown below is displayed:
NEW TIME=
15:19:22 31-AUG-2003
Initially the hours indication in the above display blink on-and-off. Use the ▲ or ▼ buttons
to set the hours.
By pressing the START button, the
‘minutes, seconds, day, month and year’
can in turn be highlighted. Use the ▲ or ▼ buttons to change any selection or all of the
settings.
Press the STOP button to return the pump to the set-up mode.
2 — 10
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Disassembly and assembly of casing
WARNING
The following procedures must only be carried out by qualified technicians.
ELECTRIC SHOCK HAZARD
The pump must be disconnected from the AC power supply before opening
the casing.
The casing must be opened to carry out adjustments that may be required to the occlusion
thrust and for various repair procedures.
Repair procedures are detailed in Chapter 5.
Each time the casing separated and reassembled, the syringe size functional tests detailed
on page 6-1 must be completed.
Opening the pump casing
Taking the
casing apart
Assembly
1. Disconnect the AC power connector and utilising a scratch free flat surface, turn the
pump over to gain access to the base.
2. Undo and retain the six screws that hold the casing halves casing together. One of
the 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
casing halves.
Being careful not to trap any leads, assemble the casing by reversing steps (2) and (3) detailed
above. Ensure that the case halves have ‘snapped’ together and that the front and rear mating
edges are equal and parallel. Tighten the screws to a torque of between 70 and 75 cNm in the
order shown in the
1
Figure 2.1
.
3
2
GM0595-B
3200 Service Manual 2 — 11
5
Figure 2.1 Case fixing screw tightening order
Issue 5 (August 2004)
4
6
Occlusion thrust
Smiths Medical International Ltd.
Occlusion
measurements
Thrust
measurements
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 in the factory by using a thrust measurement procedure.
This method measures the plunger clamp thrust by using a set of weights (see next page).
The occlusion pressure is obtained by measuring the pressure that occurs in the infusion
line. The in-line method requires the use of a new syringe and infusion line. Conversion
between the two is achieved using the formulae below, taking into consideration syringe
stiction.
The 3200 has the ability to measure in-line occlusion pressure, when using the dedicated
disposal. See page 3-2.
The internal occlusion sensing system within the pump is always active.
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 +S
732 1
where
: T = thrust in kg.
P = delivery pressure in mmHg.
A = cross sectional area of the syringe in cm2.
and
S = syringe stiction in kg.
Syringe
stiction
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 pump may, therefore, differ from the original factory set
levels.
The occlusion thrust of the 3200 pump is factory set to be 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.
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 — 12
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Occlusion thrust
Thrust checks
The following thrust checks use the weights that correspond to the factory-set occlusion
threshold levels for a 3200 (i.e. 3.5 and 4.2 kg). If a different occlusion level setting is required,
the weights must be adjusted accordingly.
The thrust adjustment procedures are shown on page 2-14.
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 saw the end off the syringe. Place the
modified syringe onto the pump so that it will act as a guide for the weight support rod and
also position the size sensor flag (see
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
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
between 30 and 60 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).
Figure 2.2
).
Figure 2.2
).
Figure 2.2 Thrust measuring set up
3200 Service Manual 2 — 13
Issue 5 (August 2004)
Occlusion thrust
Smiths Medical International Ltd.
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 2-11).
3. If necessary, rotate the leadscrew to reveal the grub screw 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 using a 50\60 ml syringe gives approximately 2.73 kg (369 mmHg) of
adjustment.
Rotating the adjusting nut to decrease the tension on the leadscrew spring. This decreases the
pump's occlusion setting.
Rotating the adjusting nut to increase the tension on the leadscrew spring increases the
pump's occlusion setting.
5. Tighten the grub screw to a torque of 15 ± 2cNm.
6. Temporarily assemble the two halves of the pump, being careful not to trap any
leads.
7. Complete a thrust check (see page 2-13).
8. To obtain the thrust required it may be necessary to repeat steps (2) to (7) above.
9. Assemble of the pump casing (see page 2-11).
10. Complete tests No. 9 and 10 detailed in the functional test procedures (see page 6-3).
2 — 14
Issue 5 (August 2004)
3200 Service Manual
CHAPTER 3
FUNCTIONAL DESCRIPTIONS
3200
In-line Pressure Syringe Pump
Smiths Medical International Ltd.
CHAPTER 3
FUNCTIONAL DESCRIPTIONS
Functional descriptions
Introduction
Drive system
Introduction
This Chapter explains how the 3200 operates. Reading this chapter will help a technician to
rectify any possible faults that may occur within the pump.
The functional descriptions of the 3200 may be divided into six separate areas. Each of these
functional descriptions are detailed separately in the sections following this list:
• Drive system.
• Internal occlusion system.
• In-line occlusion system.
• Electro/mechanical control system.
• Sensing (alarm) systems.
• Software.
The motor, gearbox, leadscrew and associated components (Figure 7.1) are mounted on a
glass reinforced polycarbonate casing. The strength of this casing enables a precise
mechanical location to be achieved for the various components.
Stepper motor
and leadscrew
Microcomputer
Toggle
mechanism
Both the inner and outer metal tubes are made of substantial material in order to eliminate
unwanted flexing.
The drive system comprises a stepper motor working through a gearbox which rotates a
leadscrew. A half nut/super nut assembly engages onto the leadscrew, and the assembly
is also connected to a steel tube. The steel tube is connected to the plunger clamp.
The rotation of the leadscrew moves the plunger clamp. This movement pushes ‘in’ the
plunger on the syringe being used (see below).
As the motor spindle rotates, the leadscrew also rotates and the half nut/super nut assembly travels to the left - along the leadscrew. The half 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 almost the length of the pump.
The microcomputer and its associated software determines the speed of the motor.
A spring-loaded toggle mechanism is attached to the bottom of the half nut/ super nut. The
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.
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Occlusion system
Smiths Medical International Ltd.
Plunger clamp
When the plunger clamp is pulled down, the half nut/super nut engages with the leadscrew
and the clamp engages with 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.
Two small push-buttons on the edge of the plunger clamp make contact with the top of the
syringe plunger. These push-buttons control the operation of a lever which protrudes from
the plunger clamp.
When the push-buttons are pressed in, by coming into 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 its down operating position.
If the push-buttons are not pressed ‘in’, the lever is locked in its protruding position thus
preventing the plunger clamp from being pulled down. This in turn prevents the half nut
from engaging on the leadscrew.
This push-button safety 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 dislodged during an infusion, the pump will automatically
and safely stop infusing. The alarm will sound.
Internal occlusion system
An occlusion sensing assembly located at the left hand end of the leadscrew (Figure 7.1)
causes the rotating leadscrew to turn a slotted disc. The rotation of this disc is detected
by an opto-sensor.
A spring mechanism at the right hand end of the leadscrew provides the pressure that is
required in order to overcome any slight resistance from the syringe plunger.
If an occlusion occurs in the syringe line and the occlusion pressure is sufficient to overcome the spring pressure, the leadscrew moves slightly to the right, thus losing contact
with the clutch. The slotted disc stops rotating. This non-rotation of the slotted disc is
detected by the opto sensor and an occlusion alarm is generated.
This method of occlusion detection is extremely sensitive as it is the lack of pressure on
the clutch that generates the alarm, rather than a detection of the movement of the
leadscrew, as used in traditional designs (UK patent no. 2249497).
In-line occlusion system
The method of directly measuring the pressure in the infusion line allows a more accurate
measurement of the lower occlusion pressures to be made, thereby making the pump
ideally suited for neonatal infusions.
The infusate flows through a disposable pressure sensing disc which is part of the pressure sensing assembly (Figure 7.1).
3 — 2
The sensing disc has a chamber which is covered by an elastic membrane. As the pressure in the infusion line increases, the pressure exerted on the membrane also increases.
The membrane in turn presses against a pressure transducer mounted on the side of the
pump. The pressure transducer is covered by an insulating film to prevent the ingress of
foreign particles.
(contd.)
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Smiths Medical International Ltd.
The above action causes a voltage proportional to the pressure in the infusion line to be
input to one of the channels of the 8 bit A-to-D converter in the micro-controller.
If the output from the A-to-D converter exceeds the predetermined value set by the user,
an in-line occlusion alarm is generated.
The presence of a pressure sensing disc on the pump is confirmed by an opto-sensor
which is located at the bottom of the sensor housing. If the sensor detects that the sensing disc has been removed during an infusion, an alarm is generated.
Electro/mech control system
The microprocessor provides the pulse train for the stepper-motor to produce the set flow
rate. The rotation of the leadscrew slotted disc (see page 3-2, Internal occlusion system) is
monitored by the opto-sensor.
If the appropriate pulses are not detected by the opto-sensor, an alarm is generated.
The mechanical characteristics of the system are:
• motor step angle: 15 degrees
• gearbox reduction ratio: 210:1
Electro/mech control system
• number of motor 5,040 at all times
steps per revolution
of leadscrew:
• leadscrew pitch: 1.5 mm
• syringe characteristic: 1 ml/1.8 mm (BD 60 ml syringe)
Sensing (alarm) systems
Introduction
End of infusion
Syringe nearly
empty
AC power
failure
In addition to the occlusion sensing system (page 3-2), the following sensing systems are
also operative within the pump.
A metal flag protrudes from the left hand side of the half nut in parallel with the leadscrew.
As the syringe plunger reaches the end of its travel, the flag de-activates opto-sensor OPT00
situated on the opto sensors board. When the microprocessor detects that this sensor is deactivated and the slotted disc is no longer rotating, it generates an END OF INFUSION/EMPTY
alarm.
When the metal flag de-activates opto-sensor OPT00 and the slotted disc is still rotating the
microprocessor makes a calculation (dependent upon the infusion rate) and issues a NEARLY
EMPTY alarm three minutes before the end of the infusion.
The sensing system will detect an AC power failure.
The pump continues to run after an AC power failure for a period of 2.5 hours or more by
switching automatically to the pump’s internal (fully charged) batteries.
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Sensing (alarm) systems
Smiths Medical International Ltd.
Battery voltage
low
Self tests/pump
malfunction
Drive
disengaged or
syringe not
fitted
Syringe sizing
system
The sensing circuits incorporate a system that monitors the output of the batteries and
registers an alarm if the voltage of the batteries drops below 5.75 V.
If the voltage falls below 5.4 V the pump turns itself off after an initial warning period.
At switch on the pump completes various self tests. In addition, 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 the calculations.
The pump’s 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 displaced during an infusion, the drive automatically stops due to the
disengagement of the half nut. The disengagement of the half nut is detected by an optosensor.
If the pump tries to operate without a syringe, or with a syringe incorrectly fitted, the pump
goes into an alarm state.
The syringe sizing system comprises a flag moulding assembly (Figure 7.2) that rests on the
barrel of the syringe. In conjunction with three size sensors (Figure 7.6), it measures the
diameter of the syringe being used.
Rate setting
The flag moulding rotates about the outer of the two guiding tubes and moves an actuating
flag between the three size sensors.
The flag is able to de-activate the three size sensors in any one of the following combinations:
none; 1; 1-2; 1-2-3; 2-3 or 3.
Depending on the operation of the size sensors, the pump monitors the size of a syringe as
being 5 ml, 10 ml, 20 ml, 30 ml or 50/60 ml.
Alternatively, if a syringe is not fitted onto the pump or a syringe smaller than 5 ml is fitted,
then the
SYRINGE INVALID
alarm is activated.
For each size of syringe, there is a maximum rate at which the pump is able to infuse. The
syringe size maximum rate can be constrained to an absolute maximum rate by using the
associated parameter within the Configuration mode.
When an infusion is started, the pump checks that the maximum rate constraints have not
been exceeded.
3 — 4
In Intermittent mode, an alarm message is given if any of the following conditions occur:
• the dose volume is too large,
• if the background rate is too high,
• if the cycle time is too short, or
• if the sdose duration is too long or too short.
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Software
Cannot zero
extension set
Cannot
calibrate
extension set
Communications
(RS232) failure
Software
Self tests
When the pump is switched on with a disposable syringe extension set fitted, the user is
alerted that an auto zero has not been carried out.
An alarm is generated if an extension set calibration is unsuccessful.
A range of 0 to 1000 mmHg is specified for the extension set, with an offset of +/-100
mmHg. If this offset is exceeded, an unsuccessful calibration alarm is generated.
If the extension set is removed from its housing while the pump is running an alarm condition will be activated.
When under the control of an external computer, an alarm is generated if a computer failure
or disconnection is detected.
The 3200 self tests include the following:
• ROM test (CRC-16),
• RAM test,
• power supply voltage test,
Design
• keyboard test (this test checks for shorted keys),
• stack usage test, and
• motor windings continuity test.
The program is held in a 256 Kbyte EPROM.
The configuration data and settings are stored in the processor’s EEPROM.
A 32 Kbyte RAM chip holds the history. The history will be lost if the AC supply to the pump
is switched off or disconnected and the internal batteries unplugged.
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Issue 5 (August 2004)
CHAPTER 4
CIRCUIT DESCRIPTIONS
3200
In-line Pressure Syringe Pump
Smiths Medical International Ltd.
CHAPTER 4
CIRCUIT DESCRIPTIONS
Circuit descriptions
Introduction
Main board
This Chapter describes the action of the circuits that operate the 3200. It also shows the
associated circuit diagrams and circuit board layouts.
The 3200 contains six circuit boards as follows:
• Main.
• Regulator (power supply).
• Syringe size sensors.
• Status sensors.
• Distribution.
• Pressure sensing module.
The overall block diagram for the 3200 is shown in Figure 4.1.
The status sensor, syringe size sensor and the pressure sensing module boards provide a
mounting for the various sensors, and also junction points for the outputs of these boards,
thus enabling the outputs to be connected to other circuits.
The block diagram for the Main board is shown in Figure 4.2. It comprises the following subcircuits which are individually described in the sections that follow:
Processor core
• Processor core.
• Motor interface.
• Power control.
• Sensors and pressure sensing interface.
• RS232 serial interface.
• Umbilical connector.
• Input/output interface.
The Processor core forms part of the Main board (see Figure 4.2). It is used to process all the
operating activities of the 3200.
The Processor core circuit is shown in Figure 4.3.
The microprocessor chip (IC14) has an on-board EEPROM which stores the programmed
settings. IC14 also incorporates an on-board RAM; an Analogue-to-Digital (A-to-D) converter;
timing circuitry; 4 pulse width modulated outputs; communications circuitry and an internal
watchdog.
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Processor core
Smiths Medical International Ltd.
The processor has the ability to address both the paged RAM and the EPROM. The 32K RAM
(IC12) is split into four 8K pages, and the EPROM (IC13) is divided into thirty-two
8 K pages. The paging system is part of the integral memory management system of the
processor.
IC15 is the microprocessor supervisor chip and has four main duties: to control the
microprocessor reset; battery backup switch-over; watchdog timer and CMOS RAM write
protection during power down.
Crystal X1 and its associated components R63, C32 and C33 form a 16 MHz oscillator,
providing clock pulses for the main-processor on pins 67 and 68.
Pins 70 and 71 on the main-processor are used to control its mode of operation. Both pins
are held high to set the processor to address the external EPROM (IC13). Pins 44 and 43
are held at Vcc and ground respectively, as the reference inputs to the processor’s built in
A-to-D converter.
Pin 21 receives pseudo non-maskable interrupts generated by the supervisor circuit in the
event of a system fault being detected.
Pulse Width Modulated (PWM) output PW3, pin 14, controls the offset trim for the pressure
sensing system, and output PW4, pin 15, controls the sounder volume. Pins 12 and 13 are
not configured as PWM outputs, they are used to activate FPSEL1 and FPSEL2 which
define which input/output chips to activate.
IC12, the RAM chip, is used as a buffer for the RS232 interface. IC12 also provides a
duplicate of critical data stored in the on-board RAM so that corrupted data may be detected.
The EPROM chip IC13 stores the system’s software.
IC16 is a real time clock, and crystal X2 provides the reference signal for the clock. When
the pump is switched on, the processor reads the time and date received from IC16, and
when the clock is changed the real time clock’s data is also changed.
The input from the pressure sensing interface circuit, SENSE1, to the A-D converter on the
processor is conditioned by a technique called dithering.
Dithering is achieved by using the signal already present on D0 ( the LSB on the data bus) as
a noise source. C40 and C41 filter this noise source signal which is then applied to the signal
from the pressure sensing interface.
Applying this dithering technique results in a noisy signal being sent to the A-D converter,
this then results in a varying output which is digitally filtered and converted to the pressure
units being displayed. The end result is that the resolution of the ADC is improved.
4 — 2
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Motor interface
Motor interface
Power control
The stepper motor is controlled by a sequence of pulses supplied from the main processor.
A common ENABLE_MOTOR signal (see Figure 4.4) and one of the four motor control lines are
fed to each AND gate. When the ENABLE_MOTOR signal is high, a pulse on one of the motor
control lines will cause one of the four power mosfet’s to be switched on, and the resulting
output pulses are used to drive the stepper motor.
The ENABLE_MOTOR signal is pulled low by the microprocessor supervisor chip IC15, when
the chip detects a watchdog timeout. R35 and R36 enable the main processor to detect
current flow through Q19 or Q20 (MOTORSENSE1) and Q21 or Q22 (MOTORSENSE0).
C26 and C27 remove any voltage spikes which may occur.
R7C and R7D are current-limiting resistors.
The ‘T’ filters L6, L7, L8, and L9 are for electro static discharge protection of the motor
interface. The diodes provide a path for the charge stored in the motor coils when the
transistors are switched off.
IC2 (see Figure 4.5) acts a linear regulator in order to provide a 5 V DC supply (Vcc) for the
logic circuits.
C11, C12 and C13 are decoupling capacitors.
IC3B and IC3C form a set/reset latch to operate the power MOSFET Q4. The latch is
triggered by a high pulse from the main processor (OFF), causing Q4 to turn off and
disconnect the power. Once tripped, the latch cannot be reset by the processor, but must
be reset by a high pulse from the keyboard ON button.
Q6, R28 and R29 form a logic level translator to shift 0 to 5 V logic levels into 0 to 7 V logic
levels for IC3, which has a permanent 7 V DC supply.
C14, C10, and R30 overcome the effects of any transients.
D5 prevents C10 from discharging into IC3B in the event of Vdd being removed.
The Vacuum Fluorescent Display (VFD) has its own independent voltage regulation circuit.
With Q7 switched on Vin will be applied to IC4, a high current 5V voltage regulator.
The output of IC4 is used to power the VFD.
The circuit comprising R23, R24, C9, bandgap references D4 and D30, and transistor Q5,
supplies a constant voltage (Vcc’) of approximately 3 V DC.
The supervisor chip transfers the power for the real time clock and RAM from the regulated
5 V DC supply, Vcc, to Vcc’ when the main power, and hence Vcc, is turned off. This
preserves any memory held in RAM and keeps the real time clock running.
LED D6 is illuminated when a voltage is present on Vac. This signifies that the AC supply is
connected to the pump.
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Sensors interface
Smiths Medical International Ltd.
Sensors
interface
The seven opto-sensors are split into three groups (see Figure 4.6) and these three groups are
multiplexed onto three lines into the microprocessor.
The three groups are used as follows:
• One group is used by the size sensor board.
• The second group monitors whether the pump's plunger clamp is open or closed,
whether the slotted disc used in the occlusion sensing system is rotating and whether
the nearly empty flag has entered the opto-sensing slot.
• The third group has only one member, which is used to signify whether a pressure
sensing disc has been inserted into the pump.
Q3 activates the size sensor LEDs, Q1 activates the status sensors LEDs and Q18 activates
the disc detector LED. The three transistors are activated independently and should not be
active at the same time.
R4, R5, R8, R9, R81 and R82 are current limiting resistors.
On the detection side of the opto-detectors, R77, R78 and R79 are pull up resistors. R6A, B,
C, D, R7A and R7B are current limiting resistors. Zener diodes D1, D2 and D3 are used for
electrostatic discharge protection.
When a photo transistor detects the LED associated with it, the line OPTO_0,1 or 2, will be
pulled low. This signal is then input to the microprocessor via SENSE3, 4, or 5.
R1, R2, and C1 make up the low battery voltage sensing circuit. R1 and R2 act as a
potential divider enabling the voltage between them to be input to the A-to-D converter of
the main processor.
The pressure sensing interface circuit (see Figure 4.7) consists of an instrumentation amplifier
with an adjustable offset. The Tee filters L3 and L4 along with C3, C4, R17 and R18 are for
electrostatic discharge protection.
IC1A, B and C with associated components R12 to R16, R19, R20, C5 and C6 make up the
instrumentation amplifier.
IC1D is a voltage follower and allows the processor to detect a signal on one of the inputs to
the instrumentation amplifier. R11 is a pull up resistor for op-amp IC1A.
OFFSET_TRIM (see Figure 4.7) is a PWM output signal from the processor and this signal is
attenuated by the potential divider R21 and R22. C42 smooths the PWM output to a DC
level. This DC signal is applied to the relevant stage of the instrumentation amplifier, so that
when the pressure sensor is being calibrated the zero mmHg calibration point will be
equivalent to 0.5 V, and this voltage appears at the PRESSURE output.
This PWM signal will remain constant until the transducer is next calibrated.
4 — 4
Each time the pressure sensing disc is inserted, or the pump is switched on, an auto zero is
carried out. This allows the zero pressure voltage to differ by up to ± 0.5 V of the calibrated
zero point.
If the voltage is outside these limits the pump will issue a warning and must be re-calibrated.
So the voltage on the PRESSURE output line will normally be between 0 and 1.0 V, and
exactly 0.5 V immediately after a calibration routine.
IC1D is a voltage follower and allows the processor to detect a signal on one of the inputs to
the instrumentation amplifier.
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RS232 interface
RS232 serial
interface
WARNING
Only items of equipment that conform to EN60950 may be connected to
the 9-pin RS232 connector that is situated at the rear of the pump. This
conformity prevents the safety of the patient being compromised.
The micro controller generates an RS232 compatible signal with a 0 to 5 V output. IC5,
with ancillary components L5, R33, C18, C19, C20, C21, and C22 converts the 0 to 5 V signal
to a +/-10 V output. IC7 is supplied with a single +5 V power rail and uses two charge
pumps to create a 10 V and -10 V supply. R34 A, B, C and D are for electrostatic
protection.
The signals on the D connector are shown on Figure 4.18, and the pin connections for the
D connector are shown on Table 4.1.
Table 4.1 RS232 D connector
Pin No. Connection
1 Not connected
2 RxD
3 TxD
4 Not connected
5 GND
6 DSR (handshake out)
7 RTS (+10 V out)
8 CTS (handshake in)
9 Not connected
Umbilical
connector
Input/output
serial interface
The umbilical ribbon cable connector (see
supplies to be sent between the main circuit board (front case) and the umbilical board on
the rear case.
The processor communicates with its input and output devices with a serial-in and a serial-out line.
The serial data, MOSI, is converted to a parallel output by three shift registers, IC 8, 9 and 10.
The parallel outputs are used to power the various LEDs and control the keyboard driving
sequence. The keyboard input along with the mains present signal is converted to the serial
signal, MISO, by a parallel input serial output shift register, IC11.
ICs 8 and 9 are linked so that they appear to work as a single 16 bit output serial input shift
register. The signal MOSI is common to IC8 and IC10.
The FPSEL1 and FPSEL2 lines define whether to activate ICs 8 and 9 or ICs 10 and 11.
The SCLK clock signal is fed to all four ICs.
The pump’s front panel input device consists of 11 press-buttons. The ON button when
pressed completes the circuit between pins 1 and 2 on PL3.
The remaining keys use a 3 x 4 matrix. The four lines on PL3 pins 6 to 9 inclusive are pulled
high by resistor R70A, and are connected to IC11. Each line is connected to one of the 4 rows
of the keyboard matrix.
The 3 columns of the matrix, PL3 pins 3 to 5 are connected to IC8, the parallel out serial shift
register. As each individual column is pulled low the status of each key in that column is input
to IC11.
Resistor R66 limits the current in the control lines out of IC8. The diodes D11 to D13 allow IC8
to pull the required control line low but let the remaining lines float when a logic high is applied
at the output of IC8.
Zener diodes D22 to D24 inclusive and quad resistor packs R73 and R74 form the electrostatic
discharge protection circuit.
Figure 4.9
) enables data and the circuit power
(contd.)
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Input/output serial interface
The remaining five output lines on IC8 are used to activate transistors Q9 to Q13 inclusive,
and these transistors control the illumination of the syringe size indication LEDs, D17 to D21.
The outputs from IC9 are used to control which group of opto-sensors are activated and also
to activate transistors Q14, Q15, and Q16: these transistors control the illumination of the
ALARM, START and STOP LEDs. Resistors R52 to R57 inclusive are current limiters.
The display is a 20 character, two line Vacuum Fluorescent Display (VFD) that is linked to the
main board by PL5.
The display data is transmitted via MOSI to IC10, which is enabled by FPSEL2. The output of
IC10 is input to the VFD by a signal from VFDSTB, when the VFD_BUSY signal signifies to the
processor that the VFD is ready to accept the next byte of data.
The supervisor chip IC15 can turn on the sounder independently of the microprocessor via
ENABLE_MOTOR. This independence occurs if the processor malfunctions and is unable to
produce its own sounder control; in which case the supervisor chip’s watchdog would timeout
thus generating an ENABLE_MOTOR control.
D28 prevents a low signal from SOUND drawing a current from IC15. Q8 and associated
components C30, R39, R40 and R41 constitute a low-pass filter which allows the PWM signal
SOUND from the micro-controller to activate the sounder. The sounder is connected to PL2.
Smiths Medical International Ltd.
Regulator
board
R3, R10, R76, C2 and Q2 enable the main processor to detect the presence or absence of
mains power. When mains power is present a low signal is applied to pin 14 of IC11.
This signal is then transmitted serially to the processor via MISO.
The pump utilizes a primary switching power supply (see Figure 4.11).
The advantages of this type of supply over a conventional secondary switching power supply
include the following:
• greater efficiency,
• larger power capability for a given size of supply, and
• a smaller transformer is needed for the equivalent power.
The regulator circuit is based on a universal input switch-mode controller, IC1 (see Figure 4.12).
IC1 uses a current mode, pulse width modulation control circuit, which allows it to operate
over a wide range of AC input voltages i.e. from at least 90 V to 270 V AC.
The regulator also provides a 7 V DC supply for the motor and the LEDs. This supply is then
used to provide a 5 V DC supply for the logic circuits
4 — 6
The regulator circuit is protected by a mains fuse, FS2. The mains supply is then filtered by
C14 and L2. R20 allows the residual charge on C14 to be dissipated when the pump is
removed from the mains supply.
The output from the bridge rectifier D7 is smoothed by C10 and transient current limited by
varistor V1. When V1 is cold, the resistance is high and current is limited. As the thermistor
warms up, the resistance decreases, allowing the current to increase. The output from VR1 is
used to start up IC1 via pin 1. It is also fed to the primary winding, pin 6 on the power
transformer.
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Once the switch-mode controller has started working, it obtains its power supply from a
bootstrap winding on pins 2 and 3 on the transformer. The power supply from the bootstrap
winding is rectified by diode D5, smoothed by C13 and regulated by the Zener diode D6.
The PWM signal output from pin 5 on IC1 controls the operation of Q3 causing it to cycle on
and off and regulate the flow of current from D7 through the primary winding. C1 and R1, C2
and R2, C3 and R4, C4 and R3 are all transient suppression circuits.
The voltage on pin 12 (IN1) of the secondary winding is rectified by diodes D1 and D3 (see
Figure 4.13). The output from D1 is then smoothed by C6 and passed to pin 4 of PL11.
The DC output from D3 is filtered by C5, C7 and L1. The link to PL11 pin 3 is protected by
a 1 amp fuse, FS1.
When the mains supply is being used there is a voltage present on pin 4 of PL11. By using
R6 and R7 as a potential divider, this voltage is used to control Q2.
When there is no mains supply, Q2 is not active and so prevents the batteries from discharging
through R8, R9, RV1 and R10.
When Q2 is activated, R8, TH1, R9, RV1 and R10 form a potential divider between the output
of D3 and 0 V. The output from this is used as the reference voltage for the adjustable
precision shunt regulator D4. Capacitor C8 is a transient suppressor.
Regulator board
PL 11 output
Thermistor TH1 varies the reference voltage according to temperature, thus compensating for
battery charging characteristics.
The feedback process occurs when the voltage at the wiper of RV1 exceeds the reference
value, D4 conducts and activates the opto-coupler IC2. The current through its photo-transistor
causes a voltage to be developed across resistor R19. This voltage is applied to IC1 which
changes the mark-space ratio of the output signal on pin 5.
An over voltage situation resulting from a malfunction in the regulator is prevented by a
crowbar protection device. When the output voltage exceeds 13 V, the Zener diode D2 conducts.
This causes a voltage to be developed across R5. This voltage is used to activate the silicon
controlled rectifier Q1 which will sink enough current to result in fuse FS1 blowing.
See
Table 4.2
for the plug PL11 connections.
Table 4.2 PL11 connections
Pin Output
1/2 Ground
3 7 V DC when on mains or battery supply
4 7 V DC when on mains supply
PL12 output
3200 Service Manual 4 — 7
PL12 provides a link to the rechargeable batteries and the link is protected by FS3 a 2 amp
fuse.
Issue 5 (August 2004)
Setting RV1
Smiths Medical International Ltd.
Setting RV1
The procedure for setting potentiometer RV1 is as follows:
1. Switch off the external AC power, remove the pump’s power connector and open the
casing (see page 2-11).
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. Pins 2 and 3 are the two middle
pins on the connector.
Note:
A Molex connector (part number 0053-0658) enables the 68 ohm resistor to be
easily connected to the pins of PL11.
WARNING
Only a qualified technician may carry out the following procedures. With the
case open, dangerous voltages are present when AC power is applied.
3. Connect and switch ON the AC power. If necessary, adjust RV1 to give a DC voltage
across the 68 ohm load, dependent on the temperature, as shown in Table 4.3.
RV1 is located near the bottom left hand corner of the board (see Figure 7.8).
Table 4.3 Temperature/voltage range for setting RV1
Ambient Voltage across
temp. (deg. C) load (volts)
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
17 7.143
16 7.154
15 7.166
4. Switch off the AC power. Remove the 68 ohm load and reconnect PL11 and PL12 to the
Regulator board. Assemble the casing (see page 2-11).
4 — 8
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Syringe size and status sensors
Syringe size
sensors
Status
sensors
Distribution
board
Pressure
sensing board
The syringe size sensors board is physically located at the centre of the lower casing. The
circuit diagram for these sensors is shown in Figure 4.14. The layout of the components
are shown in Figure 7.6.
The status sensors board is physically located on the left hand side of the lower casing.
The circuit diagram for these sensors is shown in Figure 4.15. The layout of the
components are shown in Figure 7.5.
The Distribution board routes data between each individual board and also to the umbilical
cable that connects to the Main board.
The Distribution board sits on a tray. The board and tray are situated in the lower casing of the
pump. There are seven plugs situated on the board - PL1 to PL7.
The wiring to the plugs is shown in Figure 4.16 and the layout of the connectors on the board
in Figure 7.10.
The ACAM pressure sensing board is situated in the concaved housing that is fixed to the
extreme left hand side of the pump. A six-way connector is used to route the signals to
the Distribution board.
The ACAM pressure sensing circuit is shown in Figure 4.17.
Main board
components
Regulator
board
components
Membrane
switch panel
‘D’ connector
The Main board is fixed to the pump’s top casing and the components attached to the
board are shown in Figure 7.7.
The Regulator board is located on the right hand side of the lower casing and consists of a
fused primary switching power supply. The component layout diagram is shown in Figure
7.8.
The eleven buttons and the associated connections that make up the front membrane
switch panel are shown in Figure 4.18.
The ribbon cable connections to the RS232 D connector are shown in Figure 4.19.
3200 Service Manual 4 — 9
Issue 5 (August 2004)
Overall block diagram
Smiths Medical International Ltd.
OPTO
SENSORS
BOARD
(Figure 4.15)
SYRINGE
SIZE
SENSOR
BOARD
(Figure 4.14)
PL1
PL1
MOTOR
PL4
PL3
RS 232
(Figure 4.19)
PL2
DISTRIBUTION BOARD
CONNECTIONS
(Figure 4.16)
PL7
PL5
PL6
PL1
Umbilical
connector
SOUNDER
BOARD
PL4
4.3 to 4.10
PL1
MAIN
(Figures
and 7.5)
PL5
DISPLAY
PL3
MEMBRANE
SWITCH
PANEL
(Figure 4.18)
RECHARGEABLE
BATTERIES
GM0390-D
PNK
PNK
ACAM
PRESSURE
SENSOR
(Figure 4.17)
PL11
AC SUPPLY IN LINE
CHOKE (2 off)
REGULATOR
BLK
CELL1
CELL2
CELL3
RED
PL12
BOARD
(Figures 4.11,
4.12 4.13)and
PL1
PL2
AC INPUT
POWER
Figure 4.1 Overall block diagram of the 3200 system
BRN
BLU
N
L
4 — 10
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Main board block diagram
UM[0..26]
POWER CONTROL
UM[0..26]
(See Fig. 4.5)
POWER ON
POWER OFF
SENSORS & PRESSURE SENSING
INTERFACE
OFFSET_TRIM
UM[0..26]
(See Figs. 4.6, & 4.7)
SENSE[0..7]
SENSE[0..7]
RS232 SERIAL INTERFACE
TXD
HANDSHAKE_IN
RXD
HANDSHAKE_OUT
PROCESSOR CORE
POWER OFF
OFFSET_TRIM
HANDSHAKE_OUT
RXD
HANDSHAKE_IN
TXD
SENSE[0..7]
(See Fig. 4.3)
(See Fig. 4.8)
UM[0..26]
MOTORCTL[0..3]
ENABLE_MOTOR
SOUND
MOSI
MISO
SCLK
FPSEL1
FPSEL2
VFDSTB
VFD_BUSY
MOTORCTL[0..3]
MOTOR INTERFACE
MOTORCTL[0..3]
ENABLE_MOTOR
(See Fig. 4.4)
INPUT/OUTPUT INTERFACE
ENABLE_MOTOR
SOUND
MOSI
MISO
SCLK
FPSEL1
FPSEL2
VFDSTB
VFD_BUSY
UM[0..26]
MOTORSENSE1
MOTORSENSE0
(See Fig. 4.10)
POWER ON
OPTO_CTL[0..2]
GM0373-A
UMBILICAL CONNECTOR
UM[0..26]
MOTORSENSE0
MOTORSENSE1
OPTO_CTL[0..2]
(See Fig. 4-.9)
OPTO_CTL[0..2]
Figure 4.2 Main board block diagram
3200 Service Manual
Issue 5 (August 2004)
4 — 11
Processor core
Smiths Medical International Ltd.
SENSE[0..7]
TXD
RXD
HANDSHAKE_OUT
HANDSHAKE_IN
MISO
ENABLE_MOTOR
C39
GND
100nF
TXD
RXD
MISO
SENSE[0..7]
PA2
PA1
GND
SENSE0
SENSE1
SENSE2
SENSE3
SENSE4
SENSE5
SENSE6
SENSE7
VCC'
GND
GND
1
2
5
6
7
8
13
12
9
10
C34
AN0
AN2
AN3
AN4
AN5
AN6
AN7
100nF
X2
32.768KHz
AN1
VCC
C31
100nF
GND
IC15 (SUPERVISOR)
VBAT
VOUT
BATT ON
LOW LINE
OSC IN
OSC SEL
CE IN
CE OUT
PFI
PFO
MAX691A
IC16 (REAL TIME CLOCK)
GND
2
3
R87
10K
VCC
RESET
RESET
C36
100nF
X1
X2
DS1302
WDO
WDI
GND
15
16
14
11
R64
10K
C41
220P
VCC'
SCLK
I/O
RST
C40
2P2
D0
D39
BAT85
PG6
8
7
6
5
GND
MOSI
PH4
CLOCK PULSES
C33
22pF
R63
10M
C32
22pF
VCC
R72E 100K*
R72F 100K*
1
R72G
100K*
8
R65
10K
R80
10K
X1
16MHz
VCC
PH0
PH1
PH2
PH3
PH4
PH5
61
71
GND
IC14 (MICRO-PROCESSOR)
67
EXTAL
68
XTAL
66
4XOUT
71
MODA/LIR
70
MODB/VSTBY
44
VRH
43
VRL
69
RESET
21
XIRQ
54
IRQ
12
PH0/PW1
13
PH1/PW2
14
PH2/PW3
15
PH3/PW4
16
PH4/CSIO
17
PH5/CSGP1
18
PH6/CSGP2
19
PH7/CSPROG
MC68HC11K1FN
D[0..7]
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/XA13
PG1/XA14
PG2/XA15
PG3/XA16
PG4/XA17
PG5/XA18
PG6
PG7/RW
VCC
C35
1
PA0
84
PA1
83
PA2
82
PA3
81
PA4
80
PA5
79
PA6
78
PAI
11
A8
10
A9
9
A10
8
A11
7
A12
6
5
4
55
D0
56
D1
57
D2
58
D3
59
D4
60
D5
61
D6
62
D7
72
RXD
73
TXD
74
MISO
75
MOSI
76
SCLK
77
PD5
42
AN0
41
AN1
40
AN2
39
AN3
38
AN4
37
AN5
36
AN6
35
AN7
53
A0
52
A1
51
A2
50
A3
49
A4
48
A5
47
A6
46
A7
33
A13
32
A14
31
A15
30
A16
29
A17
28
A18
27
PG6SCLK
26
R/W
65
E
E
A[0..18]
GND
C37
100nF
GND
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
GND
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
GND
12
11
10
9
8
7
6
5
27
26
23
25
4
28
29
3
2
30
31
22
24
10
9
8
7
6
5
4
3
25
24
21
23
2
26
1
20
22
27
100nF
IC13 (EPROM)
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
CE
OE
27C4001
2
8
A0
V
C
A1
C
A2
'
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
CS
OE
WE
IC12 (RAM)
62256
O0
O1
O2
O3
O4
O5
O6
O7
VPP
D0
D1
D2
D3
D4
D5
D6
D7
13
D0
14
D1
15
D2
17
D3
18
D4
19
D5
20
D6
21
D7
VCC
1
11
D0
12
D1
13
D2
15
D3
16
D4
17
D5
18
D6
19
D7
MOTORCTL[0..3]
MOTORCTL[0..3]
MOTORCTL0
PA3
MOTORCTL1
PA4
MOTORCTL2
PA5
MOTORCTL3
PA6
PA0
PH2
PH3
PD5
SCLK
MOSI
PH0
PH1
PAI
VFD_BUSY
OFFSET_TRIM
SOUND
POWEROFF
SCLK
MOSI
FPSEL1
FPSEL2
GM0381-B
Figure 4.3 Processor core circuit diagram
4 — 12
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Motor interface
VIN
MOTORCTL[0..3]
ENABLE_MOTOR
GM0376-A
MOTORCTL[0..3]
MOTORCTL0
MOTORCTL1
MOTORCTL2
MOTORCTL3
R86D
100K#
1N4448
VN0300M
C27
100nF
D10
Q22
C23
10uF
R36
1R2
R7D 1K#
78
56R7C 1K#
C24
100nF
GND
GND
GND
GND
GND
UM7
L6
TEE
UM5 MOTOR4
L7
TEE
UM3
L8
TEE
UM1
L9
TEE
MOTOR3
MOTOR5
MOTOR6
UM[0..26]
UM[0..26]
MOTORSENSE0
MOTORSENSE1
D7
1N4448
IC17A
1
2
74HC08
IC17B
4
5
74HC08
IC17C
9
10
74HC08
IC17D
12
13
8
6
2
347
5
1
GND
74HC08
C25
GND
VCC
100nF
3
VN0300M
Q19
VN0300M
R35
1R2
6
8
11
D8
1N4448
Q20
C26
100nF
D9
1N4448
Q21
VN0300M
3200 Service Manual
Issue 5 (August 2004)
Figure 4.4 Motor interface circuit diagram
4 — 13
Power control
R
VIN
Smiths Medical International Ltd.
VDD
VIN
AC LED
VDD
R25
100K
VAC
GND
R32
560R
D6
AMBER
POWER MOSFET
Q4
RFD8P05
GND
VSS
12
13
DCSW
C8
VDD
100nF
IC3D
4093B
GND
11
C17
10uF
Q7
RFD8P05
R24
100K
D30
TSC05
D4
TSC04
GND
CONSTANT
VOLTAGE Vcc')
Q5
BC184L
R23
100K
C9
100nF
DISPLAY (VFD) REGULATION
IC4
LM2940CT5
1
C15
100nF
3
2
VCC'
VFDPW
C16
100nF
POWER ON
POWER OFF
GM0380-A
VSS
VSS
R26
10K
R27
10K
10uF
D5
1N4448
C14
IC3A
4093B
3
R28
100K
R30
10K
10uF
VDD GND
R29
10K
Q6
BC184L
4093B IS POWERED FROM VDD AND VSS
C10
5
6
8
9
1
2
IC3B
4
4093B
SET/RESETLATCH
IC3C
10
4093B
C11
100nF
IC2
LM2931AZ-5-0
1
2
LINEAR REGULATOR
3
C12
100nF
VCC
C13
100uF
GND
GND
Figure 4.5 Power control circuit diagram
4 — 14
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
PRESSURE SENSING (See Fig. 4-7)
DCSW
GND
R1
11K
R2
11K
Sensors and pressure sensing
SENSE0
C1
100nF
OFFSET_TRIM
MOTORSENSE0
MOTORSENSE1
UM[0..26]
OPTO_CTL[0..2]
UM[0..26]
OPTO_CTL[0..2]
UM13
UM4
UM19
UM17
UM15
UM22 OPTDRV2
UM20
UM18
OPTO_CTL1
OPTO_CTL0
OPTO_CTL2
PRESSURE+
PRESSURE-
OPT0
OPT1
OPT2
OPTDRV0
OPTDRV1
R5
10K
R4
10K
R81
10K
D35
1N4148
R77
15K
D37
1N4148
R78
15K
Q3
BC184L
R8
47R
VCC
R79
15K
12R6A 1K#
56
R6C 1K#
12
R7A 1K#
Q1
BC184L
D36
1N4148
R9
47R
D38
1N4148
R82
560R
Q18
BC184L
D1
6v2
D2
6v2
GND
OFFSET_TRIM
PRESSURE+
PRESSURE-
34
R6B 1K#
78
R6D 1K#
34
R7B 1K#
D3
6v2
PRESSURE
PRESSURE_OK
SENSE1
SENSE2
SENSE3
SENSE4
SENSE5
SENSE6
SENSE7
SENSE[0..7]
SENSE[0..7]
GM0377-A
3200 Service Manual
GND
Issue 5 (August 2004)
Figure 4.6 Sensors and pressure sensing interface
4 — 15
Pressure sensing interface
OFFSET_TRIM
R21
4K7
R22
Smiths Medical International Ltd.
C42
10uF
PRESSURE+
PRESSURE-
GND
L3
TEE
L4
TEE
GND
GND
C3
100nF
C4
100nF
4K7
R18
100K
R17
100K
GND
5
6
R14
10K 1%
9
10
R13
100K 1%
R12
100K 1%
IC1B
7
TLC279
IC1C
8
TLC279
R15
10K 1%
R16
10K 1%
R19 220K 1%
C6
100nF
VCC GND
4
3
2
1
1
GND
C5
100nF
R20 220K 1%
IC1A
1
TLC279
VCC
R11
10K
PRESSURE
VCC
C7
100nF
GND
GM0378-A
Figure 4.7 Pressure sensing interface circuit diagram
4 — 16
GND
12
13
TLC279
Issue 5 (August 2004)
IC1D
14
GND
PRESSURE_OK
3200 Service Manual
Smiths Medical International Ltd.
RS232 interface
VCC
C18
TXD
HANDSHAKE_OUT
RXD
HANDSHAKE_IN
C19
10uF
C21
10uF
1
3
2
11
10
12
9
100nF
C1+
C1-
V+
T1IN
T2IN
R1OUT
R2OUT
1
6
VCC(+)
GND(-)
1
5
IC5
C2+
T1OUT
T2OUT
R1IN
R2IN
MAX232
C2-
V-
4
5
6
14
7
13
8
10uF
C20
C22
10uF
12
R34A 1K#
34
R34B 1K#
56
R34C 1K#
78
R34D 1K#
TD
DSR
RD
CTSCTSUM10
UM16
UM12
TXD
DSR
RXDUM14
GM0375-A
GND
+10V
L5
100uH
R33 1K
GND
RTS
UM6
SER_GND
RTSUM8
UM[0..26]
UM[0..26]
Figure 4.8 RS232 interface circuit diagram
3200 Service Manual
Issue 5 (August 2004)
4 — 17
Umbilical cable connections
OPTDRV2
OPTDRV0
OPTDRV1
TXD
RXD
DSR
CTS
RTS
SER_GND
PRESSURE-
GND
VAC
GND
UM22
UM20
UM18
UM16
UM14
UM12
UM10
UM8
UM6
UM4
Smiths Medical International Ltd.
Umbilical Connections
PL4
2526
2324
2122
1920
1718
1516
1314
1112
910
78
56
34
12
HEADER 13X2
UM19
UM17
UM15
UM13
UM7
UM5
UM3
UM1
VCC
VIN
VIN
GND
VIN
OPT0
OPT1
OPT2
PRESSURE+
MOTOR3
MOTOR4
MOTOR5
MOTOR6
UM[0..26]
GM0374-A
UM[0..26]
Figure 4.9 Umbilical cable connections
4 — 18
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Input/output serial interface
VCC
R59
10K
FPSEL1 QA'
SCLK
MOSI
GND
GND
GND
2
3
1
19
12
9
11
18
2
3
1
19
12
9
11
18
GND
C29
IC8
G1
G2
S0
S1
CLK
CLR
SR
SL
74HC299
IC9
G1
G2
S0
S1
CLK
CLR
SR
SL
74HC299
C28
VCC
100nF
A/QA
B/QB
C/QC
D/QD
E/QE
F/QF
G/QG
H/QH
A/QA
B/QB
C/QC
D/QD
E/QE
F/QF
G/QG
H/QH
VCC
100nF
FPSEL2
VFDSTB
R40
6K8
C30
100nF
R41
SOUND
4K7
ENABLE_MOTOR
GM0379-A
R39
910R
GND
D28
1N4448
QH'
QA'
QH'
Q8
BC184L
8
R66C 1K#
7
R66B 1K#
13
6
R66A
14
5
15
4
16
17
8
7
13
6
14
5
OPTO_CTL0
15
OPTO_CTL1
4
OPTO_CTL2
16
17
HEADER 2
R38
330R
PL2
SOUNDER
56
34
1K#
12
OPTO_CTL[0..2]
VCCDCSW
1 2
R57
10K
3XBAT85
Q14
BC184L
D11
D12
D14
RED
R52
560R
VDD
PL3
HEADER 10
1 2 3 4 5 6 7 8 9
D13
R50A
R50B
R50C
R50D
DCSW
R56
10K
Q15
BC184L
VAC
GND
KEYBOARD
1
0
GND
78R66D
12
34
56
78
D15
GREEN
R55
10K
R53
560R
VCC
R76
10K
Q2
BC184L
R3
10K
R10
10K
VCC
1
1
R70A
100K*
41513
2
1K#
1K#
1K#
1K#
1K#
D16
AMBER 1 2
R54
560R
Q16
BC184L
GND
C2
100nF
R73A
56
R73C
12
R74A
56
R74C
VCC
GND
2
3
1
19
12
9
11
18
1K#
1K#
1K#
1K#
D22
6v2
IC10
G1
G2
S0
S1
CLK
CLR
SR
SL
74HC299
D17
GREEN
R42
560R
Q9
BC184L
D23
6v2
D25
6v2
A/QA
B/QB
C/QC
D/QD
E/QE
F/QF
G/QG
H/QH
QA'
QH'
Q10
BC184L
D24
6v2
8
7
13
6
14
5
15
4
16
17
D18
GREEN
R43
560R
GND
D19
GREEN
R44
560R
Q11
BC184L
34R73B
78
R73D
34
R74B
78
R74D
12
R47A
78
R48D
12
R48A
78
R47D
34
R47B
56
R48C
34
R48B
56
R47C
Q12
BC184L
D20
GREEN
R45
560R
VCC
1K#
1K#
1K#
1K#
1K#
1K#
1K#
1K#
1K#
1K#
1K#
1K#
R51
10K
DCSW
Q13
BC184L
GND
VFDPWR
D21
GREEN
R46
560R
GND
GND
1
2
3
4
5
10
11
12
14
7
6
15
9
IC11
SER
A
B
C
D
E
F
G
H
CLK
INH
SH/LD
CLR
74HC166
PL5
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
HEADER 16
13
QH
VFD MODULE
POWER ON
OPTO_CTL[0..2]
MISO
VFD_BUSY
3200 Service Manual
Issue 5 (August 2004)
Figure 4.10 Input/output serial interface circuit diagram
4 — 19
Overview of the regulator
Smiths Medical International Ltd.
LIVE
NEUTRAL
GM0382-A
PL1
SPADE
PL2
SPADE
LIVE Circuits - Primary (See Fig. 4-12)
LIVE
NEUTRAL
OUT2
OUT1
BOOT1
BOOT2
SCREEN1
SENSE1
SENSE2
C4
220P/1kV
C3
220P/1kV
C2
47P
R3
220R
R4
220R
IsolationComponents
R2
220R
T1
6
5
4
3
2
111
PWR XFMR
NC
5
61
4
2
12
10
IC2
CNY17GF
C1
22P
R1
220R
ISOLATED Circuits - Secondary (See Fig.4-13)
IN1
MAINS OK
DC OUT
ESD GND
ESD GND
IN2
BATT+
BATT-
SCREEN2
FB1
FB2
PL11
4
3
2
1
HEADER 4
PL12
2
1
HEADER 2
System
Battery
Figure 4.11 Overview of the regulator
4 — 20
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
FS2
LIVE
T500mA
R20
1M
NEUTRAL
C14
470N/X
EMC Filter
L2
2x47mH
D7
W06G
V1
120R-1A
C10
47U/400V
Regulator live (primary)
OUT1
COMSIG
R19
4K7
R18
47K
COMSIG
R15
4K7
R14
330K
R13
390K
C12
10N
COMPWR
SENSE2
SENSE1
D5
BOOT1
C13
1U/35V
COMSIG
OUT
VREF
IC1
5
4
11
12
13
HV9120P
COMSIG
C11
10N
1
V
I
14
15
9
8
16
10
N
COMP
FB
OSC1
OSC2
BIAS
DISCH
7
V
C
C
SENSE
SHUTDN
C
O
M
RESET
6
COMSIG
D6
13V
C9
1N
R16
470R
Switching MOSFET
Q3
BUZ80
R17
1R8
COMPWR
11DQ10
BOOT2
COMSIG
OUT2
SCREEN1
COMPWR
GM0384-A
3200 Service Manual
COMSIG
Issue 5 (August 2004)
Figure 4.12 Regulator live (primary) circuit diagram
4 — 21
Regulator isolated (secondary)
Smiths Medical International Ltd.
IN1
D1
1N4001
D3
(Heatsinkmounted)
PBYR745
Output Filter
R6
10K
R23
470K
Feedback Reference
R8
1K2
R9
3K6 1%
RV1
470R
R10
2K2 1%
TH1
1K5 TH
C8
10N
D4
TL431
R11
220R
FS1
1Amp
FS3
2Amp
Output Crowbar Protection
D2
13V
Q1
TIC106B
MAINS OK
DC OUT
BATT+
FB1
FB2
SCREEN2
IN2
GM0383-A
Figure 4.13 Regulator isolated (secondary) circuit diagram
C6
2U2/50V
1000U
C7
R7
10K
Q2
BC184L
R5
100R
ESD GND
ESD GND
BATT-
4 — 22
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Syringe and status sensors
OPT1
SIZE SENSOR B
GM0338-A
GUARD RAIL
6
5
1
1
12
4
9
PL1
3
2
1
10
7
8
GND
1
2
3
4
5
6
Figure 4.14 Syringe size sensors circuit diagram
GM0095-A
L1
CHOKE
OPTO0
END OF TRAVEL DETECTOR
OPTO1
OCCLUSION DETECTOR
OPTO2
DRIVE ENGAGEMENT
DETECTOR
Figure 4.15 Status sensors circuit diagram
PL1
1
2
3
4
5
6
Note: Cableform is hardwired
3200 Service Manual 4 — 23
Issue 5 (August 2004)
Distribution board
GND
VAC
GND
CONN[0..26]
DOME
SENSOR
IN-LINE
PRESSURE
SENSOR
POWER
SUPPLY
GM0387-A
UM22
UM20
UM18
UM16
UM14
UM12
UM10
UM8
UM6
UM4
PL5
1
2
3
4
5
6
HEADER 6
PL6
4
3
2
1
HEADER 4
PL1
2526
2324
2122
1920
1718
1516
1314
1112
910
78
56
34
12
HEADER 13X2
GND
VCC
VAC
VIN
GND
UM19
UM17
UM15
UM13
UM11
UM9
UM7
UM5
UM3
UM1
UM22
UM19
UM13
UM4
VCC
VIN
VIN
Smiths Medical International Ltd.
UM11
UM9
UM9
UM7
UM5
UM3
UM1
UM19
UM17
UM15
UM20 OPTDRV0
UM19
UM17
UM15
UM18
UM6
UM10
UM16
UM8
UM14
UM12
VIN
GND
VIN
GND
VCC
MOTOR0
MOTOR1
MOTOR2
MOTOR3
MOTOR4
MOTOR5
MOTOR6
OPT0
OPT1
OPT2
OPT0
OPT1
OPT2
OPTDRV1
SER_GND
<power>
DTR
CTS
TD
RTS
RD
DSR
DCD
PL4
1
2
3
4
5
6
7
HEADER 7
PL3
1
2
3
4
5
6
HEADER 6
PL7
1
2
3
4
5
6
HEADER 6
PL2
1
2
3
4
5
6
7
8
9
10
HEADER 5X2
MOTOR
DRIVE
OPTO
PCB
SENSORS
SYRINGE
SIZE
SENSORS
SERIAL
PORT
4 — 24
Figure 4.16 Distribution board connections
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
RV1
5K
SOT2
1
GM0389-A
2
3
4
BR1
PRESENCE DETECTOR
HOA 1882-12
SOT1 1
2
3
4
5
6
JP1
HEADER 6
NOTE
EITHER SOT1, SOT2 OR RV1
IS FITTED AS FACTORY ADJUSTMENT
Pressure sensing
Figure 4.17 Pressure sensing circuit diagram
3200 Service Manual 4 — 25
Issue 5 (August 2004)
Membrane switch panel
1
2
3
4
5
6
7
8
9
10
HEADER 10
GROUND
SCREEN
ALARM PURGE DOWN UP
Smiths Medical International Ltd.
START STOP HISTORY RESET
GM0416-A
ENTER
Figure 4.18 Membrane switch panel circuit
PL2
SER_GND
1
RI
2
DTR
3
CTS
4
TD
5
RTS
6
RD
7
DSR
8
DCD
9
10
NOTE:
The RS232 Serial Interface connections to PL2 are shown on Fig. 4-18
OFF
ON
"D"
CONN
5
9
4
8
3
7
2
6
1
4 — 26
GM0417-A
Figure 4.19 Internal ribbon cable and ‘D’ connector connections
Issue 5 (August 2004)
3200 Service Manual
CHAPTER 5
FAULT CODES, CLEANING, RENEWAL
of FUSES and REPAIRS
3200
In-line Pressure Syringe Pump
Smiths Medical International Ltd.
Fault codes and repairs
CHAPTER 5
FAULT CODES, CLEANING, RENEWAL of FUSES and REPAIRS
Fault codes Comprehensive fault codes have been designed into the software of the 3200, and a fault
code number has been allocated to each of the faults that may occur (
making identification of a particular fault easy to trace and rectify.
The fault codes listed below are for software Version 2.20, and these codes are not expected
to change for future software versions.
Table 5.1 Main processor fault codes
Code Fault Recommended action
07 Interference or internal circuit See item 2 on page 5-3
Table 5.1
), thus
08 Interference or internal circuit See item 2 on page 5-3
10 Motor or leadscrew See item 4 on page 5-3
11 Interference or internal circuit See item 2 on page 5-3
12 Interference or internal circuit See item 2 on page 5-3
22 Interference or internal circuit See item 2 on page 5-3
25 Interference or internal circuit See item 2 on page 5-3
26 Interference or internal circuit See item 2 on page 5-3
30 Interference or internal circuit See item 2 on page 5-3
31 Interference or internal circuit See item 2 on page 5-3
32 Interference or internal circuit See item 2 on page 5-3
33 Interference or internal circuit See item 2 on page 5-3
34 Interference or internal circuit See item 2 on page 5-3
35 Interference or internal circuit See item 2 on page 5-3
36 Interference or internal circuit See item 2 on page 5-3
40 Interference or internal circuit See item 2 on page 5-3
(contd.)
3200 Service Manual 5 — 1
Issue 5 (August 2004)
Fault codes
Smiths Medical International Ltd.
Fault codes
(contd.)
Table 5.1 Main processor fault codes (contd.)
Code Fault Recommended action
42 Interference or internal circuit See item 2, page 5-3
43 Interference or internal circuit See item 2, page 5-3
45 Interference or internal circuit See item 2, page 5-3
46 Interference or internal circuit See item 2, page 5-3
47 Interference or internal circuit See item 2, page 5-3
51 Interference or internal circuit See item 2, page 5-3
52 Interference or internal circuit See item 2, page 5-3
54 Interference or internal circuit See item 2, page 5-3
55 Interference or internal circuit See item 2, page 5-3
56 Interference or internal circuit See item 2, page 5-3
57 Interference or internal circuit See item 2, page 5-3
58 Interference or internal circuit See item 2, page 5-3
61 Interference or internal circuit See item 2, page 5-3
64 Comms. or internal circuit See item 1, page 5-3
65 Comms. or internal circuit See item 1, page 5-3
68 Comms. or internal circuit See item 1, page 5-3
69 Comms. or internal circuit See item 1, page 5-3
74 Interference or internal circuit See item 2, page 5-3
75 Interference or internal circuit See item 2, page 5-3
76 Interference or internal circuit See item 2, page 5-3
77 Interference or internal circuit See item 2, page 5-3
(contd.)
Issue 5 (August 2004)5 — 2
3200 Service Manual
Smiths Medical International Ltd.
Fault codes
Fault codes
(contd.)
Table 5.1 Main processor fault codes (contd.)
Code Fault Recommended action
78 Interference or internal circuit See item 2 below
79 Interference or internal circuit See item 2 below
80 Interference or internal circuit See item 2 below
81 Interference or internal circuit See item 2 below
83 Interference or internal circuit See item 2 below
85 Power supply fault See item 5 below
86 Motor fault See item 4 below
87 Interference or internal circuit See item 2 below
88 Interference or internal circuit See item 2 below
90 Interference or internal circuit See item 2 below
91 Keyboard fault See item 3 below
92 Interference or internal circuit See item 2 below
The five items shown in Table 5.2 (and cross referenced from Table 5.1) detail the
possible cause of a fault within a pump, and the recommended action to be taken:
Table 5.2 Fault cause and action
Item Fault Possible cause Recommended action
1 Communication External interference... Check communication
(Comms.) fault. e.g. static interference link and interface cable.
or r.f. interference.
Circuit fault. Return to Smiths Medical.
2 Internal fault. External interference... Relocate the pump.
e.g. static interference
or r.f. interference.
Circuit fault. Return to Smiths Medical.
3 Keyboard fault. Damaged keyboard. Replace keyboard.
4 Motor fault. Faulty motor or Check motor and
leadscrew drive leadscrew drive
assembly. assembly.
5 Power supply. Faulty power supply. Check the power supply.
3200 Service Manual 5 — 3
Issue 5 (August 2004)
Cleaning and changing fuses
Smiths Medical International Ltd.
Cleaning
Repairs
Renewal of
fuses
Access to
fuses
WARNING
Do not immerse the pump in any liquids. Immediately wipe off any liquid
that may be 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 repairs and procedures must only be carried out by qualified
technicians.
Disconnect the pump from the AC supply before opening the casing.
The safety and reliability of the pump may be compromised by the use of parts
other than those specified in this Manual.
• FS1 is a fuse located in a DC line and has a 1 amp rating.
• FS2 acts as an AC (time delay) fuse that is rated at 500 mA.
• FS3 is a fuse located in a DC line and has a 2 amp rating.
1. Disassemble the casing (see page 2-11). This will give access to most of the
components on the regulator board.
2. To renew FS2, the protective covering over the faulty fuse must first be prised off.
The fuse can be removed and replaced with a fuse of the correct ratingand size.
3. Refit the protective covering.
4. To renew a faulty FS1 or FS3 (both are situated on the underside of the board), the
three screws that retain the board must be removed.
5. Carefully lift up the board and turn it over to reveal both fuses. Remove the faulty
fuse and replace it with a fuse of the correct rating and size.
6. Refit the board and secure with three retaining screws.
7. Reassemble the casing, being careful not to trap any leads.
Issue 5 (August 2004)5 — 4
3200 Service Manual
Smiths Medical International Ltd.
Repair procedures
Main board
renewal
Regulator
board renewal
The main board is mounted on the front casing. It is held in place by six pozi pan head
self-tapping screws.
1. Open the casing (see page 2-11).
2. Disconnect the umbilical connector (PL4) from the main board.
3. Remove and retain the six pan head fixing screws.
4. Displace the main board and then disconnect the membrane switch panel (PL3).
5. Fit a new main board by reversing steps (2) and (3) given above and then close the
casing (see page 2-11).
6. Complete tests as specified in Section 6.
The regulator board is mounted on the rear casing. It is held in place by three pan head
self-tapping screws.
1. Open the casing (see page 2-11).
2. Remove the two spade connectors and the two ribbon cable connectors from the board.
3. Remove and retain the three screws that hold the board in place.
Status sensors
board renewal
4. Remove the faulty regulator board.
5. Fit a new regulator board by reversing steps (2) to (3) given above ensuring that the
in line AC supply choke that is positioned adjacent to the rear of input connector
does not obstruct the positioning of the board.
6. Close the casing (see page 2-11).
The status sensors board is mounted on the rear case and is held in place by two pan
head self tapping screws.
1. Open the casing (see page 2-11).
2. Remove and retain the screw that holds the distribution board tray in place.
3. Remove and retain the screw that holds the plastic cable holder in place.
4. Remove and retain the two screws and washers that hold the status board in place.
5. Ease out the plastic flag from the faulty status board, as the board is lifted away
from the pump, being careful not to damage the occlusion disc.
6. Fit a new status board by reversing steps (2) to (5) given above and then close the
casing as detailed on page 2-11.
7. Carry out test No. 10 (page 6-3) and the Plunger clamp alarm test (page 6-4).
3200 Service Manual 5 — 5
Issue 5 (August 2004)
Repair procedures
Smiths Medical International Ltd.
Plunger clamp
and super nut
assembly
renewal
Pole clamp
assembly
renewal
Leadscrew
assembly
renewal
The plunger clamp and super nut assembly is held in place (in the rear casing) by two guide
tubes.
1. Open the casing (see page 2-11).
2. Remove and retain the screw that holds the distribution board tray in place.
3. Remove the narrow spring from the size sensor lever arm.
4. Remove the left and right hand brackets that hold the square lay shaft in place.
5. Displace the square shaft together with the super nut and flag moulding, and remove
the entire faulty assembly by lifting the guide tube off its two seatings.
6. Fit the new assembly by reversing steps (2) to (5) given above and then close the
casing (see page 2-11).
1. Remove and retain the two screws that are inserted into the stainless steel bracket
on the base of the pump.
2. Remove the faulty pole clamp.
3. Fit the new pole clamp to the pump by placing and tightening the two screws into
the bracket.
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 lead screw has a ‘left hand’ thread1.
1. Open the casing (see page 2-11).
2. If necessary run the motor on its batteries in order to reveal the small grub screw
situated in the occlusion adjusting 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 adjusting nut
counter-clockwise (i.e. towards the left) in order to relax the spring tension.
4. Remove and retain the two pan head self tapping screws holding the right hand
bearing clamp plate in place; remove and retain the plate.
5. Lift out the leadscrew, together 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 motor by pulling it away from the motor
shaft.
7. Fit a new leadscrew assembly (see Note below) by reversing steps (2) to (6). Tighten
the grubscrew to a torque of 15 ± 2 cNm. Alternatively, renew the motor and gear
box 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 2-11).
10. Carry out the relevant tests in Section 6, including the occlusion thrust checks (see
page 2-13) and also the plunger clamp checks (see page 6-3).
1
If the l.h. thread coupling bush is removed, the torque required when refitted must not
exceed 40 cNm.
Issue 5 (August 2004)5 — 6
3200 Service Manual
Smiths Medical International Ltd.
Repair procedures
Motor and
gearbox
assembly
renewal
Occlusion
clutch and
disc assembly
renewal
There is a plastic coupling between the leadscrew and the gearbox.
1. Open the casing (see page 2-11).
2. Carefully prise open the motor loom retain clip and then disconnect the motor loom
connector (PL4) from the distribution board.
3. Remove the leadscrew assembly (see page 5-6). The motor and gearbox
assembly is attached to the right hand end of the leadscrew assembly and therefore
will be removed with the leadscrew assembly.
4. Detach the faulty motor and gearbox assembly from the leadscrew assembly by
pulling the two assemblies apart.
5. Fit the new motor and gearbox assembly by reversing steps (2) to (4) detailed above
and then assemble the casing (see page 2-11).
6. Carry out the occlusion thrust checks (see page 2-13) and also the plunger clamp
checks (see page 6-3).
7. Complete the relevant tests detailed in Section 6.
The occlusion clutch and disc assembly is situated on the left hand side of leadscrew
assembly underneath the status sensor board.
1. Open the casing (see page 2-11).
2. Remove the status sensors board (see page 5-5).
3. Remove the leadscrew assembly (see page 5-6). The motor and gearbox
assembly is attached to the right hand end of the leadscrew assembly and will,
therefore, be removed with the leadscrew 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 the steps (2) to (4) detailed above
and then assemble the casing (see page 2-11).
7. Carry out the relevant tests in Section 6, including the occlusion thrust checks (see
page 2-13) and also the plunger clamp checks (see page 6-3).
3200 Service Manual 5 — 7
Issue 5 (August 2004)
Repair procedures
Smiths Medical International Ltd.
Membrane
switch panel
renewal
The membrane switch panel has an adhesive backing which fixes it to the casing. Take
care not to unduly bend the new panel or its flexible cable loom.
1. Open the casing (see page 2-11).
2. Disconnect the panel ribbon cable connector (PL3) from the main board.
3. Starting by lifting a corner, peel the faulty panel away from the case. Remove the
panel by pulling the connector out through the slot in the front casing.
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 panel peel back the paper backing approximately as far as
the top of the display window.
6. Push the connector and flexible lead of the new 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 panel to give light adhesion 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 label is positioned correctly into the case recess (i.e. no overhanging
edges), use a soft cloth to rub the panel down firmly pushing out any air bubbles at
the same time.
Super nut
renewal
10. Connect PL3 to the Main board and assemble the casing (see page 2-11).
Early 3200 pumps (pre s/n 56905) were fitted with a half nut. From May 1999, the half nut
was replaced with a three-quarter super nut. The following procedures refer to the super nut,
which must replace the half nut.
GM1088-A
Half nut Super nut
Figure 5.1 Half nut (obsolete)/Super nut
The super nut machined casting (see
Figure 7.2, item 3
) is clamped onto the left hand end of
the outer metal tube by an M4 countersunk screw that is tightened into a recess positioned
hexagonal nut. It is also attached to the toggle mechanism by a Spirol connecting pin.
1. Open the casing (see page 2-11).
2. Remove the plunger clamp, super nut, toggle and square shaft assembly (see
page 5-6).
3. Remove and retain the clamping screw and nut.
4. Lever the two sides of the super nut apart in order to disengage the casting pip from
the locating hole in the metal tube.
5. Remove the spirol connecting pin that holds the super nut to the toggle mechanism.
6. Fit a new super nut by reversing steps (2) to (5) detailed above and assemble the
casing (see page 2-11).
7. Carry out the relevant tests detailed in Section 6 including the plunger clamp checks.
Issue 5 (August 2004)5 — 8
3200 Service Manual
Smiths Medical International Ltd.
Repair procedures
Syringe size
sensors
assembly
renewal
Plunger clamp
repair
1. Open the casing (see page 2-11).
2. Disconnect connector PL1 from the syringe size sensors board.
3. Remove and retain the two screws that hold the sensor assembly in place. Remove
the faulty assembly.
4. If there is a thin shim attached to the faulty assembly then remove and retain this shim.
5. Fit a new sensors assembly by reversing steps (2) to (4) and close the casing (see
page 2-11).
6. Carry out the syringe size sensors test (see Section 6).
If the pump fails to pass the syringe size sensors test it is recommended that the Syringe Size
Sensors kit (part number 0137-0025) should be obtained from Smiths Medical and fitted
according to the instructions supplied with the kit (also see the Appendix).
The plunger clamp cover must be removed in order to reach the internally located lock or
pin moulding. The casing of the clamp is fixed to the right hand end of the outer tube.
1. Remove and retain the two screws that hold the plunger clamp cover onto the
casing and remove the cover.
2. The lock and pin moulding together with the associated spring will now be
accessible.
ACAM pressure
sensing
assembly
renewal
3. As required, fit a new lock and/or pin and assemble the clamp as detailed in
paragraph (1) above.
The ACAM pressure sensing assembly consists of the pressure board and its moulded
housing. Four screws attach the assembly to the metal ACAM sensor plate, and the ACAM
sensor assembly is fixed to the side of the pump by an adhesive sealant (Dow Corning
3145).
1. Open the case (see page 2-11).
2. Remove and retain the four short screws that fix the outer moulding in place.
Remove the moulding and the inner insulating film.
3. Remove and retain the four inner (longer) sealed screws.
4. Remove and retain the cable clamp screw just below the status sensors board and
remove PL5 from the distribution board.
5. Pass the connector through the hole in the case and prise off the sealed ACAM
sensing assembly.
6. Remove the faulty pressure sensing assembly from the ACAM sensing assembly.
7. Fit the new assembly by reversing the steps given in (2) to (6). Reassemble the
case (see page 2-11).
3200 Service Manual 5 — 9
Issue 5 (August 2004)
Repair procedures
CORNERS
ROUNDED
TO MINIMISE
IMPACT
GM0983-A
Smiths Medical International Ltd.
Batteries.
Checks and
replacement
Checks
Replacement
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 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.
Switch the pump on and fully charge the batteries for at least 14 hours. Remove the AC
power and run the pump at 99.9 ml/hr. If the LOW BATTERY alarm appears on the pump's
display before 2.5 hours has elapsed then all three batteries should be replaced, as detailed
below:
1. Open the case (see page 2-11).
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.
Front and/or
rear case
repair
4. Close the casing (see page 2-11).
In March 1999, a new strengthened and modified front and rear case moulding for the 3000
range of syringe pumps (see
CORNERS ROUNDED TO MINIMISE
THE DAMAGE CAUSED BY IMPACT
GM0981-A
PILLAR HEIGHT INCREASED
TO MINIMISE STRESS
Figure 5.2
RIBS ADDED,
EXTRA STRENGTHENING
) was introduced.
CORNERS ROUNDED
TO MINIMISE THE
DAMAGE CAUSED
BY IMPACT
Figure 5.2 Strengthened front and rear case mouldings
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 parts to carry out a repair.
The contents of the repair kits are shown in Tables 5.3, 5.4 and 5.5.
Issue 5 (August 2004)5 — 10
3200 Service Manual
Smiths Medical International Ltd.
Description Part No. Remarks
Front case spares kit- English 0130-0192
Front case spares kit- Other 0130-0165
Case front 0130-0163
Syringe clamp assembly* 0131-0149
Button, moulded* 0131-0216 2 off
Instruction leaflet 0131-0156
Size sensor flag spares kit* 0137-0025 See
Foam spacer type 3* 0131-0218 2 off
Case templates* 0131-0235 2 off
Radius gauge* 0131-0234 Stainless steel
Case screws (6 off) 5001-0345 M4x12, pozi pan
* These items may be obtained individually.
Note:
The Front panel label (membrane) for languages other than English must
be ordered separately (see item 3,
Table 5.3 Front case spares kit
Table 5.4
Figure 7.1
)
Spares kits
Table 5.4 Size Sensor Flag spares kit
Description Part No. Remarks
Size sensor flag spares kit* 0137-0025
Size sensor flag 0132-0090
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
Opto moulding 0130-0024 4.65 mm thick
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
* These items may be obtained individually.
3200 Service Manual 5 — 11
Issue 5 (August 2004)
Smiths Medical International Ltd.
Table 5.5 Rear case spares kit
Description Part No. Remarks
Rear case spares kit* 0130-0171
Case rear 0130-0188
Pressure sensing insulat. film 0130-0031
Foam spacer type 1* 0131-0204
Foam spacer type 2* 0131-0205 3 off
Foot, rubber* 0126-0028 2 off
Instruction leaflet 0131-0156
Case screw, M4x12, pozi pan 5001-0345 6 off
Clamp, cable 5366-2820
Catch, button 0128-0117
Strip, retaining 0128-0118
Screw, M3x10 pozi csk 5000-6317
Screw, M3x6 slot pan
* These items may be obtained individually.
Note:
The Case rear label will be Country dependent, and can also be supplied,
e.g. 0130-0156, English, 110/240 V
Issue 5 (August 2004)5 — 12
3200 Service Manual
CHAPTER 6
FUNCTIONAL TESTS
and MANUFACTURNG SETTINGS
3200
In-line Pressure Syringe Pump
Smiths Medical International Ltd.
CHAPTER 6
FUNCTIONAL TESTS and MANUFACTURING SETTINGS
Functional tests
Functional
tests
Step Test Method Correct result
1 Mechanical Before applying power to the unit, No damage.
2 Electrical safety For routine electrical safety testing, Smiths Medical recommends that units
3 Initial power on. Connect the AC supply. The AC LED lights.
The following functional tests have been designed to verify that the 3200 is safe to use.
Complete the tests before putting the pump into service for the first time, and then as
required.
Table 6.1 Functional tests
inspection. check that the case and exposed
mechanical parts are free from any
damage.
tests are test tested in accordance with the UK Medicine and Healthcare products
Regulatory Authority (MHRA) guideline document MDA DB9801, supplement 1
(December 1999) for Class II, Type CF equipment as a minimum.
Press ON. A bleep is heard and all LEDs
are briefly illuminated.
Following this bleep the syringe
type is displayed. The pump
then goes into its set-up mode
and the STOP and AC LED’s are lit.
4 Syringe sizes. Perform with plunger clamp 40 mm
from RHS and also at extreme LHS.
Insert the following rods (in turn)
into the syringe trough.
11.2 mm. Invalid syringe condition.
12.5 to 15.0 mm. 5ml LED illuminated.
16.2 to 18.2 mm. 10ml LED illuminated.
21.0 to 23.0 mm. 20ml LED illuminated.
23.7 to 26.8 mm. 30ml LED illuminated.
29.0 to 33.1 mm. 50/60ml LED illuminated.
Note:
Smiths Medical manufacture a set of 18 Syringe Size Sensor gauges,
page A-5). 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 of the Graseby 3000
Series of pumps.
part number 0131-0202
(see Appendix,
(contd.)
3200 Service Manual 6 - 1
Issue 5 (August 2004)
Functional tests
Table 6.1 Functional tests (contd.)
Step Test Method Correct result
5(i) Keyboard tests. Press OFF. The display is blank but the AC
AC connected. LED remains lit.
5(ii) Press ON. As above (3), Initial power on.
Smiths Medical International Ltd.
5(iii) Check that the pump can be Confirm display messages shown
programmed by using the ▲
and ENTER keys as described confirm that the keys change
in the Instruction Manual. the settings as required.
5(iv) Check that the
keys operate correctly as described since last reset, then resets to zero
in the Instruction manual. when the reset key is pressed.
5(v) Fit a syringe and move the plunger The syringe type and size is
clamp to the closed position. Prog- displayed. The START LED flashes
ramme the pump, then press START. and the display running indicator
5(vi) Check that the bolus facility functions ALARM and START LEDs flash
as described in the Instruction and the bolus delivered is displayed.
Manual.
5(vii) Check that the change rate facility The rate of infusion changes.
functions as described in the
Instruction Manual.
5(viii) Whilst infusing, press STOP. The pump will enter its set-up mode.
History
-display/reset Display shows volume infused
▼
in the Instruction Manual, and also
arrows flash.
5(ix) Press START to commence the The alarm sounds intermittently,
infusion and then move the plunger the ALARM LED flashes and...
clamp to its open position. PLUNGER CLAMP OPEN
is displayed.
5(x) In the above alarm state [5 (ix] press The alarm is silenced and the pump
the ALARM key. goes into its set-up mode.
6(i) AC failure. Press START to start the infusion The alarm will sound intermittently
and then switch off or remove the and ... AC POWER REMOVED
AC supply externally. will be displayed, but the pump
will continue running under battery
power.
6(ii) Reconnect the AC supply. The AC LED lights.
(contd.)
6 - 2
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Table 6.1 Functional tests (contd.)
Step Test Method Correct result
7 Linear accuracy. Set the following: Check that the plunger clamp moves
• syringe type to 60 ml BD a distance of 18 ±0.3 mm.
Use the linear accuracy • the rate to 99.9 ml. See also page 6-5.
gauge (see page 6-5). • plunger clamp to 60 ml.
Purge the system to remove any
backlash then run the pump for
exactly 6 minutes.
8 Occlusion. The occlusion thrust is factory set Refer to page 2-13.
by applying an opposing force to
the syringe plunger clamp. This is
achieved by using weights.
9 Plunger clamp Close the clamp at mid-position. Front edge of clamp must be between
alignment. Run an infusion of at least 99.9 ml/h. 8 and 10 mm above surface of top cover.
After 5 seconds check clamp position. See page 6-5,
Note:
If this test fails then the super nut will have to be loosened, this will allow 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.
Functional tests
Fig. 6.4 Taper Gauge
.
10 Plunger clamp Load syringe and set an infusion The alarm ...
open, leadscrew rate. Open the plunger clamp. PLUNGER CLAMP OPEN
disengaged. Press START. must be activated.
11(i) Syringe warning, Using a BD 60 ml syringe set the The following display will appear ...
LESS THAN plunger clamp to 15 ml before the LESS THAN 3 MINUTES TO KVO
3 MINUTES end of travel. Set KVO rate to accompanied by a quiet chirping alarm,
TO KVO 0.5 ml/h in Configuration mode. followed after three minutes by ...
and, Run an infusion at 200 ml/h. KVO 0.5 ml/h
KVO 0.5 ml/h. accompanied by a loud pulsing alarm.
11(ii) Syringe warnings, Set and run the pump as in 11 (i) At the end of travel ...
PUMP STOPPED, except that the plunger clamp is PUMP STOPPED: EMPTY/OCCLUSION
PUMP NOT RUNNING. set to 3 ml before the end of travel. appears accompanied by a loud pulsing
alarm, and after a delay ...
PUMP NOT RUNNING will appear.
Note:
When carrying out test No. 11(i) on a Perfusor pump ensure that the syringe is set to a minimum of 18 ml.
12 Transducer Test 3200 Insert Pressure Sensing Disc into Observe display.
sensor housing.
Apply pressure of :- Reading should be:300 mmHg 295 - 305 mmHg
200 mmHg 188 - 212 mmHg
100 mmHg 88 - 112 mmHg
0 mmHg -8 - +8 mmHg
13 Plunger clamp If the pump is fitted with the older style half nut (see page 5-8), the Plunger clamp
alarm tests alarm tests should be performed (see page 6-4).
3200 Service Manual 6 - 3
Issue 5 (August 2004)
Plunger clamp open flag
Square shaft bracket
Notch
GM1087-B
Obsolete 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 5-8).
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 200 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 OPEN
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 5-8). 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.
6 - 4
Figure 6.2 Ramp check - Square/Ramp style flags
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
LOCKING SCREW
MODIFIED SYRINGE
DISTANCE INDICATOR
ROTARY 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.
ROTARY ZEROING DIAL
GM1209-A
DISTANCE INDICATOR
LOCKING SCREW
10
20
30
40
METAL ROD
50
ml
MODIFIED SYRINGE
60
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
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 button until the syringe plunger just activates the gauge indicator.
This action ensures 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, part number 0131-0227
) 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 1 3
GM1210-A
Figure 6.4 Taper gauge
Test procedures
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.
3200 Service Manual 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.
Issue 5 (August 2004)
Manufacturing settings
Smiths Medical International Ltd.
Manufacturing
settings
When the tests of
settings (if required) as shown in sequence in
The settings marked with an asterisk (*) in
selected in order to allow several other associated settings to appear in the Configuration
mode. Ultimately, the final sequence of Manufacturing settings are selected as shown in the
latter part of
1 Syringe type BD PLASTIPAK
2 Syringe size NOT LOCKED
3 Lock program values NO
4 Max infusion rate 200 ml/h
5 Select pump modes ALL MODES AVAILABLE *
6 Preset volume mode with time YES
7 KVO Rate 0.5 ml/h
8 Allow mass units option YES *
9 Infusion units mg/kg/h YES
10 Infusion units mg/kg/min YES
11 Infusion units µg/kg/h YES
12 Infusion units µg/kg/min YES
13 Infusion units mg/h YES
14 Infusion units µg/h YES
15 Show rate in ml/h while infusing YES
16 Use pressure transducer YES
17 Display pressure bargraph YES
18 Allow bolus while running NO
19 Allow rate change while running NO
20 Intermittent mode start delay YES
21 RS232 baud rate 9600
22 Communication mode NONE
23 Pump ID GRASEBY_3200 (see Note over page)
24 Set key beep volume 5
25 Pressure units mmHg
Table 6.1
Table 6.2.
Option Setting
Configuration mode:
have been completed, the pump can be returned to the manufacturing
Table 6.2.
Table 6.2
Table 6.2 Manufacturing settings
are intermediate settings that are initially
6 - 6
Setup mode:
1 Infusion mode INTERMITTENT
2 Dose volume 0.2 ml
3 Dose duration STAT
4 Dose cycle time 4 hours 0 minutes
5 Background rate 0.00 ml/h
6 Start delay 0 hours 0 minutes
7 Pressure limit 75 mmHg
8 Infusion mode PRESET VOLUME
9 Infusion rate 1.0 ml/h
10 Preset volume 0.2 ml/h
11 Infusion mode CONTINUOUS
12 Infusion units mg/kg/h
13 Patient body weight 0.40 kg
14 Drug mass 1.0 mg
15 Drug volume 60 ml
16 Infusion rate 0.01 mg/kg/h
17 Infusion units ml/h
Issue 5 (August 2004)
*
*
*
(contd.)
3200 Service Manual
Smiths Medical International Ltd.
Option Setting
Configuration mode:
5 Select pump modes CONTINUOUS & PRESET
6 Preset volume mode with time NO
8 Allow mass units NO
Set-up mode:
1 Infusion mode PRESET VOLUME
9 Infusion rate 1.0 ml/h
10 Preset Volume 0.2 ml
Note:
The pump ID (item 23) accepts 12 characters exactly. A blank space is not
provided.
Manufacturing settings
Table 6.2 Manufacturing settings (contd.)
3200 Service Manual 6 - 7
Issue 5 (August 2004)
CHAPTER 7
ILLUSTRATED PARTS LIST
3200
In-line Pressure Syringe Pump
Smiths Medical International Ltd.
3200 Illustrated Parts List
CHAPTER 7
ILLUSTRATED PARTS LISTS
Figure 7.1 General assembly
Item Description Part number Remarks
Model 3200
- English 0130-0001
- 110 V model 0130-0701
- Italian 0130-0704
- Spanish 0130-0705
- German 0130-0707
- Dutch 0130-0709
- German Perfusor 0130-0714
- English without plug 0131-0721
- English with Euro mains plug 0130-0728
- Australian 0130-0740
- English 12 V DC 0130-0730
- Norwegian 12 V DC 0130-0735
1 Front case spares kit, (NOT English), 0130-0165 See page 5-11
Kit contains: Front case, Syringe barrel clamp assy, Radius Gauge, Case Templates,
Moulded button (x2), Foam spacer (x2), Size sensor flag kit, Screws M4x12 (x6) and
Instruction leaflet
Front case spares kit (English ONLY), 0130-0192
Kit contains: Front case, Syringe clamp assembly, Button moulded (x2), Size sensor
flag spares kit, Foam spacer type 3 (x2), Front panel label 3200 (English), Radius
gauge, Case templates, Screws M4x12 (x6) and Instruction leaflet,
2 Rear case spares kit 0130-0171
Kit contains: Rear case, 4 Foam spacers, Foot, rubber (x2), Pressure sensing
insulating film, Screws M4x12 (x6), Clamp, cable, Button catch, Retaining strip,
Screw M3x10, Screw M3x6 and Instruction leaflet.
3 Membrane front panel label
- English 0130-0007
- Dutch (same as English) 0130-0007
- German 0130-0064
- Italian 0130-0060
- Spanish 0130-0134
see page 5-11
see page 5-11
3200 Service Manual
Issue 5 (August 2004)
7 — 1
3200 Illustrated Parts List
Figure 7.1 General assembly (contd)
Item Description Part number Remarks
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.
3200 pump Non CE CE marked CE marked
model numbers marked Made in UK Made in Malaysia
serial no's serial no's serial no's
below 46035 from 46035 from 90000
0131-0001, English 240V 0130-0156 0130-0008 0130-0194
0131-0721, English (without plug)
0131-0728, English (euro plug)
0131-0701, English 110V 0130-0156 0130-0008 not available
0131-0704, Italian 0130-0180 0130-0061 0130-0197
0131-0705, Spanish 0130-0179 0130-0135 0130-0198
0131-0707, German 0130-0178 0130-0082 0130-0196
0131-0709, Dutch 0130-0182 0130-0069 0130-0199
0131-0714, German (Perfusor) 0130-0178 0130-0082 0130-0196
0131-0730, English DC 0130-0111 0130-0191 0130-0195
0131-0735, Norwegian DC not available 0130-0118 0130-0200
0131-0740, Australian 0130-0156 0130-0008 0130-0194
Smiths Medical International Ltd.
to 89999
5 Case screws 5001-0345 6 required
6 Motor and gearbox assembly 0131-0015
7 Leadscrew assembly see
8 Occlusion sensing assembly 0131-0067
9 Support tube 0127-0047
10 Plunger clamp assembly see
11 Nearly empty flag kit 0131-0122 2 types of flag supplied
12 Syringe barrel clamp assembly 0131-0149
13 Size sensor flag retainer kit, 0131-0238
Figure 7.4
Figure 7.2
Kit contains: Size sensor flag, anchor plate assembly, Size sensor spring
14 Bearing clamp bracket 0127-0053
15 Leadscrew bearing bracket 0127-0051
16 Square shaft bracket 0127-0052
17 Main PCB assembly 0130-0009 see
18 Regulator PCB assembly
- Regulator PCB assembly - AC Power 0130-0013 see
- Regulator PCB assembly - DC Power 0130-0101
19 Transformer 0130-0021 AC Power only
20 Opto sensors board 0128-0090
21 Opto sensors cable 0053-0670
Figure 7.5
Figure 7.6
7 — 2
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
3200 Illustrated Parts List
3200 Service Manual
Issue 5 (August 2004)
Figure 7.1 General assembly
7 — 3
3200 Illustrated Parts List
Smiths Medical International Ltd.
7 — 4
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Figure 7.1 General assembly (contd)
Item Description Part number Remarks
22 Size sensors PCB assembly 0130-0017
23 Cable assembly size sensor 0053-0678
24 Distribution board assembly 0130-0027
25 Cable assembly - Distribution to Main board 0053-0687
26 Pole clamp assembly
- Non-rotating pole clamp 0131-0129
- Rotating pole clamp 0131-0083
27 Plunger clamp open flag 0127-0019
28 Mains cable assembly
- AC Power 0053-0646 Internal; two wire
- DC Power 0053-0702 Internal; two wire
29 Power cable assembly 0053-0680
3200 Illustrated Parts List
see Figure 7.3a
see Figure 7.3b
PL11 (Regulator board) to PL6 (Distribution board)
30 Battery - Cyclon
31 Cable assembly battery A 0053-0647
32 Cable assembly battery B 0053-0648
33 Cable assembly battery C 0053-0649
34 Cable assembly D connector 0053-0657
35 ACAM sensor insulating film 0130-0031
36 ACAM sensor top moulding 0130-0043
37 ACAM pressure sensor assembly 0130-0033
38 Cable clamp 0127-0043
39 Cord set
- UK 3700-0046
- AC power, 110 V 3700-0230
- Spanish, French, German 3700-0035
- Italian, without plug 3700-0025
- Dutch 3700-0044
- Australian 3700-0056
40 Instruction Manual Not illustrated
- English 0130-0044
- Dutch 0130-0099
- German 0130-0084
- Italian 0130-0152
- Norwegian 0130-0095
- Spanish 0130-0137
41 Technical Service manual 00SM-0130 Not illustrated
42 Size sensor gauge set/kit 0131-0202 Not illustrated
(was P/N 3420-2120)
0151-0649 3 required
Kit contains: 18 size sensor gauges, Instruction leaflet for calibration
43 PC interface cable assembly 0053-0704 Not illustrated
Issue 5 (August 2004)3200 Service Manual
7 — 5
3200 Illustrated Parts List
Figure 7.1 General assembly (contd)
Item Description Part number Remarks
44 5/10 ml adaptor plate 0132-0076 Germany only
45 Perfusor conversion kit 0131-0048 Not illustrated.
Kit contains the following items: Perfusor spacer tube, see Chap. 8 for
nearly empty flag for Perfusor, Plunger clamp plate, ‘P’ label. conversion procedure.
46 Linear accuracy gauge 0131-0230
47 Taper gauge 0131-0227
48 Dual ramp gauge 0131-0084
49 Security cover spares kit, 0131-0151 Not illustrated
Kit contains: Pole clamp assembly, Syringe cover, Cover pin bearing (x2), Cover pin (x2),
Compression ring (x2), Circlip (x2), Torx screw (x2), Retaining strip, Button catch,
Drilling template, Loctite 638, Screw M3x6 slotted pan, Screw M3x10 csk pozi and
Instruction leaflet
Smiths Medical International Ltd.
see page 6-4
see page 6-4
7 — 6
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Figure 7.2 Plunger clamp and half nut assembly
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, 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 0137-0025
Kit contains: Size sensor flag moulding, Protective cap, Grub screw M4 x 6, Size sensor
shim (x4), Size sensor moulding, Instruction leaflet, screw s/tap (x20
8 Square shaft 0127-0048
3200 Illustrated Parts List
Figure 7.4
3200 Service Manual
Figure 7.2 Plunger clamp and half nut assembly
Issue 5 (August 2004)
7 — 7
3200 Illustrated Parts List
Fig. 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
Smiths Medical International Ltd.
7 — 8
Figure 7.3a Pole clamp assembly - Non-rotating
Issue 5 (August 2004)
3200 Service Manual
Smiths Medical International Ltd.
Fig. 7.3b Pole clamp assembly: Rotating
Item Description Part No. 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 containing: 0131-0052
Clamp bolt, Clamp pad, Spacer, End cap, Screw M3 x 12, Instruction sheet.
3200 Illustrated Parts List
3200 Service Manual
Figure 7.3b Pole clamp assembly - Rotating
Issue 5 (August 2004)
7 — 9
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