Medfusion®

1 Medfusion . 3000 Series Technical Service Manual s Table of Contents ii 40-5648-51C. Table of Contents Table of Contents Overview of operation 27. Controlling motor 27. I Introduction 1 Infusion control & safety 27. Important Information 1 III Theory of Operation 27. 1 Pump design description 28. 2. Logic core of Medfusion 3000 Series 28. Contents of this manual 3 Main circuit 28. Authorized use of this 3 Main 28. Watchdog 29. About the pump 4 DC power 29. Features and 4 Real time 29. Keypad 5 Graphical display circuit board (LCD).. 29. 29. Understanding Biomed mode 7 Plunger (driver) travel 29. What is biomed?.. 7 Motor rotation 29. Authorized biomed 7 Stepper 29. Biomed software program major 7 Syringe flange loaded 29. 8 Syringe size 29. Glossary of Technical 9 Interconnect printed circuit 29. AC power input & power supply 30. Preventive Maintenance Planning 15 DC power input 30.

2 30. Biomed maintenance tools 15 Rechargeable battery pack & battery 30. Using a torque 15 Plunger printed circuit 30. Electrostatic-controlled 15 Plunger force 30. Plunger Loaded 30. II Scheduled Maintenance 15 Main Board Schematic 31. Service 16 Logic Kernel 31. 68HC11K4 Main Microprocessor Interface, U19 .. 31. Periodic maintenance 17 Flash memory, 34. Installation/quick 17 Software upgrade method for programming . Quick check-out 17 flash . Cleaning and 18 34. Standard cleaning of Medfusion 3000 series 18 Static random access memory, 34. Cleaning 18 Serial EEPROM, U2 and 34. Time of day, 34. Mandatory annual maintenance Infrared 34. testing 19 Analog to digital converter, 35. General 19 Digital to analog converter, 35. Power-up 19 I/O port expansion, U3, 36. Calibration 20 Expansion port # 1 (port1_cs).. 36. Force sensor 20 Expansion port # 2 (port2_cs).. 37. Syringe size sensor 20 Power control 38.

3 Plunger position sensor 21 Always on supply, U7 .. 38. Motor drive & occlusion operational 21 Backup super capacitor, 38. Flow delivery accuracy 22 Backup audio buzzer, 38. AC line leakage 22 System reset, 39. AC line leakage test - Medfusion 23 Power management, 39. Battery 24 Power OFF 39. Shallow discharge (CPI) 24 Power ON 39. Battery calibration procedure .. 24 39. Requirements for battery pack 25 DC to DC 40. Collect 25 Logic supply, 40. Motor supply, 40. Analog supply, 40. Positive & negative supply, 41. 40-5648-51C iii Table of Contents LCD backlight supply, 41 Audio 69. Front panel interface 42 Display 69. LED drive circuit, Q26, Q27, Q40, Q33 - 42 Indicator 69. Keypad matrix 42 Keypad 70. Power switch 42 Monitor Analog 70. Graphic display interface 43 Monitor Digital 70. Data output to LCD, U32 / data input from . Monitor Battery 70. LCD, 43 Drive Train 70. LCD 43 Biomed > Diagnostics (screen 2 of 2).

4 70. LCD 43 Motor Drive 71. Motor drive 44 Monitor a2d 71. Coil A & B PWM current 44 Monitor 6811 a2d 71. Motor current regulators, U26, 44 Monitor 6811 A2D 71. Motor current detector, 44 Biomed > 71. Sensors interface 45 Set/View Last [Next] PM 71. Motor speed 45 Set Time/Date (Current).. 72. Syringe sensing 45 View Alarm 72. Syringe size 45 View Infusion 72. Syringe flange (ear) 45 View Software CRCs & View Software Plunger position sensing 46 72. Speaker drive 46 View Service 72. Speaker 46 View EEPROM Size [available only on Medfusion . Speaker 47 3500 pumps version 4 and higher).. 72. Plunger board schematic 47 Biomed > Update Firmware [not available on Force preamplifier 47 Medfusion 3500 pumps, version 4 and higher] .. 73. Force sensing interface 47 Set Language [Not available on Medfusion 3010 . Plunger flipper sensor 48 and 3010a].. 73. Interconnect board schematic 49.]

5 AC power detection 49 Maintenance warnings/cautions 75. External DC power conditioning / detection . Service warnings .. 75. 50 Service cautions .. 75. Infrared serial data port 50. Battery management 51 V Parts Replacement 75. Battery gauge 51 Opening & closing the pump housing 76. Battery 51. Charge 52 Tools 76. Battery 52 Opening the pump 76. Battery board schematic 52 Closing the pump 76. Battery gauge 52 Battery pack 77. Severely depleted battery 52. Tools 77. Problem solving alarms / alerts 53 Removing the battery 77. Types of alarms / 53 Replacing the battery 77. Verifying battery function after new battery IV Troubleshooting 53 77. Alarm messages & 54. System Advisory 60 Interconnect board 78. System Failure 61 Tools 78. General 65 Removing the interconnect 78. Replacing the interconnect 78. Smiths Medical service and support 67 Verify interconnect board 78. Using Smiths Medical service 67.

6 Returning a pump for 67 Speaker 78. Tools 78. Using Biomed for troubleshooting 68 Speaker 78. Accessing 68 Speaker 78. Biomed > Calibration .. 69 Verifying speaker function .. 78. Biomed > Diagnostics (screen 1 of 2).. 69. iv 40-5648-51C. Table of Contents AC power supply 79 Barrel clamp 88. 88. Tools 79 88. Removing AC power 79 Verify 88. Replacing the AC power 79 Barrel clamp body assembly .. 88. Verify AC power supply 79 88. AC input assembly 79 89. Tools 79 Ear clip, handle & guide 89. Removing AC input module 79 Tools 89. Replacing AC input module 79 Ear clip .. 89. Verifying AC input assembly module 80 89. Bottom housing plastic 80 89. Ear clip optical sensor .. 89. Tools 80 89. Removing the bottom 80 90. Replacing the bottom 80 90. Main board 81 90. 90. Tools 81 Tubing 90. Removing the main 81 90. Replacing the main 81 91. Drive train assembly 82 Plunger case assembly 91.

7 Tools 82 Tools 91. Motor unit (motor, worm, worm gear).. 82 Plunger 91. 82 91. 82 91. Reassemble motor 82 Plunger case 91. Position 83 91. 83 91. 83 Cam gear and timing 92. Clutch assembly 84 92. 92. Tools 84 Flipper and flipper 92. 84 92. 84 92. 84 Plunger 92. Clutch or clutch 84 Additional tools 92. Tools 84 92. 85 93. 85 Force 93. Plunger 85 Additional tools 93. 85 93. 85 93. LCD and backlight 86 Left plunger 94. Additional tools 94. Tools 86 94. Removing LCD and/or backlight 86 94. Replacing the LCD and/or backlight 86. Verify LCD & backlight assembly 87 Using Biomed > Calibration 95. Keypad 87 Biomed > Calibration .. 95. Tools 87 VI Calibration and Adjustment 95. Removing the 87 Calibrate (Syringe) size and . Replacing the 88 97. Performing both size & position . Syringe barrel clamp assembly 88 97. Tools 88. 40-5648-51C v Table of Contents Calibrate force 100 Case bottom assembly parts 155.

8 Calibrate pressure sensor . Case top assembly 156. (future option).. 102 Case top assembly w/plunger parts 157. Calibrate plunger 102 Case top assembly without 158. Calibrate syringe size 104 Case top assembly without plunger parts 159. Adjust contrast (voltage) 105 Barrel clamp 161. View calibration 106 Barrel clamp assembly parts 162. Save changes and 107 Drive train 163. Exit calibration without saving 107 Drive train assembly parts 164. Clutch 165. Retest guidelines 108. Accessories parts list 166. System layout 111 Poleclamp 166. Poleclamp 167. VII Schematics & PCB Rotating poleclamp parts .. 167. Assemblies 111 Miscellaneous 167. Calibration & repair parts 168. Main board schematics 112 Medfusion 3000 series calibration 168. Main board / logic 112 Other tools & equipment required to service Main Board / Power Control Logic 116 Medfusion 3000 series 168. Main Board / DC-DC 118 Notes 169.

9 Main Board / Keypad 120. Main Board / Graphic Display 123. Main Board / Motor 124. Main Board / Syringe 125. Main Board / Position 126. Main Board / Force 127. Main Board / Pressure 128. Main Board / Speaker 129. Main Board / ACU-ICE 130. Main Board Assembly Drawing Top 131. Main Board Assembly Drawing Bottom 132. Main Board Assembly Parts list .. 133. Plunger Board Schematic 139. Plunger Board / Force 139. Plunger Board / Flipper 140. Plunger Board Assembly Drawing .. 141. Plunger Board Assembly Parts list .. 142. Battery Gauge Schematic 143. Interconnect Board Schematic 144. Interconnect Board / Power 144. Interconnect Board / Battery 145. Interconnect Board / Infrared Serial . 146. Interconnect Board Assembly Drawing .. 147. Interconnect board assembly parts list .. 148. Assembly drawings 151. VIII Assembly Drawings & Parts Lists 151. Medfusion 3000 series main pump 152. Medfusion 3000 series main pump assembly.

10 Parts 153. Case bottom 154. vi 40-5648-51C. Introduction Important Information pump is listed as Safety Class II, Type CF equip- ment. Protection against electrical shock does not WARNING: Read this entire manual before attempt- rely only upon basic insulation, but instead relies ing and service or repair on a Medfusion 3000 Se- on double or reinforced insulation. As such, this ries Syringe Infusion Pump. Failure to follow the equipment does not utilize a third wire ground instructions and important information contained (earth ground). Therefore, when doing line leak- in this manual, or improper/inadequate testing, age test it is not necessary to measure leakage in service, repair or troubleshooting can lead to death or serious injury. Warnings, cautions and other im- both the open ground and closed ground setting. portant safety information can be found in this sec- Nor is it necessary to perform a ground resistance tion, and throughout the manual (they are contained test.)