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Micro 505
User manual
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Smiths 500, Micro 505 User manual

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Model 3000/500 and Micro 3100/505
Volumetric Infusion Pump
Technical Service
Manual
0473
Graseby Medical Ltd.
Volumetric Infusion Pumps
Warnings
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.
1. WARNING: You 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 .
2. WARNING: Do not use a faulty pump. If the pump detects a fault when it is first turned on, or if it develops a fault during operation then a continuous system alarm sounds. The pump must be referred to a suitably qualified technician or returned to Graseby Medical in order to have the fault rectified.
3. WARNING: Before using the pump, it should be inspected for physical damage. The pump should not be used if damage is evident, and should be returned to service personnel for repair before being returned to use. Failure to do so may result in compromised function of the product, patient injury or user injury .
4. WARNING: Do not use the pump if you detect any cracks, chips and loose or bent parts, or if the buttons do not move in and out freely when they are pressed. Failure to do so could cause inadvertent disconnection of the pumps.
5. WARNING: Do not push or pull on the pumps, or the IV pole may tip over or the pumps fall to the floor . Do not try to remove modular connected pumps from the IV pole whilst they are joined together. Either of these could cause the administration set to separate from the fluid container thus spilling the medication, or the pumps themselves could be damaged.
6. WARNING: Correct entry of data is essential in order to ensure that the intended infusion is performed. Before confirming any displayed data when setting up an infusion, you 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: Dose-rate calculation requires care in entering data. Refer to specific product drug labelling for information on appropriate administration techniques and dosages. Entering incorrect data may result in patient injury or death.
8. WARNING: When delivering drugs in the epidural space, use only those medications specifically indicated for epidural use. Epidural administration of other drugs could result in serious patient injury or death.
9. WARNING: The use of administration sets incorporating injection sites could lead to an improper or inappropriate infusion resulting in serious patient injury or death.
10. WARNING: Failure to clearly identify the pump and administration sets could lead to an improper or inappropriate infusion resulting in serious patient injury or death.
11. WARNING: Remove any air to prevent air embolism. The presence of air within the infusion can result in complications resulting in patient injury or death.
12. WARNING: To avoid over infusion, do not prime the infusion line when the administration set is connected to the patient. Over infusion can result in patient injury or death.
13. WARNING: The Occlusion alarm level must be checked before starting an infusion to ensure that it is appropriate for the infusion. Failure to do so may result in an unacceptably slow time to Occlusion alarm, resulting in patient injury or death.
14. WARNING: Prior to starting an infusion, inspect the fluid path for kinks, a closed clamp or other obstructions. Failure to do so may result in the infusion not being delivered correctly , resulting in patient injury or death.
15. WARNING: If using a blood pressure cuff above the patient’s venipuncture site take extra care in setting the Occlusion alarm pressures. Failure to do so may result in unnecessary Occlusion alarms, resulting in patient injury or death.
16. WARNING: The Occlusion detection system measures downline pressure in the administration set, but does not detect infiltration. In accordance with local protocol, you must periodically inspect the patient’s infusion site for signs of infiltration. Failure to do so may result in an unacceptably slow time to Occlusion resulting in patient injury or death.
17. WARNING: If an Occlusion alarm occurs, immediately clamp the line to the patient. Then inspect the fluid pathway to determine what has caused the obstruction. An unintentional bolus of medication can result in patient injury or death.
18. WARNING: Do not run parallel infusion lines below the pump. Delivering a Secondary infusion means
above
running a second line resulting in patient injury or death.
19. WARNING: Check the Secondary set carefully, since an occlusion above the pump on the Secondary line could cause the Primary fluid to be delivered instead of the Secondary infusion. Administering the wrong medication may cause serious patient injury or death.
the pump. Failure to do so may result in an inaccurate delivery of medication,
Volumetric Infusion Pumps
20. WARNING: The Secondary volume to be infused must match the amount of fluid in the secondary container. Primary flow resumes when the secondary container is empty. If the volumes do not correspond, the wrong infusion may be delivered which could cause serious patient injury or death.
21. WARNING: Correct management of battery charging, as described in this documentation is essential to ensure that the pump can operate on battery for the time specified. Failure to do so may result in compromised function of the product or patient injury .
22. WARNING: If a backup alarm sounds, the pump should be immediately removed from the patient and sent to be repaired by a Graseby Medical qualified technician. Failure to do so may cause patient injury or death.
23. WARNING: Failure to use the power cord retainer means that the pump may be accidentally or erroneously disconnected from the mains. Although there is a battery backup in case this happens, the battery may not be charged sufficiently . Consequently , there is a risk of the pump not functioning which could lead to patient injury or death.
24. WARNING: Do not open the pump housing. Refer all service faults only to qualified technical personnel. Opening the pump housing may cause electric shock leading to patient or user injury or death.
25. 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 back of the pump, otherwise patient safety may be compromised.
26. WARNING: While Graseby Medical Limited have taken all reasonable steps to ensure that the pump operates correctly while under remote control, it is the responsibility of the person who designs and implements the controlling device to ensure that the resulting system (pump and controlling device) is fit for its intended purpose. Failure to do so may result in compromised function of the product, patient injury or user injury .
27. WARNING: Use only Graseby Medical administration sets with this product. Failure to do so may result in compromised system accuracy leading to complications resulting in patient injury or death.
28. WARNING: Do not perform these tests while the pump is in use on a patient, as this may cause patient injury or death.
29. WARNING: Unplug the AC power cord before opening the pump housing to avoid risk of electric shock, which could result in death or serious injury .
30. WARNING: Potentially dangerous voltages are exposed when the pump housing is open and the AC power cord is plugged in. These voltages are present in the transformer and AC fuse on the CPU/Power supply board and the RFI line filter where the power cord connects. T o avoid electric shock with potential for severe injury or death, do not touch these areas when the power cord is plugged in.
Graseby Medical Ltd.
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Volumetric Infusion Pumps
Cautions
Cautions tell you about dangerous conditions that can occur and cause damage to the pump if you do not obey all of the instructions in this manual.
1. CAUTION: Refer all service, repair and calibrations only to qualified technical personnel. Unauthorised modifications to the pump must
2. CAUTION: Do not autoclave, steam sterilize, ETO sterilise or subject the pump to temperatures in excess of 45° C (113° F). Excessive temperatures may cause damage to the pump.
3. CAUTION: To prevent serious damage to the pump it must not be immersed in any liquids or exposed to strong organic solvents. Wipe off spills immediately . Do not allow fluid or residues to remain on the pump. Additionally , the pump is not designed to allow it to be sterilised. Failure to observe these cautions may cause internal damage to the pump.
4. CAUTION: Carry out periodic cleaning following the detailed instructions in this manual Do not use unapproved cleaning agents.
5. CAUTION: When turning the pump on, if screens similar to those illustrated are not displayed, do not use the pump, and send the pump to authorised service personnel.
6. CAUTION: Only carry the pump by the handle. Failure to do so may result in damage to the pump, or the pump may be dropped which could cause internal damage to the pump.
7. CAUTION: The backlight has a limited life and may , if used constantly , cause the light to dim. Eventually the message display may then need to be replaced. T o preserve the life of the message display, you should only turn on the Message Display Light as described here if it is specifically required. Misuse of this feature could lead to both battery and LCD depletion.
8. CAUTION: The Functional and Accuracy Check should be performed following any significant disassembly or repair of the pumps.
9. CAUTION: The circuit boards consist primarily of surface mounted technology , component level repairs are not recommended.
10. CAUTION: Disconnect the battery connection P104 on I/O board before disassembling the circuit boards to avoid circuit damage. After disconnecting P104, press the
11. CAUTION: Handling of printed circuit boards is required during disassembly/assembly . A static controlled work station including a conductive mat and grounded wrist strap should be used to provide protection against electrostatic discharge (ESD) or circuit board damage could result.
12. CAUTION: Do not use a screwdriver or other sharp instrument to separate the front and rear housing as this action could cause pump damage.
13. CAUTION: Do not damage or puncture the kapton tape. If the tape is damaged or punctured it could result in the pump not being ESD protected. Special care should be taken when placing the kapton tape and also when assembling the front and rear cases together as the front case lugs may puncture the tape.
14. CAUTION: Crossed wires must be shielded with suitable insulation as described. Failure to carry out the procedure as specified may result in permanent damage to the LCD.
not be carried out.
On/Off
key twice to discharge the circuitry.
Volumetric Infusion Pumps
Graseby Medical Ltd.
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd. Volumetric Infusion Pumps
Published by Graseby Medical Limited. All possible care has been taken in the preparation of this publication, but Graseby Medical Limited accepts no liability for any inaccuracies that may be found.
Graseby Medical reserves the right to make changes without notice both to this publication and to the product which it describes.
© Graseby Medical Limited 2002
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 Graseby Medical Limited.
GRASEBY MEDICAL LTD,
Colonial Way, Watford, Hertfordshire, UK WD24 4LG
TEL: (+44) (0)1923 246434 FAX: (+44) (0)1923 231595 WEB: www.graseby.co.uk
REGISTERED IN ENGLAND
COMPANY No. 995550
Trademarks and acknowledgements:
Graseby; and Smiths are all trademarks of the Smiths Group plc.
All other trademarks are acknowledged as the property of their respective owners.
Contents — i
Volumetric Infusion Pumps
Graseby Medical Ltd.
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Contents — ii
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd. Volumetric Infusion Pumps
Contents
Chapter 1 - Introduction
Introduction
Scope of this manual...................................................................................................... 1 - 1
Related manuals ............................................................................................................ 1 - 1
Graseby service contacts .............................................................................................. 1 - 1
Product Overview............................................................................................................. 1 - 2
System description ........................................................................................................ 1 - 2
Optional labels................................................................................................................ 1 - 2
Software versions .......................................................................................................... 1 - 2
Chapter 2 - Specification
Specifications.................................................................................................................... 2 - 1
Standards .......................................................................................................................... 2 - 8
T rumpet curves ................................................................................................................. 2 - 9
Chapter 3 - Overview of Pump Operation and Initial Checks
Overview of Pump Operation & Initial Checks .............................................................. 3 - 1
Exterior of the 500/3000 pump - front ............................................................................. 3 - 2
Exterior of the pump - rear ............................................................................................. 3 - 3
How the pump is powered.............................................................................................. 3 - 4
How the pump works ..................................................................................................... 3 - 5
Power up tests and checks............................................................................................ 3 - 9
Powering down............................................................................................................. 3 - 12
Power monitoring.......................................................................................................... 3 - 13
Alarms.......................................................................................................................... 3 - 15
Chapter 4 - Volumetric Pumps Menus
Volumetric Pump Menus .................................................................................................. 4 - 1
Which version of software is in the pump?..................................................................... 4 - 1
Introduction to menus..................................................................................................... 4 - 1
About the T echnician menu ............................................................................................ 4 - 2
Summary of Technician menu parameters .....................................................................4 - 3
Using Technician parameters ......................................................................................... 4 - 4
About the Biomedical menu............................................................................................ 4 - 8
Summary of Biomedical menu parameters .................................................................. 4 - 10
Contents — iii
Volumetric Infusion Pumps
About Snapshot screens.............................................................................................. 4 - 11
Decoding Snapshot screen-a ....................................................................................... 4 - 12
Decoding Snapshot screen-b ....................................................................................... 4 - 15
Using Biomedical Parameters ...................................................................................... 4 - 22
Enabling special programming functions...................................................................... 4 - 27
About the Service Functions menu .............................................................................. 4 - 29
Service Functions menu parameters ........................................................................... 4 - 30
Graseby Medical Ltd.
Chapter 5 - Mechanical Systems
Mechanical Systems ......................................................................................................... 5 - 1
Linkage system.............................................................................................................. 5 - 1
Cassette housing and door ............................................................................................ 5 - 2
Safety clip retention slot .................................................................................................5 - 2
Cam housing switch and safety clip switch ................................................................... 5 - 4
Cam housing ..................................................................................................................5 - 4
Stepping motor ............................................................................................................... 5 - 4
Cams, pistons and valves of the pumping mechanism.................................................. 5 - 6
Encoder wheel and interrupter ....................................................................................... 5 - 9
Empty bag contacts ..................................................................................................... 5 - 10
Sensors........................................................................................................................ 5 - 10
Pole clamp and IV pole................................................................................................. 5 - 12
Modular connection system ......................................................................................... 5 - 12
Chapter 6 - Electronic Circuits
Electronic Circuits ............................................................................................................ 6 - 1
Definitions....................................................................................................................... 6 - 1
Functional block diagram ............................................................................................... 6 - 1
System control ............................................................................................................... 6 - 2
Power ............................................................................................................................. 6 - 2
Interconnection summary............................................................................................... 6 - 3
PCB design .................................................................................................................... 6 - 3
CPU/power supply board............................................................................................... 6 - 3
Power supply.................................................................................................................. 6 - 9
I/O board ...................................................................................................................... 6 - 11
Display board ............................................................................................................... 6 - 14
RS232 interface ........................................................................................................... 6 - 17
Contents — iv
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd. Volumetric Infusion Pumps
Chapter 7 - Maintenance Procedures
Maintenance Procedures ................................................................................................. 7 - 1
Introduction..................................................................................................................... 7 - 1
Recommended test equipment....................................................................................... 7 - 2
Recommended troubleshooting equipment ....................................................................7 - 2
Service tool kit................................................................................................................7 - 3
Periodic cleaning ............................................................................................................ 7 - 4
Recommended yearly checks and tests ........................................................................ 7 - 6
Recommended Functional & Accuracy Tests:
Checklist.......................................................................................................................... 7 - 18
Troubleshooting.............................................................................................................. 7 - 19
Replacing the LCD ....................................................................................................... 7 - 23
Reinitialising the pump after replacing the NVRAM (IC18)........................................... 7 - 25
Adjustment of the “Cassette Fitted” micro switch......................................................... 7 - 32
Chapter 8 - Disassembly and Reassembly Instructions
Disassembly and reassembly instructions .................................................................... 8 - 1
Battery removal.............................................................................................................. 8 - 1
AC fuse removal ............................................................................................................ 8 - 1
Front housing removal.................................................................................................... 8 - 2
Door assembly removal ................................................................................................. 8 - 3
CPU/Power supply board removal................................................................................. 8 - 5
I/O board assembly removal .......................................................................................... 8 - 6
Display board assembly removal................................................................................... 8 - 7
Membrane switch replacement - old case...................................................................... 8 - 8
Membrane switch replacement - new case.................................................................... 8 - 9
Pump assembly removal.............................................................................................. 8 - 10
Motor assembly removal.............................................................................................. 8 - 11
Realignment of motor coupler....................................................................................... 8 - 12
Cassette housing disassembly .................................................................................... 8 - 13
Safety clip mechanism disassembly............................................................................ 8 - 13
Cam housing switch disassembly................................................................................ 8 - 14
Calibration and adjustment of components................................................................. 8 - 15
Cam housing switch adjustment .................................................................................. 8 - 15
Occlusion alarm adjustment......................................................................................... 8 - 16
Voltage Checks ............................................................................................................... 8 - 18
Power supply voltage check ........................................................................................ 8 - 18
Low and dead battery alarm check .............................................................................. 8 - 21
Contents — v
Volumetric Infusion Pumps
Graseby Medical Ltd.
Chapter 9 - Illustrated Parts List
Illustrated Parts List for pump Serial numbers
from 3000 to 60,000........................................................................................................... 9 - 1
General assembly of the volumetric pump..................................................................... 9 - 2
Pump assembly ............................................................................................................. 9 - 8
Rear housing assembly ................................................................................................. 9 - 9
Display board assembly............................................................................................... 9 - 12
CPU power supply/RS232 board assembly ................................................................ 9 - 14
I/O board assembly...................................................................................................... 9 - 16
Illustrated Parts List for Serial numbers from 60,000 ................................................. 9 - 17
General assembly of the volumetric pump................................................................... 9 - 18
Pump assembly ........................................................................................................... 9 - 22
Rear housing assembly ............................................................................................... 9 - 23
Display board assembly............................................................................................... 9 - 25
CPU power supply/RS232 board assembly ................................................................ 9 - 26
I/O board assembly...................................................................................................... 9 - 27
Chapter 10 - Electrical Diagrams
Electrical Diagrams ........................................................................................................ 10 - 1
Introduction................................................................................................................... 10 - 1
Overall functional block diagram .................................................................................. 10 - 2
Power routeing block diagram ...................................................................................... 10 - 3
Electrical routeing block diagram ................................................................................. 10 - 4
Display board schematic.............................................................................................. 10 - 5
CPU/Power supply schematic (sheet 1 of 3) ............................................................... 10 - 6
CPU/Power supply schematic - CE (sheet 2 of 3)....................................................... 10 - 7
CPU/Power supply circuit (sheet 3 of 3) ....................................................................... 10 -8
Input/Output schematic ................................................................................................. 10 -9
RS232 schematic........................................................................................................ 10 -10
Chapter 11 - Waveform Diagrams
Waveform Diagrams..................................................................................................... 11 - 1
Introduction................................................................................................................... 11 - 1
Contents — vi
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd. Volumetric Infusion Pumps
Chapter 12 - Remote monitoring and controlling of the pump
Remote monitoring and controlling of the pump ........................................................ 12 - 1
Introduction................................................................................................................... 12 - 1
Organisation of this chapter ......................................................................................... 12 - 1
Summary of commands - V ersion 0.67 and below....................................................... 12 - 2
Protocol definition......................................................................................................... 12 - 2
Record Format - Version 0.67 and below.................................................................... 12 - 3
Command Codes ......................................................................................................... 12 - 3
Error Processing.......................................................................................................... 12 - 7
Summary of hardware connection and handshaking ...................................................12 - 7
Example Commands.................................................................................................... 12 - 8
Interfacing with pump software version 0.68 and above ............................................ 12 - 9
Model 3000/500 3100/505 Computer Interface ............................................................ 12 - 9
Protocol Definition ........................................................................................................ 12 - 9
Character ..................................................................................................................... 12 - 9
Format - version 0.68 and above ............................................................................... 12 - 10
Command Record Format - version 0.68 and above ................................................. 12 - 11
Return Record Format ............................................................................................... 12 - 15
Command Summary .................................................................................................. 12 - 18
Pump Powered Down - AC/Battery............................................................................ 12 - 23
Exiting CI Mode - Terminated vs. Disabled................................................................. 12 - 23
Response Time-outs and Error Processing............................................................... 12 - 24
Summary of Handshaking and Hardware Connection............................................... 12 - 24
Example Commands.................................................................................................. 12 - 25
Contents — vii
Introduction
Chapter 1
Graseby Medical Ltd.
Introduction
Volumetric Infusion Pumps
Scope of this manual
This manual is aimed at service personnel to enable them to service and repair the Volumetric range of pumps. It has been revised and updated to cover the Version 0.71 pump software, and where appropriate it describes and illustrates the revised case design (for pumps with serial numbers from 60,000). However, the manual is backwards compatible with all earlier versions of pump software and case design.
Related manuals
Refer to the Instruction Manual and Technical User Manual when more detailed operating information is required, since this is outside the scope of the Service Manual. The following manuals are applicable to the Volumetric Infusion Pumps with Version 0.71 software and are listed in Chapter 9 Illustrated Parts List:
1
Instruction Manual and Technical User Manual - old case
design, see pages 9-6 and 9-7 for part numbers
Instruction Manual and Technical User Manual - new case
design, see page 9-21 for part numbers
The Instruction Manuals for Version 0.67 and earlier software are listed in the first section of Chapter 9 Illustrated Parts List, see page 9-6.
Graseby service contacts
If you have any queries or problems with your pump that cannot be solved by this manual, please contact the appropriate Service Centre.
UK service address
GRASEBY MEDICAL LIMITED TEL: (+44) (0)1923 246434 COLONIAL WAY WATFORD FAX: (+44) (0)1923 447773 HERTFORDSHIRE WD24 4LG Website: www.graseby.co.uk ENGLAND
USA service address
DELTEC INC. TEL: 001 651 633 2556 1265 GREY FOX ROAD TOLL FREE 0800 433 5832 ST PAUL FAX: 001 651 628 7459 MINNESOTA 55112 Website: www.deltec.com U.S.A.
3000/3100 and 500/505 Service Manual
Issue A (April 2002)
1 — 1
1
Volumetric Infusion Pumps
Product Overview
System description
The Model 3000/500 and Micro 3100/505 Volumetric Infusion pumps, including the dedicated administration sets, are for use by trained medical professionals in the intravenous and intra-arterial delivery of fluid and medications. In addition, they may be used for epidural delivery.
Note: Graseby Volumetric Infusion Pumps are also known as the Model 500
and Micro 505. With the exception of the numbering the 3000/500 and the 3100/505 versions of the pumps are identical.
Optional labels
To assist users to differentiate the pump and IV set being used for epidural delivery, from those being used for other infusions, a yellow Epidural Label Set for the Volumetric Infusion Pump (part no. TPF-
00306) is available from Graseby Medical Ltd.
Graseby Medical Ltd.
Software versions
If a pump label lists more than eight options, Version 0.71 software is installed. If there are fewer options, the pump has an earlier version of software. You can find out the software version of the pump by checking on the Biomedical Menu, see Chapter 4, Volumetric Pump
Menus.
1 — 2
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
About Version 0.71
The new software contains some completely new features as well as improvements to existing features. These include many new configurable options such as selectable default settings for the occlusion alarm levels, Primary/Secondary Rate and Volume to be Infused selectable minimum and maximum limits, drug library and bolus functions. Added to this, the Quick Rate Change option is now a configurable feature, and may be enabled or disabled as required.
For a complete list of the functions please see the new Volumetric Instruction Manual and the Technical User Manual.
Upgrading to Version 0.71
It is possible to upgrade earlier Graseby Medical Volumetric range pumps to the latest software version 0.71. For 3000/500 pumps order part no. 0150-0671 and for 3100/505 pumps order part no. 0150-0672 (note these are English only kits). The upgrade kit contains the following items:
Volumetric Infusion Pumps
1
V0.71 CPU Board Prom  3.66A Display Prom  Keypad Overlay (3000/500, 3100/505)  Keypad  Start up Label  Overlabel (3100/505)  Lower door recess label  Instruction Manual  Technical User Manual  Instructions for upgrade.
3000/3100 and 500/505 Service Manual
Issue A (April 2002)
1 — 3
Specification
Chapter 2
Graseby Medical Ltd.
Volumetric Infusion Pumps
Specifications
General
Weight 5 kg (11 pounds).
Dimensions for pumps with serial numbers from 3000 to 59,999
including pole clamp Height 25 cm (10 inches). Width 21.5 cm (8.6 inches). Depth 23.5 cm (9.45 inches).
for pumps with serial numbers from 60,000
including pole clamp Height 28 cm (11 inches). Width 21.5 cm (8.6 inches). Depth 23.5 cm (9.45 inches).
2
Temperature Operating 18° to 40° C (64° to 104° F)
Storage -25° to +55° C (-13° to 131° F).
Relative humidity Operating 30% to 75% (non-condensing).
Storage 30% to 75% (non-condensing).
Pressure range Operating 50 kPa to 106 kPa
Storage 19 kPa to 106 kPa
Immunity levels Immunity levels are the full levels specified in
EN60601-1-2 (radiated immunity is 3 V/m and ESD immunity is 3 kV contact and 8 kV air).
Free flow protection The pump mechanism operates the safety clip on
the administration set.
Head-height From bottom of drip chamber to top of pump
Model 3000/500 15 cm (6 ins) minimum for flow rates <500 mL/h
30 cm (12 ins) minimum for flow rates >500 mL/h 30 cm (12 ins) when using 60 drops/mL sets 30 cm (12 ins) when using thick solutions*
Micro 3100/505 15 cm (6 ins) minimum
30 cm (12 ins) when using 60 drops/mL sets 30 cm (12 ins) when using thick solutions*
* certain cytotoxic agents, lipid-based fluids and other viscous solutions, for example Total Parenteral Nutrition.
2 — 1
Volumetric Infusion Pumps
Self test Dual microprocessors independently test each other.
Maximum over infusion Under a single-fault condition, the maximum over
infusion that may occur is 12.5% over the selected flow rate. Larger inaccuracies are detected by the pump, and cause it to stop infusing and to alarm.
Graseby Medical Ltd.
2
Air detect system Air bubbles are detected by electronic opto-
encoder detection device (with self-checking sensors) located on cassette housing.
Accuracy ± 2% of displayed rate and volume to be infused.
The quoted accuracy is ±2% for a long-term infusion. Below rates of 1 mL/h this accuracy may not be achieved for a short-term infusion. During the total infusion time the accuracy averages out (see trumpet curves in this chapter).
Accuracy measurement equipment
50 mL glass measurement burette graduated in
0.1 mL increments and traceable to National Institute of Standards and Technology or appropriate international standards bureau.
Test solution Sterile water or normal saline at room
temperature (70°F ±5°/21°C ±3°). Graseby standard (primary), 20 drops/mL, non­checkvalve administration set (8C820).
Testing conditions
Accessories
Model 3000/500 fluid level in the solution container 46 cm (18
inches) above top of the pump, rate set at 999 mL/h and volume to be infused of 49 mL.
Micro 3100/505 fluid level in the solution container 46 cm
(18 inches) above top of the pump, rate set at
99.9 mL/h and volume to be infused of 25.0 mL.
For a complete list of Administration Sets, please contact Graseby Medical or your local distributor.
2 — 2
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Volumetric Infusion Pumps
Power
AC power supply Internally configured for either
100-120 V AC, 200 mA, 50/60 Hz.
or,
220-240 V AC, 80 mA, 50/60 Hz.
Battery type Rechargeable, sealed lead-acid, 12 Volt, 1.3 Ah.
Battery operating time 6 hours at 100 mL/h (99.9 mL/h on Micro 3100/505),
with approximately 1/2 hour warning of discharged battery.
Battery recharge time Approximately 10 hours, depending on the
operating conditions. The batteries will be charging during an infusion.
Leakage current 100 to 120 V less than 20 microamps ungrounded
or,
220 to 240 V less than 50 microamps ungrounded
This is measured between the ground stud and the earth protective prong of the AC mains connector.
Over-current protection
Voltage AC line fuse Thermal fuse Battery fuse
100 to 120 V 200 mA 130° 1.0 amp
2
220 to 240 V 2 x 80 mA 130° 1.0 amp
Note: All fuses are time delay fuses
2 — 3
2
Volumetric Infusion Pumps
Primary and Secondary Infusions
Rate range
Model 3000/500 Range Increment
Micro 3100/505 Range Increment
Volume to be infused
Model 3000/500 Range Increment
Micro 3100/505 Range Increment
Rate Taper Infusions
Graseby Medical Ltd.
0.1 to 99.9 mL/h 0.1 mL/h 1 to 999 mL/h 1 mL/h
0.1 to 99.9 mL/h 0.1 mL/h
0.1 to 999.9 mL 0.1 mL 1 to 9999 mL 1 mL
0.1 to 999.9 mL 0.1 mL
Rate range
Model 3000/500 Range Increment
Micro 3100/505 Range Increment
Volume to be infused
Model 3000/500 Range Increment
Micro 3100/505 Range Increment
Time range
All pumps Range Increment
Volume Over Time Infusions
0.1 to 99.9 mL/h 0.1 mL/h 1 to 400 mL/h 1 mL/h
0.1 to 99.9 mL/h 0.1 mL/h
0.1 to 999.9 mL 0.1 mL 1 to 4400 mL 1 mL
0.1 to 999.9 mL 0.1 mL
0 to 59 minutes 1 minute 0 to 48 hours 1 hour
2 — 4
Rate range
Model 3000/500 Range Increment
0.1 to 99.9 mL/h 0.1 mL/h 1 to 999 mL/h 1 mL/h
Micro 3100/505 Range Increment
0.1 to 99.9 mL/h 0.1 mL/h
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Volume to be infused range
Model 3000/500 Range Increment
Micro 3100/505 Range Increment
Time range
All pumps Range Increment
Dose-Rate Calculation Infusions:
Dose range
Volumetric Infusion Pumps
0.1 to 99.9 mL 0.1 mL 1 to 9999 mL 1 mL
0.1 to 99.9 mL 0.1 mL 1 to 999 mL 1 mL
0 to 59 minutes 1 minute 0 to 48 hours 1 hour
Range Increment
0.01 to 99.99 0.01
0.1 to 999.9 0.1 1 to 9999 1
2
Body weight range
Units Range Increment
Kilograms (kg) 0.10 to 99.99 kg 0.01 kg
Pounds (lbs) 0.22 to 99.99 lbs 0.01 lbs
Drug amount modes/range
Mode Range Increment
MG drug/bag 0.01 to 99.99 0.01
Gm drug/bag 0.01 to 99.99 0.01
mcg drug/bag 0.01 to 9.99 0.01
units/bag 0.01 to 99.99 0.01
0.1 to 453 kg 0.1 kg
0.2 to 999 lbs 0.1 lb.
0.1 to 999.9 0.1 1 to 99999 1
0.1 to 99.9 0.1 1 to 999 1
0.1 to 99.9 0.1 1 to 9999 1
0.1 to 999.9 0.1 1 to 99999 1
2 — 5
2
Volumetric Infusion Pumps
Rate range
Model 3000/500 Range Increment
Micro 3100/505 Range Increment
Volume to be infused range
Model 3000/500 Range Increment
Micro 3100/505 Range Increment
Occlusion sensing
Graseby Medical Ltd.
0.1 to 99.9 mL/h 0.1 mL/h 1 to 999 mL/h 1 mL/h
0.1 to 99.9 mL/h 0.1 mL/h
0.1 to 999.9 mL 0.1 mL 1 to 9999 mL 1 mL
0.1 to 999.9 mL 0.1 mL
KVO rate
Alarm levels
(approximate values)
Pressure units Low Medium High
mmHg 103 mmHg 259 mmHg 517 mmHg
psi 2 psi 5 psi 10 psi
kPa 13.5 kPa 34.5 kPa 68.9 kPa
Time to occlusion
This table shows the maximum (measured +25%) delay times for activation of the Occlusion below pump alarm:
Rate Low Occlusion setting High occlusion setting
1 mL/h 11 min, 5 sec. 1 hour, 10 min.
25 mL/h 15 sec. 2 min, 35 sec.
max time to alarm max time to alarm
2 — 6
Default KVO rate
3.0 mL/h, or at the programmed rate if set at less than these values.
Configurable KVO rates
Model 3000/500 0.1 to 10.0 mL/h
Micro 3100/505 0.1 to 3.0 mL/h
Issue A (April 2002)
(Version 0.71 software and above)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Symbols used on the pump
Volumetric Infusion Pumps
Front panel symbols
Battery is charging/mains power applied.
Audio alarm silence button.
Side panel symbols
Use pump only in upright position.
Rear panel symbols
Attention: consult accompanying documents.
Data input/output.
Inside battery door symbols
Attention: dangerous voltages, risk of electric shock if the housing is opened.
2
Equipotential point.
Internal battery.
Dispose of in an environmentally safe manner.
Battery symbols
Recycle battery
Dispose of in an environmentally safe manner.
~
CF Application (cardiac floating)
Audio alarm volume control.
Alternating current.
Nurse call option (only if option is fitted)
2 — 7
Volumetric Infusion Pumps
Standards
Electrical Safety
Classified as Internally Powered Equipment Class 1, Type CF (Cardiac Floating) insulation on all inputs.
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2
Design Standards
EN60601-1, EN60601-1-2, IEC 601-2-24 (Draft).
Fluid Ingress Protection
IPX 1 Drip proof
CE Marking
The CE mark demonstrates that the pump conforms to the requirements in the European Council Directive 93/42/EEC concerning medical devices.
The number 0473 identifies the Notified Body under which the Quality Systems operated within Graseby Medical Ltd are assessed.
Disposal
When the time comes to dispose of the pump, its batteries, or any of its accessories, do so in the best way to minimise any negative impact on the environment.
You may be able to use special recycling or disposal schemes. To find out about these contact your local waste disposal service. Separate any other parts of the equipment where arrangements can be made for their recovery, either by recycling or energy recovery.
Patents
Important: Existing national or local regulations concerning waste disposal must take precedence over the above advice.
USA 5401256
5103214 5429485 5017192
GB 2247765 France 2715073
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Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
T rumpet curves
The curves were developed while testing the Model 3000/500 using a Graseby Standard Adult Set, 8C-820 administration set.
The curves for the Micro 3100/505 are identical since both pumps have the same pumping mechanism.
The trumpet curve represents the worst-case rate error in any given observation window over the whole infusion period.
These trumpet curves were prepared according to the requirements of IEC 601-2-24.
Volumetric Infusion Pumps
2
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2
Volumetric Infusion Pumps
Graseby Medical Ltd.
2 — 10
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Overview of Pump
Operation
& Initial Checks
Chapter 3
Graseby Medical Ltd.
Volumetric Infusion Pumps
Overview of Pump Operation & Initial Checks
This chapter provides an introduction to the Volumetric pump. It gives an overview of:
The exterior of the pump (the revised case design is shown)  How the pump is powered  How the pump works  Power up - tests and checks  Powering down  Power monitoring and battery testing  Alarms and alerts. The revised case design is shown on the diagrams on the next three
pages, but the keys, indicators and displays apply equally to the original Volumetric case design.
3
Finding further information
Detailed information about the topics covered in this chapter may be found later in this manual: Chapter 5 through Chapter 9.
The menus that allow the configuration of the pump are described in Chapter 4.
Troubleshooting is described in Chapter 7 page 17.
Note:If you want to find out how to use the pump, you must read the
Instruction and Technical User Manuals. It contains not only the full instructions, but also all the warnings and cautions that must be followed for the safe use of the pump.
3 — 1
Volumetric Infusion Pumps
Graseby Medical Ltd.
3
Exterior of the 500/3000 pump - front
Indicators and displays
*
(Revised case design shown here)
Programming keys
*
* Bolus function available on
V0.71 software only
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Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Exterior of the pump - rear
(Revised case design shown here)
Volumetric Infusion Pumps
3
3 — 3
3
Volumetric Infusion Pumps
How the pump is powered
The pump can be powered in two ways, either:  AC power connection  Battery operation, for backup, or portable operation.
AC power connection
The pumps are equipped with a detachable power cord, which has a three-prong, hospital grade plug. The power cord is designed to minimise leakage current inducing potentials on the ground wire.
The power cord is secured to the rear housing, but can be removed if safety testing of the cord becomes necessary. A cord retainer is attached over the cord by four screws. The cord retainer must be reinstalled whenever the cord is reattached or replaced, or ground and power connections may become unreliable.
If the cord is damaged, replace it immediately. Replacements should be made using original equipment in order to maintain grounding safety and an acceptable level of leakage current. Integrity of the three-prong plug is also important to prevent electric shock. Do not use extension cords, adapter plugs, or attempt to defeat the plugs ground connection. Always hold the plug itself when unplugging the power cord, as pulling on the cord could damage plug connections.
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Battery and portable operation
The pumps contain a rechargeable 12 volt battery for portable operation, or if AC power fails or is unavailable. Monitoring and testing the battery is described on page 3-13.
The infusion pumps may be operated while standing on any flat surface, provided the bottom of the administration set drip chamber is at least 15 cm (6 inches) above the top of the pump.
On Model 3000/500, 30 cm (12 inches) may be required for rates over 500 mL/h. On both Model 500 and Micro 505, 30 cm (12 inches) may be required when using thick solutions and/or 60 drops/mL sets.
Typically, however, the pump is attached to an IV pole using the pole clamp on the rear housing. IV pole mounting and battery operation make the pumps portable for patient mobility.
When multiple infusion lines are required, you can connect up to three pumps to a single pole using the hooks and rails that make up the modular connection system. As all pumps have connectors on both sides, you can use any one as the centre, left, or right pump.
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Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
How the pump works
This section provides a overview of how the pump works. Further details are provided in Chapters 5 to 8.
For details of how to use the pump, refer to the Instruction Manual and the Technical User Manual.
Microprocessors
The pumps contain a central system control microprocessor (CPU1), with two peripheral microprocessors used for display control (CPU3) and fail-safe system monitoring (CPU2). The central microprocessor controls all user programmable functions, alarm condition sensors, and inter-processor communications.
Pumping mechanism
The central microprocessor also controls a 4-phase stepping motor which is used to operate the pumping mechanism. Smooth fluid delivery is accomplished by uninterrupted forward rotation of the pumping mechanism when the pump is running.
Volumetric Infusion Pumps
3
Door latch open
Pulling the door latch handle open moves the cam housing and pumping mechanism to the load position. The pistons are best positioned to accept a fluid filled cassette when in the load position.
When the door is opened to turn the pump on, or if the door is opened while the pump is powering up, the hold light does not turn on until the motor has backed off to its load position.
Door latch closed
Pushing the door latch closed moves the pumping mechanism to the operate position.
Completion of cassette loading results in some additional reverse rotation of the motor as pressure (which develops during the loading process) on the cassette is reduced and the pumping mechanism prepares for delivery. To allow up-line pressure release, the over pressure valve seals the lower fluid pathway during reverse rotation of the pumping mechanism and reopens upon initial forward rotation.
Free flow prevention system - safety clip
The Free-Flow Prevention System consists of the Safety Clip (located under the cassette on the administration set) and the mechanical clip retention slot and associated mechanics on the lower cassette housing. The Safety Clip must be placed in the retention slot when loading the cassette, or the pump will not operate.
 When the door is closed the Safety Clip opens to allow fluid
delivery.
 When the door is opened, the Safety Clip closes, preventing
unrestricted gravity flow even when the administration set is removed from the pump.
3 — 5
Volumetric Infusion Pumps
Pressure / occlusion monitoring
Downline pressure is developed by the pumping pistons at the upper and middle cassette chambers, and is continuously monitored at the middle cassette chamber.
Occlusion monitoring is performed by the pressure transducer mounted in the door. The Occlusion alarm is activated if pressure exceeds the user selected threshold level. The pump briefly backs off to reduce downline pressure, which minimizes fluid bolus to the patient. At that point, the pump stops and fluid delivery ceases.
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3
Pumps with revision 0.64 and higher software
In the Medium or High Occlusion Alarm Settings, when downline pressure exceeds the selected threshold, the motor pauses (Run remains lit), and the pumping indicator stops. If, within 10 seconds, the pressure drops back below the threshold, then pumping resumes and no alarm is sounded (if pressure remains high, the Occlusion below pump alarm is activated). If repeated pressure spikes occur, causing the pump to enter the filtering process for a total of 30 seconds, measured over the last 4 minutes the pump was infusing, the alarm also sounds. Occlusions detected in the Low Occlusion Alarm Setting cause an immediate alarm.
Message Display
The Message Display is an alphanumeric liquid crystal display, consisting of 2 lines by 16 characters. It shows infusion status, visual alarms, options, and other messages.
When the pump is running, some messages are displayed briefly, then the display reverts to the standard message. The general rule is: informational messages are displayed for 5 seconds; messages with instructions or which require input are displayed for 10 seconds. Pressing a key which has a different display associated with it causes its screen to be instantly displayed before the 5 or 10 second timeout expires on the first message.
3 — 6
Numeric Displays
During operation, the rate and volume to be infused are continuously shown in the numeric displays. The Message Display shows the volume infused for the current infusion as fluid is delivered, and the volume to be infused display counts down as the volume in the Message Display counts up. Also, appropriate status lights are lit to show the current status of the pump.
Numeric and Message Display Memory
When the pump is turned off, data in the Message Display and numeric displays are stored in nonvolatile memory and displayed again when the pump is turned on. The memory is maintained by a 3 volt lithium battery integrated with the memory chip.
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Backlight for Message Display
The Message Display is backlit when any key is pressed, and when the door is opened. The backlight will remain on for approximately 1 minute. The backlight timeout feature has different characteristics when the pump is on AC power and battery power.
Backlight on AC
With the pump on hold, and with the door closed, the backlight will always be on. With the pump on hold, and with the door open, the backlight will timeout after approximately 1 minute. After timeout, if the door is closed, the Message Display backlight will turn on.
Backlight on Battery
When on battery power, the backlight will timeout after approximately 1 minute whether the door is open or closed.
Backlight during an alarm or alert
During an alarm or alert, the backlight flashes on and off with the audible alarms and remains on after the audio has been silenced.
Volumetric Infusion Pumps
3
Analog to digital monitoring
In addition to controlling the Message Display, numeric displays, and LEDs, the display software monitors a number of analog to digital conversion values. These are:
 Pressure  Battery level  Cassette position  Ambient lighting level  LED/segment forward voltage drops. The LED/segment voltage
drops are checked during power-up.
Pressure, battery , light and cassette monitoring
A CPU periodically checks the current analog levels for the pressure sensor input, the battery level, the pressure plate position input, and the photo sensor used to measure ambient lighting. These levels are each measured at least once per second, and their values (0-255) are accessible to the on-board CPUs. Decisions based on sensor readings require at least two reads of the sensor.
The pressure sensor input is used to check for occlusions.  The pressure plate position switch indicates whether the
cassette is in place.
The battery level input is used to check for low battery levels, or
when a battery test is initiated. Low battery levels result in appropriate alarm messages.
The ambient lighting level input is used to adjust the intensity
of LEDs based on the current room lighting.
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Volumetric Infusion Pumps
LED/segment monitoring
The Display board CPU periodically (once per second) checks the status of each individual LED and digit segment. If an LED or segment should be off, it is checked to make sure there is no forward voltage drop. If there is supposed to be a forward voltage drop and it is absent, or it is outside the acceptable range a fault is reported to the on-board CPUs and a System Error alarm message appears in the Message Display.
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Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Power up tests and checks
This section explains the sequence of the pumps internal initialisation tests and checks carried out on a Cold boot which takes place if the On/Off key is pressed, or the door is opened whilst the pump is switched off.
The end of this section describes what happens during a Warm boot, which takes place if the microprocessor is reset when the pump is already switched on.
Volumetric Infusion Pumps
Cold boot
3
When the pump is turned on, the cold boot sequence is as follows:  The I/O ports of the microprocessors are initialised, placing all
system components in the start up configuration.
 A write/read back test is performed on non-volatile RAM. If this
test fails, the following message is displayed and the software is locked allowing no further processing:
If the pump is plugged into AC power, the message remains until the pump is unplugged. If being powered by the battery, the message is displayed for 5 seconds, then the pump automatically turns off.
 A checksum comparison is performed on non-volatile RAM, and, if
it fails, system warning 13 is recorded for viewing in Biomedical Special Functions. A memory location is then checked to
determine if the initialization was from a cold-boot or warm boot.  All CPU RAM locations are cleared.  The main CPU computes a checksum of its ROM contents and
compares this against a predetermined value. If a ROM checksum
error occurs, the following message is displayed, and the software
is locked allowing no further processing:
If the pump is plugged into AC power, the message remains until
the pump is unplugged. If being powered by the battery, the
message is displayed for 5 seconds, then the pump automatically
turns off.  Timers, counters, registers, and interrupts are initialised for
operation.  Counters and timers are initialised for pump history information.  A jumper wire is detected, thus determining whether the pump is
micro/macro (Model 500/3000) or micro only (Micro 505/3100).
3 — 9
3
Volumetric Infusion Pumps
Communication is established between the CPUs. Commands are exchanged signalling that initialization is completed and ROM checksums are correct.
 The keypad is scanned to determine whether Options was pressed
along with On/Off. If so, the pump enters Biomedical Menu.
 The keypad is scanned to determine whether Silence was pressed
along with On/Off. If so, the pump activates Quiet Pump operation.
 A display test is run. The numeric displays illuminate the number
8 in each digit with decimal points active. While the numeric displays are showing 8s, the pumping motion LEDs display the number 8, then go blank. The message display briefly shows a checker-board pattern.
 The microprocessor checks to see if the pump is operating on AC
power or battery. If on AC power, the charge light is already lit. If on battery power, the battery light illuminates, and the battery voltage is checked to see if it is in operating range (> 11.6 V DC). If the voltage is out of range (11.6 V DC), the low battery alarm appears. See Power Monitoring, page 3-13.
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 The motor monitor microprocessor runs a motor cut-off test to
verify proper function of the motor driver shut off. If the motor driver shut off is not working, a system warning is noted. Cold boot stops, a snapshot is taken, and the following system warning is displayed:
 If the motor driver shut off is working, the cold boot continues and
the motor is backed off to its home position.
 Primary parameters are retrieved from memory and displayed.
Secondary parameters are stored and ready for display. Secondary volume to be infused defaults to zero and must be re-entered.
Successful completion of cold boot
 A value is written in non-volatile memory as an indicator that a
cold boot process was completed.
 The pump enters hold. Unless it was previously switched off in a
special infusion mode, for example, Rate Taper, or Dose-Rate Calculation (recovery) mode, the standard message is displayed, indicating that initialisation tests and checks are complete:
3 — 10
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
End of cold boot - special infusion modes
If the pump was turned off in a special infusion mode, the standard message is not displayed. Instead, the pump shows a screen indicating the infusion mode, for example, with a Rate Taper program set (but not delivered), the message display is:
If the pump was turned off during or after running a Rate Taper program, the display will be:
If the pump was switched off after programming a Dose-Rate Calculation infusion, and the Dose-Rate Calculation Recovery parameter is enabled in the Technician Menu, then the display will be:
Volumetric Infusion Pumps
3
Warm boot
A warm boot occurs if the microprocessor is reset when the pump is already powered up. If a reset occurs the pump begins its power up initialization routine. During the power up routine, the microprocessor looks for a value in non-volatile memory normally stored during the pumps power down routine. Since the normal power down routine is not completed during a reset, the value is not found and the current routine is considered a warm boot.
The rate display shows 0.1 and the volume to be infused display shows 0.0 if a RAM checksum failure occurs.
If a warm boot occurs, the insistent audio alarm sounds, and a system warning is displayed:
3 — 11
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Volumetric Infusion Pumps
Powering down
This section explains what happens when the pump is powered down (switched off). It describes:
 Manual power down, when the On/Off key is pressed  Automatic power down, which occurs when the pump has been left
on and alarming for 72 hours, or if the battery voltage becomes too low.
Manual power down
The pump can only be turned off by pressing On/Off while the door is closed. If the pump is running, you must first press Hold, then On/
Off.
The master CPU stops pumping operations and all system components are disabled. The non-volatile memory is updated with checksums. At this point, if the pump is on AC power, it will continue to keep track of AC on time for pump history. The green charge light is lit, indicating that the battery is charging. If powered by battery, a non-volatile memory location is initialised, indicating power down has occurred, after which the pump turns off.
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If the pump is operating on battery power, and if the pump is stuck in a fault mode where the CPUs are not operating properly, a special command (OFFCPU2) allows On/Off to operate.
If the pump is connected to AC power, turned off, and the cord is then unplugged, the pump powers down completely after writing data to pump history.
Automatic power down
If the pump is left on hold (following an alarm, or if left idle) for approximately 2 minutes with the door closed, the insistent audio alarm sounds. If the pump is left on hold with the door open, the pump alarms after approximately 6 minutes. In either case, if left alarming for 72 hours, the pump automatically shuts off.
If the battery status in the Message Display indicates:
the pump enters hold (if running), sounds the insistent audio alarm, and the hold light flashes. If left alarming, the pump will automatically turn off in 15 minutes, or when the battery reduces to 10 volts.
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Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Power monitoring
On AC Mains
If the pump is plugged in, the charge light is steadily lit. Software also records and stores in the pump history the period of time that the pump is plugged in.
Note: If the pump is switched off and connnected to AC power and the saftey keypad lockout feature is active, the pump cannot be switched on via the keypad, see Instruction Manual, Security on the
pump.
On battery power
If there is a dropout in the voltage regulator due to AC line or component failure, the pump automatically switches to battery power. The battery light is steadily lit (unless the battery is low or dead, in which case it flashes), the charge light is off, and the period of time on battery is recorded and stored in the pump history.
Volumetric Infusion Pumps
3
Battery voltage levels are determined by: Normal operating voltage: Voltage > 11.6, ± 0.2 V DC.
Low battery: 11.0 < Voltage £ 11.6, ± 0.2 V DC. Dead battery: 10.0 < Voltage £ 11.0, ± 0.2 V DC. Automatic Turn Off: Voltage < 10.0, ± 0.2 V DC.
Once a low battery state occurs (low battery, dead battery, or automatic turn off) it remains in that state unless:
 The pump is plugged in to AC power,  The voltage drops to a level consistent with another state, or  The pump is turned off, then on. When the pump is turned on, on battery power, with Version 0.71
software loaded, the pump automatically carries out the battery test described in the next section.
T esting the battery
When the pump is powered on, the battery is always tested. In addition, the Options key provides access to the Battery Test option so that the approximate battery voltage can be tested without powering down the pump.
To run the Battery Test:
1. With the pump powered up, disconnect from the AC mains supply
and press Hold.
2. Press the Options key then 4, or press Options until the following
message is displayed:
3 — 13
Volumetric Infusion Pumps
3. Press the key to start the test. The pump turns on all LEDs, and the rate and volume to be infused displays all zeros to form a known battery load.
The pump then measures the battery voltage. After five seconds the battery gauge displays the approximate battery capacity.
For example, this display would indicate a battery about half charged:
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3
Each + indicates increasing battery voltage, as follows:
11.1 +
11.2 +
11.3 ++
11.4 +++
11.5 ++++
11.6 +++++
11.7 ++++++
11.8 ++++++++
11.9 +++++++++
12.0 ++++++++++
12.1 +++++++++++++
12.2 ++++++++++++++++
The display below indicates a fully charged battery:
If the battery capacity is low, you must connect the pump to the AC mains supply to recharge the battery.
3 — 14
It is possible to get a false reading if the battery is in poor condition. A new, fully charged battery operates the pump for approximately six hours at 100 ml/hr (99.9 mL/h on Micro 505).
The test described above is also carried out automatically when a pump loaded with Version 0.71 software (or later) is switched on, on battery power.
WARNING: Correct management of battery charging, as described in this
documentation is essential to ensure that the pump can operate on battery for the time specified. Failure to do so may result in compromised function of the product or patient injury .
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Alarms
This section explains the three different types of alarms made by the pump.
 insistent  non-insistent  continuous (backup alarm).
If more than one alarm condition exists simultaneously, insistent alarms take precedence over non-insistent alarms.
Volumetric Infusion Pumps
When an alarm condition occurs, the red Hold light illuminates and flashes at 1 Hz. The Message Display flashes with the alarm and an error or alarm message is displayed.
When the audio alarm is silenced, the hold light stops flashing and the Message Display remains lit with the alarm message displayed.
Software Version 0.67 and earlier
When a pump displaying the Battery too low - Plug in cord message is connected to the AC mains supply, the unit will stop alarming, if not previously stopped using the Silence or Hold key. The unit is on Hold, and the Hold LED is on. However, the Message Display does not show the On Hold message and the associated insistent alarm is not sounded. To continue the infusion, the operator must press the Run key.
Insistent alarm
This type of alarm indicates that fluid delivery has stopped, or cannot be started.
The insistent audio alarm consists of three tones: two high pitched and one low pitched, repeated at two-second intervals. (High/high/ low chime).
3
To silence an insistent alarm, press the Silence or Hold key. The alarm will recur unless the problem is corrected.
If an insistent alarm condition is detected, the microprocessor stops the pump and sounds the insistent audio alarm. One of the following messages is displayed:
 Air in cassette  Battery too low  Close clamp! Load Safety Clip  Door open  Loading problem. Check tubing set  No flow above pump  Occlusion below pump  On Hold  Secondary Complete  Preset limits exceeded.
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Volumetric Infusion Pumps
Non-insistent alarm
This type of alarm indicates that there is a condition requiring attention which has not caused the infusion to stop. For example, if the pump is running on batteries and the batteries are low, or if the infusion has switched to a KVO rate.
The non-insistent audio alarm consists of two tones, one high pitched and one low pitched, repeated at two second intervals. (High/low chime.)
In KVO, the green run light flashes at 1 Hz with 50% duty cycle. In low battery, the yellow battery light flashes at 1 Hz with 50% duty cycle.
To silence this type of alarm, press the Silence or Run key to silence the alarm without stopping fluid delivery, or press the Hold key to silence the alarm and stop fluid delivery.
Detection of the following alert conditions cause the microprocessor to sound the non-insistent audio alarm:
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 Dose setup not completed  Dose change not completed  Dose change not accepted  KVO xxx mL this infusion  Low battery. Plug in cord  Rate change not completed  Secondary was set.
Continuous - backup alarm
In addition to the insistent and non-insistent operational alarms, the Volumetric pump has a fail-safe backup alarm system. This has a distinctive high-pitched tone:
 Should the audio alarm system fail, then the pump sounds the
backup alarm, with a 1.5 second pause between alarm tones;
 Should an electromechanical system failure occur, the pump
sounds the backup alarm continuously.
The pump displays one of these messages when sounding the backup alarm:
 Pump needs service  System check. Turn off then on.
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3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Audio alarm specifications
The table below shows the specifications of the audio alarms. See Biomedical Menu, page 4-26 for details on how to test these:
Name of alarm Description Frequency of chimes
Insistent high/high/low chime 3,000 Hz 2,200 Hz
Volumetric Infusion Pumps
High Low
every 2.25 seconds
Non-insistent high/low chime 3,000 Hz 2,200 Hz
every 2.25 seconds
Back Up high pitched 3,000 Hz
every 1.5 seconds
Continuous high pitched 3,000 Hz
without pause
3
3 — 17
Volumetric Pump Menus
Chapter 4
Graseby Medical Ltd.
Volumetric Pump Menus
Which version of software is in the pump?
This manual reflects the menus that are available in Version 0.71 software for the Volumetric pump. A pump has version 0.71 software (or later) if:
The Secondary infusion key appears as:  The Instruction Label on the right hand side of the pump lists
more than eight options.
The Biomedical Model Number and Software Version menu (see
Biomedical Menu, page 4-11) shows V0.71, for example:
Volumetric Infusion Pumps
4
This manual also covers the Version 0.53, Versions 0.63, 0.65, and
0.67 software that may be installed in a Volumetric pump.
Introduction to menus
The menus are decribed in the following sections. However, for detailed operating procedures refer to the Instruction Manual and Technical User Manual.
The number of menus (some of which have overlap of features) available on a pump varies depending on the software installed. The full set of menus is as follows:
Technician
This menu is only present on pumps with version 0.71 software and later. You use the Technician menu to enable the features of the pump that have been introduced with version 0.71 software, as well as enabling the features that existed in earlier versions.
Biomedical
Available in all software versions. In previous documentation it is called the Biomedical Special Functions. As well as enabling or disabling features, it displays data for fault finding and calibration.
Service Functions
Contains functions for servicing and setting the time in the pump.
Special Functions
Used to initialise the pump, for example after NV RAM or CPU board replacements, or any software upgrades. Details of how to use the Special Functions to initialise the pump vary with the software version and are explained in Chapter 7, Troubleshooting section.
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Volumetric Infusion Pumps
About the Technician menu
This menu appears in version 0.71 software (or later). It allows you to define how the pump behaves by setting values or by disabling or enabling parameters.
Common parameters on T echnician and Biomedical menus:
The common parameters on both the Technician and Biomedical menus are Rate Taper, Volume Over Time and Dose Rate Calculation.
Entering the T echnician menu
To enter this menu, first switch off the pump if it is switched on. Then press the Total Volume key while simultaneously pressing the
On/Off key. When you take your fingers off the keys, the pump switches on and you are asked to enter the Technician menu ID.
Enter the numbers 0002.
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As you enter the digits, asterisks (*) are displayed for security protection. If you make a mistake, you must switch the pump off to enter the correct ID. When prompted:
Enter the password 2020. The password is always 2020, and cannot be changed.
Using the T echnician menu
When you enter the Technician menu, the first parameter is the one to enable or disable the display of the Pump Identifier. Move down the list by pressing the Options key. Use the * key to toggle a parameter. Thus if you see a screen like the following:
then the feature is disabled and you must press the * key to enable it. You cannot move back through the menu. If you make a mistake, then
you can continue to move through the list by continuing to press the Options key and the first item appears again when you reach the end. You may find it faster to switch off and start again.
4— 2
To move through the list quickly, and avoid going past the item you want, you may also find it faster to count the number of times you press the Options key. The table on the next page has been numbered to help you do this.
Leaving the T echnician menu
To exit from the menu, switch off the pump.
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Summary of Technician menu parameters
The numbers on the left of this table show the number of Options key presses to reach the parameter. The default settings are the factory settings.
Configuration Parameter Operation Default
Pump Identifier Enable or Disable Disabled
1 Drug List Enable or Disable Disabled
2 Primary rate limits Enable or Disable Disabled
3 Primary Max VTBI Enable or Disable Disabled
Volumetric Infusion Pumps
4 Secondary/bolus rate limits Enable or Disable Disabled
5 Sec / Bolus Max VTBI Enable or Disable Disabled
6 KVO rate entry Enable or Disable Disabled
7 Occlusion Default High, Medium or Low Medium
8 Secondary Stop Enable or Disable Disabled
9 Bolus Enable or Disable Disabled
10 Quick Rate Enable or Disable Enabled
11 Rate Taper Enable or Disable Enabled
12 Volume over Time Enable or Disable Enabled
13 Dose Rate Calculation (DRC) Enable or Disable Enabled
14 DRC Recovery Enable or Disable Disabled
15 Backlight Enable or Disable Enabled
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16 Autolock Keypad Enable or Disable Disabled
17 GMT Timestamp Enable or Disable Enabled
18 Service Date Review or Date Entry 00/00/00
19 Micrograms Selection 1 (µg) or 2 (mcg) 2
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Volumetric Infusion Pumps
Using Technician parameters
Most parameters enable or disable features that appear when the Options key is pressed. All only affect one feature, but for some you may need to think about making another setting at the same time. For example, if you enable Primary rate limits, you might also enable Primary Max VTBI.
Pump Identifier
If you enable this parameter, when you press the Options key to move to the next parameter you can edit the identifier text. When the pump leaves the factory, this identifier is set to the serial number of the pump. You can change the identifier character by character by using the up and down keys (1 and 3) to cycle through alphanumeric values. Press the * key to move to the next character. Press the Options key when you are finished.
Note: Another separate identifier appears on the Special Functions Menu. This
also contains the pump serial number and will need to be reset to the serial number if the pumps PCB is changed. See item 5 on page 4-30.
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Drug list
Enabling this parameter gives the user the ability to choose a Drug label from a preset list of drugs. If it is disabled, then the label is not displayed.
Minimum and maximum primary rate
Enabling this parameter allows the user to define a range to limit the Primary rate.
Maximum primary VTBI
Enabling this parameter allows the user to set the maximum volume that can be infused for a Primary infusion.
Minimum and maximum secondary/bolus rate
Enabling this parameter allows the user to define a range to limit the Secondary rate or bolus rate.
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Maximum secondary/bolus VTBI
Enabling this parameter allows the user to set the maximum volume that can be infused for a Secondary or Bolus infusion.
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KVO rate entry
If this is enabled, then the user can set their own KVO rate. If it is disabled, the default KVO rate (as shown in the specifications) is used.
Occlusion default setting
Use this option to set the occlusion default setting that should be applied when the pump is switched on. Press * to change the default.
The user can press the Occlusion Alarm Setting key to change the occlusion level for a particular infusion regardless of this default parameter setting. However the default setting is reapplied when the pump is switched off and on again.
Secondary stop
With this parameter enabled, the pump stops when a Secondary infusion is completed. It sounds an insistent alarm and displays a message to say that the secondary infusion is complete.
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If Secondary stop is disabled, when a secondary infusion is complete, the pump sounds a non-insistent alarm twice and then automatically restarts the infusion at the primary rate.
This parameter is independent of the setting of the Bolus parameter and only affects a Secondary infusion; at the end of a Bolus infusion the pump always reverts to the previously programmed Primary rate.
Bolus
When this parameter is enabled, the user is given a choice of whether a Secondary or a Bolus infusion is to be run when they press the Secondary/Bolus key. If Bolus is chosen, the volume infused is deducted from the Primary VTBI. If Secondary is chosen, the Secondary volume infused is kept as a separate total and does not affect the Primary VTBI.
If Bolus is disabled, the user is not given a choice when they press the Secondary/Bolus key: they can only make settings for a Secondary infusion.
Quick Rate Change
In software versions before 0.71, the Quick Rate Change parameter was always enabled, and could not be disabled. From version 0.71, the parameter may be enabled or disabled on the Technician Menu.
Enabling this feature allows users to use the Options key to put the pump into a mode in which they can change the rate quickly while the pump is running or on hold.
Rate T aper
Enabling this parameter allows the user to taper the infusion rate, either up or down, for the administration of Total Parenteral Nutrition (TPN), Total Parenteral Admixture (Three-in-One) or other applicable therapies.
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Volumetric Infusion Pumps
V olume Over Time
Enabling this parameter allows the user to set up an infusion using the volume to be infused and the total time, with the pump automatically calculating the infusion rate. This can be done with either Primary or Secondary infusions.
Dose-Rate Calculation
Enabling this parameter allows the user to set the dosing rate, patient weight, the drug amount in the fluid bag and the volume in the container, from which the pump then calculates the infusion rate.
Note: If you enable Dose-Rate Calculation, the Micrograms unit should also be
set (using the Micrograms parameter on this menu) according to your hospitals protocol.
DRC Recovery
Enabling this feature allows a Dose-Rate Calculation mode infusion to be accessed quickly when the pump is switched on.
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Backlight
This parameter sets the default for how the backlight behaves when the pump is switched on. With the parameter disabled, the backlight will go off after a minute of keypad inactivity.
If the parameter is enabled, the user can use the Options key to control whether the Message Display Light is permanently on or behaves as described above when the option is disabled.
Autolock Keypad
With this parameter enabled, the keypad will automatically lock one minute after a key was pressed.
The user can unlock the keypad by pressing twice on the Keypad lock/unlock button on the back of the pump.
This is in addition to the manual keypad lock.
GMT Timestamp
Enabling this parameter displays the message GMT to the right of the time display.
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CAUTION: The backlight has a limited life and may, if used constantly, cause
the light to dim. Eventually the message display may then need to be replaced. T o preserve the life of the message display , you should only allow the Message Display Light to be turned on as described here if it is specifically required. Misuse of this feature could lead to both battery and LCD depletion.
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Service Date
This parameter is used to set the service due date that is displayed during power up when the pump is switched on. You can set or clear the service date when this screen is displayed with the date flashing on the Technician Menu:
Enter the new date in the format MM/DD/YY To disable the Service Date feature, set the month, day and year to
zeroes. When the pump is switched on, if the date set is reached or exceeded,
then an alarm is sounded and the following message is displayed:
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to notify the user that the pump should be serviced.
Micrograms
Use this feature to determine the units to be displayed as µg or mcg for the Dose-Rate Calculation. If you are not enabling Dose rate calculation, you can ignore this item.
Note: Since the pump does not confirm the chosen unit display, test that the
display is set correctly. Switch the pump on normally and press the Options key until the Message Display asks you to set the Dose-Rate calculation. Then press * to examine the next screen.
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About the Biomedical menu
The Biomedical menu allows you to access technical information about the pump and carry out adjustments and tests. In previous documentation it has also been called the Biomedical Special Functions
System faults
If a fault occurs while the pump is infusing on a ward, an error code is recorded. An audio alarm sounds and the Message Display shows:
If the system error resulted from a temporary condition, turning the pump off then on clears the alarm and allows you to continue the infusion. However, if the above message persists, the pump must be removed from the ward for service and repair.
Error codes resulting from system errors can be viewed in the Message Display at a later time by entering the Biomedical menu and perusing the menu parameters described overleaf. The pump defaults to the screen displaying the error code.
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Although the error codes are cleared when exiting the Biomedical menu, they are stored as a snapshot event.
Entering the Biomedical menu
To enter this menu, first switch off the pump if it is switched on. Press the Options key while simultaneously pressing the On/Off
key. When the keys are released, the pump switches on and you are asked to enter the Biomedical menu ID.
Enter the numbers 3031. As you enter the digits, asterisks (*) are displayed for security
protection. If you make a mistake, you must switch the pump off to enter the correct ID. When prompted:
Enter the password 7867. The password is always 7867, and cannot be changed.
Leaving the Biomedical menu
Switch off the pump to exit the menu.
Using the Biomedical menu - if no error has occurred
When you enter the Biomedical menu, the first screen you see depends on whether an error has occurred while the pump was running.
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Navigate through the screens by pressing the Options key. If no error has occurred, you go directly into Snapshot screen-a, see
page 4-10. To view further menu screens, press the Options key.
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Using the Biomedical menu - after a fault has occurred
If you enter the menu after a fault has occurred, system errors and warnings are displayed, for example:
When you switch off the pump to exit from the Biomedical menu, the warning/error code is cleared but stored as a Snapshot event, see page 4-11.
The table below shows the numbers that appear on the System Error and System Warning screens.
Code Error/warning
Volumetric Infusion Pumps
01 Power Fail (Battery) Detected. 02 Motor Monitor Communication time-out error. 03 Motor Monitor RAM error. 09 Motor Monitor Watchdog error. 10 CPU1 ROM Checksum error. 11 Motor Monitor Checksum error. 12 CPU1 RAM failure. 13* NV RAM checksum mismatch. 14 Main audio alarm Failure. 15 Motor fast error detected by Motor Monitor. 16 Motor slow error detected by Motor Monitor. 17 Motor disable test failure. 19 Air detect test failure. 20 No flow above pump circuit error. 21 Display board communications error. 22 Display digit error, 0-9. 23 Display LED error, 0-6. 24 Display Board ROM error. 25 Display Board RAM error. 28 Motor stall/interrupter. 30 Warm Boot. 31 Micro/Macro discrepancy error. 32 Pressure Plate Position Switch change during RUN. 33* Corrupted Triple Redundant variable in NV RAM. 34 LCD Display Failure. 35 Undefined Interrupt occurred. 36 Display field overflow error. 37 Display field parameter error. 38 Nonvolatile RAM battery low. 39 Stack overflow. 40 Pressure Plate Position Switch =1 when door is open. 41 Pressure >1 psi when door is open. 42 Safety clip in place when door is open.
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Items 31 and 33 are system errors; all others are system warnings. * See Faulty Component Identification in the Troubleshooting section
on page 7-17 for more details.
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Summary of Biomedical menu parameters
The numbers in the left hand column of this table indicate the number of Options key presses to reach the parameter.
Screen Use Notes/see page ...
0 Two snapshot screens See About snapshot screens,
are available: a and b. page 4-12. Press * to toggle between the two screens.
1 Time and date display. See the Service Functions
GMT shown if enabled on Menu, page 4-23 the Technician menu.
4
2 The display shows: See page 4-23.
 cumulative running hours,  cumulative volume,  number of loading cycles.
3 Cumulative hours that the See page 4-23.
pump has been:  used on AC mains whilst switched on,  charging: plugged in but switched off,  used on batteries.
4 Allows you to run a See page 4-24.
calibration test.
5 Shows the current rate Rates of 300, 600, 1200, 2400 and
setting of the serial port. are available. See page 4-25.
6 Displays the language Only one language is
installed in the pump. supplied in a pump.
7 Displays the number of Use the scroll keys (1 and 3)
times a pump was used to change the displayed on battery for the number number of hours. of hours indicated. See page 4-25.
8 Displays the model See page 4-26.
number and software revision.
9 Use this screen to test See page 4-26.
the alarms by pressing 1, 2 and 3 on the keypad
10 Rate Taper Enable or Disable. See Technician menu.
11 Volume Over Time Enable or Disable. See Technician menu.
12 Dose Rate Calculation Enable or Disable. See Technician menu.
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About Snapshot screens
Two Snapshot screens contain detailed information about the operation of the pump. Snapshot screen-a contains the first level of detail about an event, snapshot screen-b contains further details.
The information on the snapshot screens is encoded, in order to present a large amount of detail on the display area. This section describes the snapshot screens, and explains how to decode the information that they contain.
The pump stores 200 events (50 on a pre-version .63 pump). For each event, there is a snapshot screen-a and associated snapshot screen-b.
Using PC history software to interpret snapshot screens
A Graseby Medical History Download Software Kit is available. This enables you to view, log, store and print out the encoded information in an easy-to-read format, rather than carry out the manual decoding described here.
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To display Snapshot Screen-a
If no error message has occurred on the pump immediately before you access the Biomedical Menu, then the first item displayed on the Biomedical Menu is Snapshot screen-a, showing event number 1. For details, see Decoding Snapshot screen-a, on page 4-12.
To display Snapshot Screen-b
When Snapshot screen-a is displayed, you can change the display to show the associated Snapshot screen-b:
Press *. To move back to Snapshot screen-a, press * again. For details, see Decoding Snapshot screen-b, on page 4-15.
To display snapshots of next or previous events
To see snapshots of other events, use the 3▲ and 1t keys. For example:
On event 1, press 3▲ to see event 2. Press 1t to go to event 200 (or 50 on a pre-version 0.63 pump).
On event 200 (50) press 1t to go to event 199 (49) or press 3▲ to go to event 1.
To show the next parameter
To move from the snapshot screens and show the next parameter (time and date display), press Options. Press Options repeatedly to move through all the parameters. A description of the Biomedical Menu parameters starts on page 4-23.
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Volumetric Infusion Pumps
Decoding Snapshot screen-a
Snapshot screen-a contains information in these fields, explained in the table below:
This is an example of values in fields in Snapshot screen-a, shown in the right hand column of the table below:
Top row of snapshot screen-a:
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Field Contains Values/range Example shows
### Event number 1 is most recent event Event number 26
In range 1 - 200 or 1 - 50 for pre­version 0.63 pumps
MMDD Month and day Month 1 - 12, May 9th
day 1-31
HRMM Hour and minute Hour 0 - 23, 11:45
minute 0 - 59
ZZ System state code 0 - 99 - see table State code 19
on page 4-13 air detector
Bottom row of snapshot screen-a:
Field Contains Values/range Example shows
RATE Rate 0 - 999.0 mL/hr* 350.0 mL/hr
on model 500/3000. 0 - 99.9 mL/hr * on micro 505/3100
VTOBI Volume to be infused 0 - 9999.0 mL* 1400.0 mL
at the time of the on model 500/3000. snapshot 0 - 999.9 mL*
on micro 505/3100
VOLUM Total volume infused 0 - 9999.0 mL* 100.0 mL
this infusion on model 500/3000
0 - 999.9 mL* on micro 505/3100
* Implied decimal point, not displayed: rightmost digit is in 10ths mL
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Snapshot screen-a - system state codes
This list shows the possible system/state codes shown on the top right hand line of a Snapshot screen-a:
Code Meaning
00 No action, initialization value. 01 Power Fail (Battery) Detected. 02 Motor Monitor Communication time-out error. 03 Motor Monitor RAM error. 09 Motor Monitor Watchdog error. 10 CPU1 ROM Checksum error. 11 Motor Monitor Checksum error. 12 CPU1 RAM failure. 13* NV RAM checksum mismatch. 14 Main audio alarm Failure. 15 Motor fast error detected by Motor Monitor. 16 Motor slow error detected by Motor Monitor. 17 Motor disable test failure. 19 Air detect test failure. 20 No flow above pump circuit error - return pump to SIMS
21 Display board communications error. 22 Display digit error, 0-9. 23 Display LED error, 0-6. 24 Display Board ROM error. 25 Display Board RAM error. 28 Motor stall/interrupter. 30 Warm Boot. 31 Micro/Macro discrepancy error. 32 Pressure Plate Position Switch change during RUN. 33* Corrupted Triple Redundant variable in NV RAM. 34 LCD Display Failure. 35 Undefined Interrupt occurred. 36 Display field overflow error. 37 Display field parameter error. 38 Nonvolatile RAM battery low. 39 Stack overflow. 40 Pressure Plate Position Switch =1 when door is open. 41 Pressure >1 psi when door is open. 42 Safety clip in place when door is open.
Volumetric Infusion Pumps
This is the system state code
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Graseby or Service centre.
* see Faulty Component Identification in the Troubleshooting section on page 7-17
list continues ...
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System state codes, continued
Code Meaning
43 Service Due Alarm. 44 Secondary Stop Alarm 45 Preset Limits Exceeded Alarm. 62 Computer Interface Event. 63 Time Change Event. 64 On HOLD Alarm. 65 Stop pumping - Occlusion. 66 Stop pumping - Air. 67 Stop pumping - No flow above pump. 68 Stop pumping - Door Open. 69 Stop pumping - Loading problem, Pressure Plate. 70 Status of pump - Low Battery (11.0 < = voltage < 11.6). 71 Stop pumping - Dead Battery (voltage < 11.0 volts). 72 Stop pumping - Safety Clip. 73 Change rate to KVO. 74 Running rate change not completed. 75 On battery (loss of main power). 76 Start pumping using RUN key. 77 Stop pumping using HOLD key. 78 Secondary to primary switch. 79 Occlusion Alarm Setting change to low. 80 Occlusion Alarm Setting change to medium. 81 Occlusion Alarm Setting change to high. 82 Running rate change. 83 84 Taper to new rate. 85 Power down. 86 Pump on Battery. 87 Turn off AC. 88 Turn on AC. 89 Motor reverse stall. 90 Power change - battery to AC. 91 Dose change not completed. 92 Dose change not accepted. 93 Dose-Rate Calculation setup. 94 Dose field overflow. 95 Volume Over Time setup. 96 Dose-Rate Calculation setup not completed. 97 Door has been opened. 98 Pause pumping - excess pressure detected (software
99 Resume pumping - pressure reduced (software revision
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rate change.
revision 0.64 and higher).
0.64 and higher).
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Decoding Snapshot screen-b
On Snapshot screen-a, press * to display Snapshot screen-b. This is an example of Snapshot screen-b:
Snapshot-b contains information in eight fields, explained in the table below. You would normally use the PC utility to interpret these fields.
Volumetric Infusion Pumps
Note: Fields are all decimal numbers in the range 0-255
The contents of GGG depend on the value of the System state code (ZZ) on Snapshot screen-a.
Field Contains Action and Detail Chart Ref.
### Event number
1 is most recent event
AAA Pumps main modes Convert decimal to binary
then use Chart A
BBB Pumps state modes Convert decimal to binary
then use Chart B
CCC Pumps physical modes Convert decimal to binary
then use Chart C
DDD Pumps sensor flags Convert decimal to binary
and status of the pumps then use Chart D occlusion alarm setting Occlusion alarm setting see
bits 4 and 5 and use Chart D-D
4
EEE Keyboard state input mode Use Chart E
FFF Battery voltage at time Use Chart F
of snapshot, shown as the average of the last two analog-to-digital readings.
GGG Pumping pressure at time Carry out calculation to (all System state of snapshot: average compute the pumping pressure codes except for pressure reading of the last as described in Chart G 33, 35 or 93) two analog-to-digital readings.
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Field Contains Action
GGG state code 33 Identifier for the Corrupted Use Chart G - State Code 33
Triple Redundant variable in NV RAM
GGG state code 35 Identifier for the Undefined Use Chart G - State Code 35
Interrupt
GGG state code 93 Dose-Rate Calculation dose Convert to hexadecimal then
mode and amount mode use Chart G - State Code 93 selected
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Converting Snapshot screen-b values from decimal to binary
This section does not explain the process of conversion, but shows the conversion of the fields on this sample Snapshot screen-b.
Fields A, B C and D on snapshot screen-b need to be converted into a binary format. If you do not have access to the History Download Software Kit for decoding snapshot screens (see page 4-11), you can use the examples in this section to remind yourself how to convert a decimal number to its binary equivalent.
The numbers on the screen above are explained in the table below:  The top heading line shows how the bits are numbered, with bit
zero on the right.
 The next heading line, in italics, shows the value that is assigned
to each of the 8 bits.
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 Each detail line shows the decimal value taken from the example
screen in bold, and shows how each of the the bits are set to represent that decimal value (0 is off, 1 is on). For example, AAA has a decimal value of 72, so bit 6 (value 64) is set, and bit 3 (value 8) is set:
Bit number 76543210
Binary digit value 128 64 32 16 8 4 2 1
Field AAA 072 01001000 Field BBB 004 00000100 Field CCC 029 00011101 Field DDD 139 10001011
Issue A (April 2002) 3000/3100 and 500/505 Service Manual
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Volumetric Infusion Pumps
Chart A Pump Main Modes
Once you have converted the decimal value in field AAA into binary format, use this chart to find out the pumps state modes. The example of Snapshot-b shows field AAAs value as 072 (decimal), which converts into 01001000.
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 = Not used Unit not Unit not Unit not Unit not Unit not Unit is in Unit not
in dose- in quick in dead in low in KVO primary running rate calc rate change battery battery
condition condition
1= Not used Unit is in Unit is in Unit is in Unit is in Unit is in Unit is in Unit is
dose-rate quick rate dead low battery KVO secondary running calc. change battery condition
condition
Chart B Pump State Modes
This chart shows the state modes that can be decoded from field BBB on Snapshot-b when the value is converted to binary. The example of Snapshot-b shows a value of 004 (decimal) which converts into
00000100.
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Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 = Primary/ Secondary Secondary Primary Primary Standard Pump not Pump not
secondary VTBI does rate does VTBI does rate does message in rate in rate rate/volume not have not have not have not have not in taper end taper not decimal decimal decimal decimal decimal message early since total place place place place display volume last cleared
1= Primary/ Secondary Secondary Primary Primary Standard Pump is in Pump is in
Secondary VTBI has rate has VTBI has rate has message is rate taper rate taper rate/volume decimal decimal decimal decimal in message end early was decimal place place place place display since total volume last cleared
Chart C Pump Physical Modes
Convert the value in CCC to binary then use this table to decode the bits. In the example screen, the decimal value is 029, or binary
00011101.
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 = Not used Run not Not used Cassette not Not used Safety clip Door not Pump not
pending in position not in place open turned on
1 = Not used Run Not used Cassette in Not used Safety clip Door open Pump
pending position in place turned on
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Chart D Pump sensor flags and occlusion alarm setting
Once you have converted the decimal value into binary format, use this chart to determine the pumps sensor flags and status of the pumps occlusion alarm setting. In the example Snapshot screen-b, field DDD shows a value of 139 decimal. This converts to 10001011 in binary format.
Bit 7 Bit 6 Bit 5 and Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 = Micro Not Occlusion alarm status Auxilliary CTS not Keypad Pump on
jumper Used - see Chart DD below power off active not locked AC
1 = No Micro Auxilliary CTS Keypad Pump
jumper power off active locked on battery
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Chart DD - Occlusion alarm status
Use this table to determine the occlusion alarm status from bits 5 and 4 of the binary representation of field DDD.
Bit 5 Bit 4 Occlusion alarm setting
0 0 Undefined 0 1 Low 1 0 Medium 11 High
Chart E - Keypad State Input Mode
Use this chart to determine the keypad state input mode. Do not convert to binary. Take the value from field EEE on Snapshot screen-b.
Value Mode
0 Keypad default mode. 1 Occlusion Alarm Setting. 2 Options. 3 Quick Rate Change. 4 Total Volume. 5 Taper End Early. 6 Taper setup. 7 Keypad Locked. 8 Rate input. 9 Volume to be Infused input. 10 Taper Run. 11 Volume Over Time setup. 12 Dose-Rate Calculation setup. 13 Dose Run. 14 Dose-Rate rate titrate. 15 Dose-Rate dose titrate.
4— 18
The example snapshot screen-b shows field EEE with a value of decimal 008, so the keypad state input mode is Rate input.
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Chart F - Battery V oltage
Use this chart to convert the average value of the last two analog-to­digital readings into the battery voltage at time of snapshot. Take the value from field FFF on Snapshotscreen-b.
Analog-to-Digital Value Voltage
186 11.1 188 11.2 190 11.3 191 11.4 193 11.5 195 11.6 197 11.7 199 11.8 200 11.9 202 12.0 204 12.1 205 12.2
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Analog-to-digital values that fall between those listed in the table may be interpolated to determine the voltage.
For example, the example snapshot screen-b shows the value as decimal 194, so the voltage value is 11.55.
Chart G - Pumping pressure
Use this section to interpret field GGG on snapshot screen-b for all system state codes except 33, 35 or 93 which are described later in this chapter. This example shows field GGG with a value of 131.
These instructions explain how to compute the pumping pressure of the pump at the time of the snapshot.
The pressure sensor has a zero offset Analog-to-Digital value of 0 to 3. In addition to that, every increment of 21 represents 1 psi.
Use the following steps to compute the pumping pressure contained in field GGG on Snapshot-b:
1. Take the decimal value in GGG and subtract 5.
2. Divide the result by 21 to give the pressure in psi. These steps can be represented by the formula:
(GGG-5) / 21 = n psi
As an example of how the formula works:
If the value of GGG is 131: (131-5) / 21 = 6 psi
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Chart G - State Code 33 - Corrupted T riple Redundant variable in NV RAM
If the system state code on screen-a is 33, find the identifier of the corrupted variable by checking the value of GGG on screen-b:
GGG Variable Identifier
0 Micro/Macro flag 1 Rate calibration factor 2 Pressure search limit 3 Back off pressure 4 Language select 5 Baud rate 6 Pump serial number 7 Pump enabled for Volume Over Time 8 Pump enabled for Dose-Rate Calculation 9 Rate Taper enable flag 10 Volume Over Time enable flag 11 Dose-Rate Calculation enable flag 12 Alternate search pressure 13 Alternate search rate 14 Search occlusion pressure 15 Back off range low 16 Back off range high 17 Serial key flags 18 Back off method 19 Long search half step limit
Chart G - State Code 35 - Undefined interrupt
If the system state code on screen-a is 35, find the cause of the undefined interrupt by checking the value of GGG on screen-b:
GGG Interrupt Identifier
0 Reset 1 Clock monitor 2 Cop watchdog 3 Bad opcode 4 Software interrupt (SWI) 5 Non-maskable interrupt (XIRQ) 6 Hardware interrupt (IRQ) 7 Real time interrupt 8 Timer input capture 1 9 Timer input capture 2 10 Timer input capture 3 11 Timer output compare 1 12 Timer output compare 2 13 Timer output compare 3 14 Timer output compare 4 15 Timer output compare 5 16 Timer overflow 17 Pulse accumulator overflow 18 Pulse accumulator input edge 19 Serial Peripheral Interface 20 Serial Communications Interface
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Chart G - State Code 93
If the system state code (ZZ) on Snapshot screen-a is 93, then GGG on snapshot screen-b contains a decimal representation of a hexadecimal value. This hex value encodes the amount mode and dosing mode selected by the operator during a Dose-Rate Calculation program setup.
If the system state code is 93 use the instrucitons in this section to convert the value to hexadecimal and then interpret the result using the table below.
To convert the GGG value:
1. Take the decimal number, and divide it by 16.
2. The initial quotient is digit 1 and the remainder is digit 0.
Volumetric Infusion Pumps
As an example, if the value of GGG was 052:
052 / 16 = 3 (digit 1), with a remainder of 4 (digit 0).
To interpret the result
Look up the resulting values for digit 1 and digit 0 in the table below to find out the dosing mode and amount mode:
Digit 1 - Amount mode Digit 0 - Dosing mode
0 MG/bag 0 mcg/kg/min 1 Gm/bag 1 mcg/min 2 mcg/bag 2 MG/min 3 units/bag 3 MG/hr
4 units/hr 5 MG/kg/hr 6 mch/kg/hr 7 MG/kg/min 8 units/kg/hr
In the example above:
Digit 1 with a value of 3 indicates an Amount mode of units/bag
4
Digit 2 with a value of 4 indicates a Dosing mode of units/hr.
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Volumetric Infusion Pumps
Using Biomedical Parameters
This section explains how to use the Biomedical Menu parameters, summarised on page 4-10. To find out about the snapshot screens and how to decode them, see page 4-11.
Press the Options key to navigate from one parameter to the next. You cannot move backwards; to redisplay a parameter, press the
Options key repeatedly to move through all the parameters until you see the one you require.
Time and date display
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The first line displays the time in the format hh:mm:ss. GMT is only displayed if it has been enabled on the Technician menu,
see page 4-6. The second line displays the date in the format mm/dd/yy. To change the date or time, use the Service Functions menu
described on page 4-29.
Pump history display
This parameter shows a summary of the statistics for pump usage. It shows:
Hrs: cumulative hours that the pump motor has been running.
The number of hours can range from 0 to 99999. This example shows that the pump has been running for 19 hours.
Liters: cumulative volume infused, in liters. The volume
infused ranges from 0 to 99,999 litres. The volume shown in the example above is 9 litres.
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Load: number of loading cycles - the number of times that the
door has been opened. The value is in the range 0 to 99999. The example above shows 22 load cycles.
Issue A (April 2002) 3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Charge History
This parameter shows a summary of the pumps charging history. It shows:
Volumetric Infusion Pumps
AC: total number of hours that the pump has been turned on
whilst plugged into the AC mains supply. The hours can range from 0 to 99999. This example shows 18 hours.
Charge: AC charge time. This is the accumulation of time the
pump is plugged in and turned off. Range from 0 to 99999. For software versions 0.67 this accumulation is updated provided the pump is turned on before being unplugged. For software versions 0.71 the pump will log the time it is plugged into the AC and not switched on as Charge Time, regardless of whether the pump was switched ON before AC was removed. The example shows AC charge time of 73 hours.
4
Batt: total number of hours the pump has been turned on and
powered by battery, i.e. not plugged in. The example shows 2.
The total number of hours that the pump has been switched on (cumulative hours of operation) is the sum of AC and Batt hours, in this example, 20 hours.
Pressure display parameter (on battery power)
You can only calibrate the pressure transducer on the front door assembly sensor of the pump when the pump is connected to the AC mains supply.
If the pump is operating on battery power, the pressure calibration mode parameter is not shown. Instead, you see the screen:
If you connect the pump to the AC mains supply while this screen is shown, the pressure calibration mode screen will appear, as shown over the page.
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Volumetric Infusion Pumps
Pressure display - calibration mode
If the pump is operating on AC mains supply, the pressure transducer on the front door assembly sensor may be calibrated, so you see this parameter:
ABCD
The bottom line of this screen shows four fields, marked on the above example as A, B, C and D. They are described in the table below:
Field Range Comment
A 0 to 1919 Represents motor position. It shows unref if
unref the motor cam position is unreferenced. It shows or * * in the first position if a motor stall was detected.
B 0 to 1919 Represents the position immediately before the
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last motor home position realignment. If there is no significant motor slippage, expected display values are between 0 and 40 or 1880 and 1919.
C 0 to 255 Raw analog-to-digital pressure reading from the
display board. This value is read and the Message Display value updated at least twice per second. This permits occlusion alarm calibration to a known pressure by adjusting two potentiometers, see Occlusion alarm adjustment on page 8-15..
D 1, 0 or
Pressure transducer calibration screen
The default rate is 25 mL/h. To adjust the rate:  Press Rate and enter a rate with the number keys. The run light
flashes whenever a rate can be entered using number keys.
To accept the entered rate:  Press Run. The rate appears in the rate display.
- Represents the pressure plate position
switch, where: 1 = cassette-in-position 0 = no cassette present
- = communication error when switch is read.
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To toggle the motor direction:  Press Primary. If the motor is running backwards, the pumping
indicator shows a minus sign. If the motor is running (forward or backward) the run light is continuously lit.
To stop the motor.  Press Hold. When the motor stops the hold light is lit.
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Baud rate
This screen displays the current baud rate selection for the computer port: 300, 600, 1200, 2400, 4800, or 9600. The default baud rate is 9600 baud.
Volumetric Infusion Pumps
Language
Press 1 ( If you press 1 (
9600. If you press 3 ( changes to 300.
Press Options or On/Off to accept the last baud rate shown.
This screen displays the language currently in the pump's software. The above example shows English, but the pump may show any one of the following:
English French German Italian Spanish Dutch Swedish Japanese Portuguese Only one language is supplied in any one pump. Contact Graseby
Medical to determine language availability. Pressing 1 ( not change the language selection.
) or 3 ( ) to display the next or previous baud rate.
) when 300 baud is shown, the display changes to
) when 9600 baud is displayed, the display
) or 3 ( ) will
4
Battery use
The pump records information about the number of times it is used on battery. It records the information against the period of time for which it was used.
For example, the screen above shows Battery use 0 - 1 hr: 42, indicating that the pump has been used 42 times for one hour or less.
Use 1 ( battery for the other periods of time:
0-1 hours 4-5 hours 1-2 hours 5-6 hours 2-3 hours 6-7 hours 3-4 hours 7+ hours
The maximum number of hours that can be shown is 99999.
) or 3 ( ) to see how many times the pump has been used on
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Volumetric Infusion Pumps
Model number and software version
The model number and software version parameter contains information in these fields, explained in the table below:
This is an example of the screen:
The values in this example are shown in the right hand column of the table below.
Field Contains Example
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XXXXX Model number: 3000 or 3100 3000
(In the U.K. only, the Volumetric Infusion Pumps are called 500 and 505.)
VY.YY Software version resident in the 0.71
ROM of the main processor
DB:Z.ZZz Software version resident in the 3.65A
Display Board microprocessor
MM:G.GG Software version resident in the 1.10
Motor Monitor microprocessor
The lower case z in the above screen is always present on Dose-Rate pumps. It signifies the language selected. It is only present when a language other than English was selected on non Dose-Rate pumps.
Audio alarm test
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This screen allows you to verify proper operation of the audio alarms by pressing a key to sound each type of alarm:
Press 1 to initiate a non-insistent alarm  Press 2 to initiate an insistent alarm  Press 3 to initiate a backup audio alarm  Press any other key to stop the alarm. The hardware which produces the Back Up audio alarm is the same
as that used by the Continuous alarm.
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Audio alarm specifications
The table below shows the specifications of the audio alarms:
Type of alarm Repetitions Frequency of chimes
Insistent high/high/low chime 3,000Hz 2,200Hz
Non-insistent high/low chime 3,000Hz 2,200Hz
Back Up high pitched 3,000 Hz
Volumetric Infusion Pumps
High Low
every 2.25 seconds.
every 2.25 seconds.
every 1.5 second.
Continuous high pitched 3,000 Hz
without pause.
Enabling special programming functions
In software versions before version 0.71, the Rate Taper, Volume over Time and Dose-Rate Calculation pump programming modes could only be enabled or disabled on the Biomedical Menu of Dose-Rate pumps.
From version 0.71, these parameters appear on the Technician Menu described on page 4-2, as well as on the Biomedical Menu.
It is recommended that you should place an external label on a pump to indicate which functions have been enabled.
Enable/disable rate taper
Enabling this parameter allows the user to taper the infusion rate, either up or down, for the administration of Total Parenteral Nutrition (TPN), Total Parenteral Admixture (Three-in-One) or other applicable therapies.
Use the * key to toggle this parameter. Thus if you see a screen like the following:
4
then the rate taper is enabled and you must press the * key to disable it.
If you press *, the screen changes to:
Press the * key again to re-enable the Rate Taper mode.
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Volumetric Infusion Pumps
Enable/disable volume over time
Enabling this parameter allows the user to set up an infusion using the volume to be infused and the total time, with the pump automatically calculating the infusion rate. This can be done with either Primary or Secondary infusions.
Use the * key to toggle this parameter, as described for Enable/ Disable Rate Taper, on page 4-27.
Enable/disable dose-rate calculation
Enabling this parameter allows the user to set the dosing rate, patient weight, the drug amount in the fluid bag and the volume in the container, from which the pump then calculates the infusion rate.
If you enable Dose-Rate Calculation, the Micrograms unit should also be set (using the Micrograms parameter on the Technician Menu, see page 4-5) according to your protocol.
Use the * key to toggle this parameter, as described for Enable/ Disable Rate Taper, on page 4-27.
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About the Service Functions menu
The Service Functions menu allows you to set the date and time on the pump and to test some pump functions.
Entering the Service Functions menu
To enter this menu, first switch off the pump if it is switched on. Then, press the Occlusion Alarm Setting key while simultaneously
pressing the On/Off key. When you take your fingers off the keys, the pump switches on and you are asked to enter the Service Function menu ID.
Enter the numbers 7557. As you enter the digits asterisks (*) are displayed for security
protection. If you make a mistake, you must switch the pump off to enter the correct ID. When prompted:
Enter the password 3796.
Volumetric Infusion Pumps
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The password is always 3796 and cannot be changed.
Using the Service Functions menu
When setting up the pump, the main use of this menu is to set the date and time.
Setting the date
To set the date and time:
1. Enter the service functions menu as described above.
2. Press Options to display the screen:
3. Enter the time and date as a string of numbers in the format HH:MM:SS MM/DD/YY.
4. Press Options again to display the next parameter. The parameters on the menu are described on the next page.
Note: If Version 0.71 (or later) software is installed, GMT may be hidden, by
disabling the GMT timestamp parameter on the Technician Menu, see page 4-6.
Leaving the Service Functions menu
Switch off the pump to exit the menu.
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Volumetric Infusion Pumps
Service Functions menu parameters
The numbers on the left of this table show the number of Options key presses to reach the parameter.
This list is for software versions 0.67 and 0.71 only. For older software versions including 0.53 and 0.63 there are other screens displayed where the displayed parameter should not be adjusted.
Screen Use Notes
Information for Graseby Medical Service Department use.
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1 Use this to set the time In order to set the date, first you
and date in the format must enter the time. In Version 0.71 HH:MM:SS and software, GMT can be disabled on MM/DD/YY. the Technician menu
2 The top line shows the The event is the event in Snapshot
number of times that screen-a of the Biomedical Menu. each event code has Event Codes 43, 44 and 45 will not occurred. Use the scroll be logged in this Event History keys to select an event code Summary . to be displayed.
3 Status of six sensors as shown
on the table below.
4 Press a key to check Pressing the Options key once will
that it is functioning show that you have pressed that key correctly. The key pressed Pressing it again will take you to shows on the second line of the next menu option the screen.
5 Shows the serial If you need to enter the serial
number of the pump number on a pump that has been as on the back of the upgraded or had the main board case. changed, press * to enter the
number.
6 Take care with this You can download history
option, since the action by using the Volumetric is irreversible. You are Infusion Pump History given a chance to Download Kit. change your mind.
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Status of sensors
Sensor Description Value = 0 Value = 1
Volumetric Infusion Pumps
DR Door Closed Open CL Clip Out In CS Cassette None Fitted PL Keypad Lock Unlocked Locked ON On/Off key Released Pressed JP Jumper JP10 3000/500 3100/505
on CPU board
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Mechanical Systems
Chapter 5
Graseby Medical Ltd.
Mechanical Systems
Linkage system
The pumps employ a linkage system to move the cam housing/ pumping mechanism between the load position and the operate position (see Fig. 5.1). The load position is used to load and unload the fluid filled cassette.
The operate position brings the pistons and valves of the pumping mechanism in contact with the cassette, and is monitored by the microprocessor as it reads a signal from the cam housing switch positioned on the cam housing.
The pumping mechanism is spring loaded to keep it in the load position whenever the door is opened. When the door is closed the linkage mechanism is actuated by the handle/arm assembly and the pumping mechanism is drawn forward into the operate position. Once in the operate (door closed) position, the latch lever secures the pumping mechanism in place.
Volumetric Infusion Pumps
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Linkage
Safety Clip Switch
Safety Clip Retention Slot
Cam Housing Switch
Wedge
Figure 5.1 Linkage system and safety clip switch
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Volumetric Infusion Pumps
Cassette housing and door
The cassette housing and door of the pump (see Fig. 5.2) are designed for one step loading. Opening the door turns the pump on and causes the microprocessor to set the pistons and valves in the ready position. After a cassette and Safety Clip are loaded the door can be closed by swinging the door shut and pushing the door latch in.
The cassette housing and door secure the cassette in the proper position for loading and operation. The cassette position is established by placing the cassette (flat side out) over the 4 loading pins built into the cassette housing. The cassette housing is mounted to the front cover of the pump and is stationary.
The door is also mounted to the front cover using 2 hinge brackets. When the door is closed, it provides a flat stable surface for valve sealing and manipulation of the cassette chambers by the pistons.
In the door is a spring loaded pressure plate. When a fluid filled cassette is placed on the cassette housing and the door is closed, there is a considerable amount of pressure developed in the cassette. The pressure plate is spring loaded to accommodate this pressure build up. The pump relieves the pressure by reversing motor direction and channelling the solution back up to the fluid container.
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Once pressure has been reduced, the pressure plate springs push the plate toward the cassette housing. A position sensor (mounted on the plate) is activated when the pressure plate reaches a specified distance from the cassette housing. The microprocessor reads this sensor and determines if the pressure has been adequately relieved. If loading was successful, the pump can be run; if not, an insistent alarm sounds and an alarm message is displayed.
The pressure plate also houses a pressure transducer used to monitor occlusion alarm pressure. The transducer is positioned over the middle cassette chamber, and provides continuous pressure monitoring while pumping. Amplifier gain and zero offset are adjusted using trimpots R439 and R448, which can be accessed at the bottom of the door assembly. If pressure exceeds the selected Occlusion Alarm Setting, an insistent alarm is generated.
In addition to the pressure plate and sensors described above, the door assembly also houses the display board, LCD, keypad, CPU3 memory chip, and photosensor.
Safety clip retention slot
The Safety Clip, located on the administration set, is inserted into the Safety Clip retention slot on the cassette housing (see Fig. 5.1). The Safety Clip occludes the IV tubing whenever the door latch is pulled out. When the door latch is pushed in, the arms of the Safety Clip are spread apart by the wedge inside the safety clip slot, thus allowing an infusion.
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Figure 5.2 Cassette housing and door
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Volumetric Infusion Pumps
Cam housing switch and safety clip switch
The cam housing switch and safety clip switch are two sub-miniature switches that monitor the cassette loading process (see Fig. 5.1). They alert the microprocessor to the door open and safety clip alarm conditions. If either switch is not activated, the pump will not operate.
The cam housing switch (which is normally closed) is mounted to the upper right side of the cam housing. It is activated by the cassette housing as the pumping mechanism is drawn forward during the loading process. The cam housing switch is opened as the door is closed.
The safety clip switch (which is normally open) is mounted to the bottom front of the cam housing. It is activated by the safety clip on the administration set, when the clip is inserted into the retention slot and the door is closed.
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Cam housing
The moulded cam housing is coupled to the front housing of the pumps via the linkage system (see Fig. 5.3). The cam housing acts as the main supporting structure for the electro-mechanical pumping mechanism. The stepping motor mounts onto the lower portion of the cam housing with its shaft pointing upward. Coupled to the motor shaft is the vertical cam shaft which turns in the bushing inserts. The encoder wheel, valve and piston cams of the pumping mechanism are moulded onto the cam shaft.
The electro-mechanical components, the overpressure piston; valve; two pumping pistons and valves, all operate within the cam housing. Mounted to the cam housing are the cam housing switch, safety clip switch, flex wedge assembly and the I/O circuit board.
Stepping motor
A four phase, synchronous stepping motor (see Fig. 5.3, item 3) is used in the pumping mechanism. The step angle is 7.5 degrees and the gearbox reduction ratio is 20:1.
The motor is operated by circuitry on the I/O board according to a control program in micro-processor memory. To provide smooth rotation, the motor is half-stepped for rates 0.1 mL/h through 499 mL/ h. At rates of 500 mL/h and above the motor is whole stepped. The CPU1 sends commands to U106 on the I/O board, which sends on/off signals for each of the four motor coils. These signals, in conjunction with a step pulse, cause motor motion.
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Due to the 20:1 gear reduction and half stepping, 1,920 pulses yield one full revolution for rates of 499 mL/h and less. Each cam shaft revolution and the resulting cycle of the pumping mechanism delivers approximately 1.7 mL of fluid. Delivery of fluid to the patient is smooth since each mL is delivered in approximately 1,130 increments. The 3100/505 pump is half stepped at all rates.
At rates of 500 mL/h and above, due to the gear ratio of 20:1 and whole stepping the motor, each mL of fluid is delivered in approximately 565 increments.
Volumetric Infusion Pumps
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Volumetric Infusion Pumps
Cams, pistons and valves of the pumping mechanism
The motors mounting shaft is connected to a vertically mounted cam shaft (see Fig. 5.3, item 13) by the motor coupler (item 4), interface coupler (item 5), and hub coupler (item 6). Four cams (items 8, 9, 11 and 12) and an encoder wheel (item 10) are moulded onto the cam shaft. The cams actuate four horizontal shafts, which in turn drive two valves and two pistons which produce the pumping action.
Pumping cycle description (Figs 5.3, 5.4 and 5.5)
1. The cam shaft revolution causes the upper valve (item 17) to open, allowing flow to the upper cassette chamber and upper piston (see item 18). The lower valve (item 20) closes, thus stopping flow between the upper and lower cassette chamber (lower piston).The smaller, lowest chamber on the cassette is in contact with the overpressure piston (item 22) and is the point where internal pumping pressure is continuously regulated.
2. The upper piston (see item 18) begins to draw back as fluid flows from the upper tubing into the upper cassette chamber. At the same time, the lower piston (item 21) begins to slowly push forward, forcing the fluid in the lower cassette chamber into the lower tubing, towards the patient.
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3. Once the upper piston (item 18) has moved fully back and the lower piston (item 21) fully forward, the upper valve (item 17) closes and the lower valve (item 20) opens. The upper piston (item
18) then begins to push forward to force the fluid in the upper cassette chamber downward into the lower cassette chamber, where the lower piston (item 21) is beginning to draw back to receive the fluid. The upper piston moves forward delivering fluid more rapidly when the lower piston draws back, causing a continuous stream of fluid to be forced out of the lower tubing to the patient.
4. The lower valve (item 20) closes and the upper valve (item 17) opens as the upper piston (item 18) reaches its furthest forward point of travel and the lower piston (item 21) its furthest back travel. The cycle then repeats.
The result of the above cam, piston and valve action is a smooth flow of fluid through the lower tubing to the patient. Each full revolution of the cam shaft delivers approximately 1.7 mL of fluid as governed by the precise and unvarying travel of the pistons. The rate of fluid delivered is determined by the rate at which the motor is stepped.
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Volumetric Infusion Pumps
[13] [14] [15] [16]
[12]
[11]
[10]
[9]
[8]
[7]
[6]
[5]
[4]
[17]
[18] [19]
[20]
[21]
[22]
[23]
[24]
[25]
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[1] Spring [2] Swing Arm [3 ] Stepping Motor [4 ] Motor Coupler [5 ] Interface Coupler [6 ] Hub Coupler [7 ] Cam Housing [8 ] Piston Cam [9 ] V alve Cam [10] Encoder Wheel
[1][2][3]
[1 1 ]Piston Cam [1 2 ]Valve Cam [1 3]Cam Shaft [1 4]Wire Contact [1 5]Spring Contact [16 ]Cassette Housing [1 7]Upper Valve [1 8]Upper Piston [19]Piston Spring [2 0]Lower Valve
Figure 5.3 Pumping mechanism
[26]
[21] Lower Piston [22] Overpressure Piston [23] Connect Shaft [24] Overpressure Valve [25] Safety Clip Retention Slot [26] Pressure Plate/Door
5 — 7
Volumetric Infusion Pumps
Graseby Medical Ltd.
valve opens to allow fluid flow to upper
upper piston draws
valve closed while upper piston draws
lower piston moves forward to deliver
overpressure piston monitors downline
5
Figure 5.4 Pumping cycle
valve closes when upper chamber is full
upper piston moves forward
valve opens to allow flow to lower piston
lower piston draws back to fill
overpressure piston monitors downline pressure in set
5 — 8
Figure 5.5 Pumping cycle
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Encoder wheel and interrupter
The encoder wheel (item 10) is mounted to the cam shaft (item 13) which is turned by the stepping motor to drive the pumping mechanism (see Fig. 5.3 and 5.6). The interrupter assembly is mounted to the back of the cam housing (via the I/O board) so its emitter and detector arms straddle the encoder wheel. A light beam, produced by the emitter, is alternately allowed to reach the detector and then blocked by the teeth of the encoder wheel as it turns.
Data from the interrupter detector is read through the parallel to serial interface chip U108 on the I/O board. The microprocessor monitors the interrupter output in relation to the motor drive pulses delivered.
If the micro-processor senses an incorrect response from the pumping mechanism, a system warning is generated, sounding an alarm and displaying the message:
Volumetric Infusion Pumps
In this manner, the encoder wheel and interrupter alert the micro­processor to binding, hesitation or stalling of the motor and pumping mechanism.
Figure 5.6 Encoder wheel
5
5 — 9
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Volumetric Infusion Pumps
Empty bag contacts
The empty bag contacts (see Fig. 5.3) consist of a rigid wire contact and a spring contact and are used in detecting the No flow above pump alarms. The wire contact (item 14) is connected to ground potential. The spring contact (item 15) is mounted to the cam housing. The position of the spring contact is adjusted by a set screw located on the right hand side of the cam housing. The empty bag contacts must touch briefly, once per revolution of the pumping mechanism. Contact occurs only when the upper piston is in the major depression area of the metering cam.
The upper piston (item 18) is loaded to the out position by a light spring (item 19). Pressure caused by the solution container and proper head-height overcomes this spring tension and causes the upper piston shaft to maintain contact with the drive (metering) cam throughout the pumping cycle. An empty fluid container or inadequate head-height allows the piston to lose contact with the metering cam. The wire contact fails to touch the spring contact and an alarm results.
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Sensors
Pressure sensor
The occlusion pressure and alarm conditions are monitored by a solid state pressure transducer which interfaces directly with the middle chamber of the fluid filled cassette. The transducer is a differential pressure transducer which, when activated by a constant current source provides an output voltage proportional to the applied pressure. The output of the transducer is amplified by a two-stage instrumentation amplifier which provides output analog voltages in the range of 0 to 5V. Output voltages from the amplifier are read by the display board microprocessor via an 8-bit analog to digital converter.
When an Occlusion below pump alarm occurs, the motor briefly backs off before entering hold. The over pressure condition is thus reduced while you locate and correct the cause of back pressure. A swing arm closes the over pressure valve to prevent reverse fluid flow while the motor is backing off.
Pressure plate position sensor
The pressure plate position sensor (housed in the pressure plate in the door) provides information to the display board microprocessor regarding the position of the cassette housing and pressure plate. The sensor itself is a microswitch that activates when the pressure plate comes within a specified distance from the cassette housing.
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Photo sensor
The pump systems include a photo sensor device used to monitor ambient light levels and adjust the LED display intensities accordingly. The photo sensor is a photoconductive cell which has a cell resistance that varies inversely with illuminance. The cell resistance varies from approximately 10K ohms to approximately 1M ohms. The cell is designed into one leg of a resistor divider network and the voltage generated across the cell is read by the display board micro-processor via the 8-bit analog to digital converter.
Over pressure valve and swing arm
The over pressure valve (item 24, Fig. 5.3) is located directly below the over pressure piston (item 22). The swing arm (item 2) is attached to the cam housing at the rear of the over pressure valve shaft. The toothed section of the swing arm engages the motor coupler and is held in ready position by a torsion spring. The swing arm rides on the toothed surface of the motor coupler while the pump is running. When the motor backs off, the swing arm catches on the motor coupler and forces the over pressure valve outward, occluding the fluid pathway. In this way, reverse fluid flow is prevented whenever the pumping mechanism backs off.
Volumetric Infusion Pumps
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In the event an administration set is loaded improperly, excess pressure can build up in the cassette. If this happens the pump alarms and remains on hold. During this period, the excess pressure within the cassette pushes the pressure plate away from the cassette housing. In this situation the pressure spring, mounted on the over pressure valve shaft, forces the valve outward, keeping it in contact with the pressure plate and preventing free flow.
Back pressure regulation
Proper performance of the pump depends on constant conformity of the fluid filled cassette to the cassette housing and pistons during the pumping cycle. A small amount of pressure within the cassette is therefore needed to maintain proper cassette form. The over pressure valve (item 24, Fig. 5.3) and the over pressure piston (item
22) function together to create a resistance to the fluid flow for the purpose of providing this needed pressure. Internal cassette pressure must be great enough to maintain cassette form, yet kept below the threshold of the Low Occlusion Alarm Setting.
The over pressure valve restricts fluid flow during operation which results in internal cassette pressure. The position of the over pressure valve and resulting pressure is influenced by the over pressure piston.
The over pressure piston and valve are coupled by a vertical connect shaft (item 23). The over pressure piston is slotted where it joins the connect shaft. This slot allows semi-independent movement between the valve and piston.
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Volumetric Infusion Pumps
During operation, the rear edge of the piston slot makes contact with the connect shaft. The piston assembly contains a spring (item 1) which is precisely adjusted for the proper force. It is this spring force (which is applied to the over pressure valve via the shaft) that governs internal cassette pressure.
Should a small temporary pressure increase occur within the cassette, the over pressure piston is pushed to the rear of the pump. The vertical shaft disengages from the piston. The internal pressure also pushes the over pressure valve to the rear, causing less flow restriction. The resulting decrease in internal cassette pressure allows the piston to move forward and engage the connect shaft, thus reasserting spring tension to the valve. This restores the desired level of internal cassette pressure.
The preloaded over pressure valve opens as forward rotation of the pumping mechanism begins. The preload force is overcome when pressure reaches approximately 1 psi. However, the break open pressure varies and is sometimes higher than 1 psi.
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To avoid nuisance occlusion alarms in the Low Occlusion Alarm Setting during start up, the pressure threshold is temporarily set to 5 to 6 psi. After a brief transition period to allow break open of the over pressure valve, the pressure threshold reverts to 2 psi. The Low setting should only be used with lower flow rates.
Pole clamp and IV pole
The pole clamp is designed to function with pole diameters of 1.2 cm and 3.8 cm (0.5 and 1.5 inches). It supports the weight of three infusion pumps. Turn the knob clockwise to attach the pump to the pole and counter clockwise to remove the pump.
Modular connection system
In use, Graseby Medical recommend that the pump should be connected to a suitably balanced IV pole using the pole clamp as illustrated in the diagram on the opposite page.
To provide maximum stability when using the modular connection system, ideally the IV pole should have 6 wheels and low centre of gravity. The base diameter should be 56 cm (22 inches).
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Attaching a single pump to an IV pole
To attach the pump to a suitably balanced IV pole:
1. Loosen the screw on the pole clamp.
2. Hold the pump by the handle and slip the arms of the pole clamp onto the pole.
3. Tighten the screw on the pole clamp to firmly attach the pump to the pole.
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Attaching more than one pump to an IV pole (Revised case design shown here)
When multiple infusion lines are required, you can connect up to three pumps to a single pole using the hooks and rails that make up the modular connection system.
As all pumps have connectors on both sides, you can use any one as the centre, left, or right pump.
This diagram shows how three pumps may be connected together using the Volumetrics modular connection system:
Volumetric Infusion Pumps
Inspecting the modular connections
Before connecting the pumps, you must check that the modular connection parts are all in good condition:
1. Carefully inspect the modular connection system for damage, including cracks, chips, loose or bent parts.
2. Press the disconnect buttons several times to make certain that the buttons move in and out freely.
WARNING: Do not use the pump if you detect any cracks, chips and loose or
bent parts, or if the buttons do not move in and out freely when they are pressed. Failure to do so could cause inadvertent disconnection of the pumps.
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5
Volumetric Infusion Pumps
How to connect pumps together
Once you have inspected the modular connection system as described in the previous section, connect the pumps as follows:
1. Clamp the first pump to the IV pole. This is now the "centre" pump.
Note: As you tighten the screw on the pole clamp, the actuator arm adjusts the
modular connection hook and disconnect button. Once the pump is securely attached to the pole, the hook is in the correct position to allow connection of further pumps.
2. Take the second pump, grasping it by the handle and hold it so that the modular connector rails are directly above or below the connector rails of the centre pump.
3. Engage the edges of the modular connector rails and slide the second pump up or down until it is connected to the centre pump. When the connection is secure, you hear a distinct click. If you do not hear a distinct click when connecting the pumps then the modular connection system has not engaged properly.
4. Before releasing the handle of the second pump, double-check that the connection is secure by moving the pump up and down and exerting pressure on the top of the pump.
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To attach a third pump to the other side of the first pump, repeat steps 2, 3 and 4.
White Disconnect Button
Modular Connector (rails)
Hook
Poleclamp Assembly
Actuator Arm
GM0700-A
Figure 5.8 Pole clamp and modular connecting system
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WARNING: Do not use the pump if you detect any cracks, chips and loose or
bent parts, or if the buttons do not move in and out freely when they are pressed. Failure to do so could cause inadvertent disconnection of the pumps.
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Moving an IV pole with pumps connected
If you need to move the IV pole once the pumps are attached, always ensure that you grasp the IV pole with one hand and steady the pumps with the other hand if necessary.
Disconnecting modular connected pumps
You must always disconnect modular connected pumps one by one before removing the centre mounted pump from the IV pole.
Disconnect the left and right hand pumps from the centre mounted pump as follows:
1. Grasp handle of pump to be removed.
2. Lift the pump slightly.
3. Press the disconnect button and slide the pump up or down to
4. Place the pump in a location where it will not be damaged.
Volumetric Infusion Pumps
disconnect from the centre pump.
WARNING: Do not push or pull on the pumps, or the IV pole may tip over or
the pumps fall to the floor. Do not try to remove modular connected pumps from the IV pole whilst they are joined together. Either of these could cause the administration set to separate from the fluid container thus spilling the medication, or the pumps themselves could be damaged.
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Electronic Circuits
Chapter 6
Maintenance Procedures
& Troubleshooting
Chapter 7
Graseby Medical Ltd.
Maintenance Procedures
Introduction
The information and procedures presented in this chapter are intended to enable the user to achieve satisfactory performance over the life of the pump. However, this maintenance information should not be considered inclusive. The purchaser is encouraged to contact the Graseby Service Centre when necessary. The contact details are listed in Chapter 1.
Note: Infusion pumps are precision medical instruments. When returning a
pump to the Service Centre for repair it should be packaged for shipment in a manner which provides protection against physical shock or other shipping damage. It is strongly recommended that the pump is shipped back in the original shipping carton to prevent damage.
Volumetric Infusion Pumps
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Volumetric Infusion Pumps
Recommended test equipment
The following equipment is recommended for performing the functional and accuracy checks described on page 7-8:
 An air regulator which ranges from approximately 2 psi to 12 psi
(Bellofram 10-B or equivalent). This compressed air source is connected to the lower end of an installed administration set in order to verify the accuracy of occlusion alarm thresholds and valve sealing integrity.
 An in-line digital pressure meter with a minimum range of 0 to 15
psi (BioTek Universal Pressure Meter DPM-2).
 A 50 mL burette graduated in 0.1 mL increments is used to verify
the ±2% accuracy. The burette must be traceable to the National Institute of Standards and Technology (NIST).
 A digital stopwatch (Microtimer), with a minimum 2 decimal
places (100ths of second) is used to verify the rate accuracy.
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Recommended troubleshooting equipment
The following equipment is recommended for troubleshooting possible infusion pump malfunctions:
 A multimeter (Beckman 3010 or equivalent) is used to verify AC
and DC voltages, battery charging current, resistance, continuity, etc.
 An oscilloscope (Tektronix 2213 or equivalent) is useful for
electronic signal tracing and viewing various waveforms.
 Regulated DC power supply (B & K 1601 or equivalent) is used to
power the pump when the AC power cord and battery are both disconnected. The power supply must be capable of providing at least 2 Amperes at 12 Volts. The output must be adjustable to 0.01 Volt increments. A 2K Ohm trimpot placed in a series with the power supplys voltage adjusting component yields fine voltage adjustment.
The power supply is used in place of the pumps battery when testing battery voltage trip points. The DC voltage is varied to simulate decreasing battery voltage.
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 A ground tester is used to test ground resistance.  A digital Safety Analyser (BioTech Model 170 or equivalent) is
used to measure leakage currents.
Issue A (April 2002)
3000/3100 and 500/505 Service Manual
Graseby Medical Ltd.
Service tool kit
To assist in the servicing of a pump Graseby supply a Service tool kit. This tool kit can be ordered from the Graseby Customer Care department. The part number of the Service tool kit is:
The tool kit consists of the following items:  Torx bit handle.  T7 torx bit.  T7W torx bit.  T10 torx bit.  T15 torx bit.  Keypad tool (label peeler).
Volumetric Infusion Pumps
78-8061-4214-3
 C-ring tool.  Tool pouch.  Allen key (0.89 A/F).  2 sizes of feeler gauge,
Note: the 2 sizes of feeler gauge may also be purchased separately using the following part numbers:
Diameter Length Part number
0.31 mm 65 mm 78-8098-2259-2
0.012 inch 2.5 inch
0.38 mm 65 mm 78-8098-2262-6
0.015 inch 2.5 inch
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Volumetric Infusion Pumps
Periodic cleaning
The pump may require periodic cleaning. This section lists the recommended cleaning agents, and describes the recommended procedure for cleaning the pump.
Recommended cleaning agents
Use any of the cleaning agents listed here as directed in Cleaning Procedure and precautions, on the next page.
Soap
It is recommended that only soap and water solutions are used to clean the outer surface of the pump. These solutions have little disinfecting and sterilizing properties.
Quaternary ammonia salt-based solutions
Quaternary ammonia salt-based solutions are typically liquid concentrates mixed with water, and are used for routine wipe-down to clean and disinfect. These solutions may be effectively used for routine wipe-down of the pumps with no adverse effects.
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Alcohol solutions
It is recommended that only 70% concentrations of isopropyl or ethyl alcohol in water be used in cleaning and disinfecting the pumps. However, solutions of methyl alcohol should never be used in cleaning the pumps.
Bleach solutions
Bleach solutions diluted to 1 part bleach to 10 parts water (approximately 0.5% solution) may be effectively used for routine wipe-down of the pumps with no adverse effects. Care should be taken to use only the concentration recommended (1/10) as adverse effects to the pumps may occur.
Phenol based solutions
Phenol based solutions are routinely used to clean and disinfect. They come in various forms, such as liquid concentrate and aerosol sprays. Long-term use of concentrates could have harmful effects on the pumps unless used in exactly the dilution strength (in water) specified in the manufacturer's labelling.
CAUTION: Do not autoclave, steam sterilize, ETO sterilise or subject the pump to temperatures in
excess of 45° C (113° F). Excessive temperatures may cause damage to the pump.
CAUTION: To prevent serious damage to the pump it must not be immersed in any liquids or exposed
to strong organic solvents. Wipe off spills immediately . Do not allow fluid or residues to remain on the pump. Additionally , the pump is not designed to allow it to be sterilised. Failure to observe these cautions may cause internal damage to the pump.
CAUTION: Carry out periodic cleaning following the detailed instructions in this manual. Use only the
recommended cleaning agents.
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Issue A (April 2002)
3000/3100 and 500/505 Service Manual
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