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Cardinal Health Alaris GW Technical & Service Manual

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Technical Service Manual

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  • Page 1 Alaris GW Volumetric Pump ® Technical Service Manual...
  • Page 2 This manual has been prepared for use by qualified service personnel only. Cardinal Health cannot accept any liability for any breakdown or deterioration in performance of parts or equipment resulting from unauthorised repair or modification. t Cardinal Health, 1180 Rolle, Switzerland Alaris®...

  • Page 3: Table Of Contents

    Contents Chapter Introduction & Start up Configuration & Calibration Routine Maintenance Troubleshooting Circuit Descriptions Spare Parts Replacement Procedures Appendix Specifications Disposal Spare Parts Listing Fitting and Replacement Guidelines Compatible IV Infusion Sets Configuration Records Service Contacts Document History Alaris® GW Volumetric Pump 3/77 1000SM00006 Issue 4...

  • Page 4: Introduction & Start Up

    Chapter 1 Introduction & Start up In this chapter Introduction General precautions Views of the Alaris® GW Volumetric Pump Controls and indicators Operating the Alaris® GW Volumetric Pump Starting the Alaris® GW Volumetric Pump Features of the Alaris® GW Volumetric Pump...

  • Page 5: Introduction

    Introduction & Start up Introduction The Alaris® GW Volumetric Pump is designed to deliver a continuous and accurate infusion. High performance, comprehensive alarm protection and sophisticated monitoring systems, combined with simple operation, make this pump ideal for general care and critical care in a variety of areas within a hospital.

  • Page 6: Views Of The Alaris® Gw Volumetric Pump

    Introduction & Start up Views of the Alaris® GW Volumetric Pump Front view Main Display - Displays the infusion rate, VTBI, VI and time remaining for VTBI / Time infusions. Display will flash when pump is operating on battery. Display Indicators Keypad Flow Stop Mechanism When activated the...

  • Page 7: Controls And Indicators

    Introduction & Start up Controls and indicators PRIMARY / SECONDARY   Switches the pump between Primary and Secondary infusion modes (if enabled). ON / OFF   Switches the pump on and off. PRIME / BOLUS   Primes the IV infusion set. ...

  • Page 8: Operating The Alaris® Gw Volumetric Pump

    Introduction & Start up Operating the Alaris® GW Volumetric Pump  Follow the instructions supplied with the individual IV infusion set.  Use of non-specified IV infusion sets may impair the operation of the pump and the accuracy of the infusion. ...

  • Page 9: Starting The Alaris® Gw Volumetric Pump

    Introduction & Start up Starting the Alaris® GW Volumetric Pump Close in-line clamp. Load IV infusion set. Half fill the drip chamber. Open in-line clamp.  Press to switch pump on.     Prime ( ) set: Press once.

  • Page 10: Configuration & Calibration

    Chapter 2 Configuration & Calibration In this chapter Access codes Configurable options Calibration procedures...
  • Page 11 Configuration & Calibration Configuration & Calibration Access codes The pump software contains a number of configuration and test routines that can be accessed by the user. The majority of tests are driven from a technical access code (see below). Entering Access Codes ...
  • Page 12 Configuration & Calibration Configuration & Calibration Configurable options (continued) Code Description Default Summary OFF: Disable odd communications parity bit generation. Odd Parity Comms Enable odd communications parity bit generation. Pump Address Comms Set pump address used for communications (1 to 250). AUTO: Pump automatically detects flow sensor if connected.
  • Page 13 All of these calibrations should only be carried out by qualified biomedical engineers. If in any doubt about how to perform the tests, in particular the pressure sensor calibration checks, contact your local Cardinal Health Service Centre who will be able to assist.
  • Page 14 Configuration & Calibration Configuration & Calibration Calibration procedures (continued) Pressure Sensor Calibration (CODE 17) An internal pressure sensor is used to detect downstream occlusions. This sensor requires calibration whenever a new sensor, Main PCB is fitted or if door is changed or removed. It is necessary when servicing a pump, to carry out an occlusion pressure test to verify that the sensor is calibrated correctly (see self test routine in Chapter 3 Routine Maintenance).

  • Page 15: Routine Maintenance

    Chapter 3 Routine Maintenance In this chapter Routine maintenance Test procedures General cleaning and inspection for damage Storage Data transfer Performance verification procedure...

  • Page 16: Routine Maintenance

    Routine Maintenance Routine Maintenance Routine maintenance For routine maintenance, the following self-test and performance verification procedures should be performed in addition to the tasks described in the section on General Cleaning and Inspection for Damage. Refer to the relevant “Directions for Use” for the recommended routine maintenance period. Test procedures Important Service Information: Important Service Information:...
  • Page 17 Routine Maintenance Routine Maintenance Test procedures (continued) Self test routine  Enter access code 3. Press the key to advance to next test. Level Test Description Confirm display indicates correct button pressed. When level is entered the display will show “b-1”, press buttons 1 to 8, after pressing button 8 the test will automatically proceed to level 2.
  • Page 18 Routine Maintenance Routine Maintenance Test procedures (continued) Volumetric Accuracy Verification Test (CODE ) Important Notes: Important Notes: The balances need to be switched on for 30 minutes prior to use to enable the electronics to The balances need to be switched on for 30 minutes prior to use to enable the electronics to warm up and settle.
  • Page 19 Routine Maintenance Routine Maintenance Test procedures (continued)  Zero scales or burette. Press to begin the verification check. The pump will automatically pump at 125ml/h for a total of 20ml, which will take approximately 9½ minutes. During the run, it will display the volume infused up to that point and intermittently flash "r"...

  • Page 20: General Cleaning And Inspection For Damage

    Routine Maintenance Routine Maintenance General cleaning and inspection for damage To ensure that this pump remains in good operating condition, it is important to keep it clean and carry out the routine procedures described below. All servicing should only be performed by a qualified service engineer, with reference to this manual. ...

  • Page 21: Data Transfer

    Routine Maintenance Routine Maintenance Data transfer Upgrading Software The optional upgrade of the Alaris® GW Volumetric Pump software to V5R1F should be considered at the next product service for all Alaris® GW Volumetric Pumps fitted with software version V4R2C. Perform upgrades by acquiring the software upgrade kits specified in the spares parts listings.
  • Page 22 Routine Maintenance Routine Maintenance Data transfer (continued) Teach Learn (Software Versions VR1F and above) For both the teach and learn pumps in Technician Mode enable IrDA communications (Code 4), and ensure that ASCII / Binary mode and parity bit options (Codes 38 and 3 respectively) are the same. Turn the teaching pump on in normal operation.

  • Page 23: Performance Verification Procedure

    Routine Maintenance Routine Maintenance Performance verification procedure Model / Serial Number: Service Order / Inventory Number: Hospital Name / Reference: Software Version: Physical Inspection and Clean UPDATE  Not fitted / Not Fitted Recommended When Serviced Updates REF.  Applicable Grease the pumping mechanism with Molykote PG54.

  • Page 24: Troubleshooting

    Chapter 4 Troubleshooting In this chapter Software alarm codes & displayed messages Alarm types General fault diagnosis...
  • Page 25 Troubleshooting Troubleshooting Software alarm codes & displayed messages Note: The alarm codes are intended only for fault finding and diagnostic purposes and are therefore not displayed directly to the user. The alarm history log stores the last ten alarm codes in a “first in, first out” sequence once the maximum ten codes have been exceeded.
  • Page 26 Troubleshooting Troubleshooting Software alarm codes & displayed messages (continued) Alarm Display Type Description Troubleshooting Guide Code Withdraw the pump from service and ensure it is inspected No. of encoder revolutions too low. by a qualified service engineer. Ensure JP12 is firmly connected. Replace the Control PCB if Time base difference.
  • Page 27 Troubleshooting Troubleshooting Alarm types Non Recoverable Alarms In this state the pump will stop the infusion and give an audible and visible warning to alert the user that a non recoverable alarm (registered on the pump as a Fatal alarm) has occurred. With the exception of a micro-controller (MCU) error or internal communications fault with the external EEPROM, each alarm condition is identified by a unique code, which is stored in the alarm history log each time an alarm occurs, to enable the qualified service engineer to trace the error condition.

  • Page 28: Circuit Descriptions

    Chapter 5 Circuit Descriptions In this chapter Module overview functional description Control Board Power Supply Unit and Communications Board Pressure Sensor and Encoder Board Functional module block diagram...

  • Page 29: Module Overview Functional Description

    The pump is designed to be serviced generally to major assembly level. The PCBs are designed as non-serviceable items and as such, can only be replaced as complete parts. Cardinal Health will make available, on request, circuit diagrams, which will assist appropriately qualified technical personnel to repair those parts of the pump which are designated by the manufacturer as repairable.

  • Page 30: Power Supply Unit And Communications Board

    Circuit Descriptions Circuit Descriptions Power Supply Unit and Communications Board Power module The selection of 115V or 230V is made via S1. The secondary is rectified to an unregulated DC Voltage. F2 is a Polyswitch resetable fuse. The raw DC is output to the Control PCB. The battery is connected via JP3, the maximum current being limited by F1. RS3 &...

  • Page 31: Functional Module Block Diagram

    Circuit Descriptions Circuit Descriptions Functional module block diagram Control PCB Pressure Switches Sensor Door Motor Sensor Encoders Display Motor LEDs Control Sensor (Door) Air Sensor Safety (Front panel) Sensors Backup Audible Audible Backup Alarm Alarm Speaker Backup Flow Flow Sensor Battery Sensor Power...

  • Page 32: Spare Parts Replacement Procedures

    Chapter 5 Spare Parts Replacement Procedures In this chapter Separation of front and rear cases Front case assembly Door assembly Pumping block assembly Air sensor assemblies Pressure sensor assembly Flow-stop assembly Control PCB Rear case assembly Battery PSU & Comms PCB Speaker Rear case connectors Rear Case Rail Cam Mechanism...

  • Page 33: Separation Of Front And Rear Cases

    For fastener torque settings, refer to Appendix C Fitting & Replacement Guidelines. For additional technical assistance, contact your local Cardinal Health Service Centre. Remove the 4 corner screws, which secure the rear case to the front case.

  • Page 34: Front Case Assembly

    Spare Parts Replacement Procedures Front case assembly In order to replace a front case, it will be necessary to fully strip down the old case and insert all of the components into the new front case. The task requires a good knowledge of the pump, so be certain that you are fully conversant with all of the procedures in this section before undertaking this replacement.

  • Page 35: Door Assembly

    Spare Parts Replacement Procedures Door assembly Remove the air sensor assembly from the back of the door and retain the small screws for re-assembly later. Remove circlips and push out the two shafts that form the hinge of the door so that they clear the first part of the hinge. Do not free the main pressure plate that is sprung on the door.

  • Page 36: Pumping Block Assembly

    Spare Parts Replacement Procedures Pumping block assembly (E) Fixing screws (x4) Unplug the motor wiring loom from the Control PCB in the front case. Washers (x2) Remove the flow direction indication label from the front of the pump. (D) Strip finger (C) Motor wiring loom Pumping fingers (A/B) Pumping block assembly...

  • Page 37: Air Sensor Assemblies

    Spare Parts Replacement Procedures Air sensor assemblies 1. Unplug the four-way connector for the two air sensors. 2. Unscrew the door air sensor from the back of the door and pull out the two wires through the hole to free the sensor. (A) Front panel air sensor (A) Door air sensor 3.

  • Page 38: Pressure Sensor Assembly

    Spare Parts Replacement Procedures Pressure sensor assembly Remove the three screws that hold the pressure sensor assembly in place. Unplug the assembly from the Control PCB. Carefully remove the pressure sensor from the case. Reassemble in reverse order. Tighten the larger 2 screws first, then the smaller screw. Underside View Side View (D) Screws (x3)

  • Page 39: Flow-Stop Assembly

    Spare Parts Replacement Procedures Flow-stop assembly Remove the flow direction label to reveal one of the screws holding the flow-stop assembly. Remove the two screws that hold the flow-stop housing mechanism onto the front case and remove the whole assembly as a single item. This includes the sprung arm and the small cover that provides the locking position for the arm.

  • Page 40: Control Pcb

    Spare Parts Replacement Procedures Control PCB Removal of the Control PCB Unplug all of the connectors that plug into the Control PCB - i.e. the pressure sensor, the air sensors and the motor wiring loom, as well as the main linking cable to the rear case. Remove the two securing screws and two washers that hold in the Control PCB and remove the PCB from the front case.

  • Page 41: Rear Case Assembly

    Spare Parts Replacement Procedures Rear case assembly In order to replace a rear case, it will be necessary to fully strip down the old case and insert all of the components into the new rear case. The task requires a good knowledge of the product, so be certain that you are fully conversant with all of the procedures in this section before undertaking this replacement.

  • Page 42: Battery

    Spare Parts Replacement Procedures Battery It is recommended that the battery is replaced at least every 3 years, in order to guarantee maximum backup battery time. Remove the small plastic clamp and clip that holds the battery in place. Unplug the battery from the PSU and Comms. PCB and remove the battery from the rear case.

  • Page 43: Psu & Comms Pcb

    Spare Parts Replacement Procedures PSU & Comms PCB Unplug the mains inlet, the battery and the 4-way cable assembly from the PSU and Comms. PCB and 8-way connector and flow sensor connector. Remove the four securing screws that hold in the PCB and remove the PCB from the rear case. Reassemble in reverse order.

  • Page 44: Speaker

    Spare Parts Replacement Procedures Speaker Remove or replace insulator or speaker as required. (B) Insulator (A) Speaker Item Description Part Number ASSY SPEAKER ALARM P8000 1000SP00099 INSULATOR ASENA GW 1000ME01429 Alaris® GW Volumetric Pump 44/77 1000SM00006 Issue 4...

  • Page 45: Rear Case Connectors

    Spare Parts Replacement Procedures Rear case connectors Remove RS232 connector. Remove screws holding Flow Sensor Clamp and remove clamp. Remove Flow Sensor connector. Reassemble in reverse order. Item Description Part Number ASENA GW, ASSY, DROP SENSOR CABLE 1000SP01133 ASENA ASSY, KIT, RS232 CABLE 1000SP00336 ASENA GW, KIT, FIXINGS(SCREWS,WASHERS,ETC) 1000SP00489...

  • Page 46: Rear Case Rail Cam Mechanism

    Spare Parts Replacement Procedures Rear Case Rail Cam Mechanism Assemble rail cam internal mechanism as per diagrams below. Remove and replace cam rail components as required. Reassemble in reverse order. Stage 2 Stage 1 (H) Seal ring (I) Cam rail clamp Item Description Part Number...

  • Page 47: Mains Inlet

    Spare Parts Replacement Procedures Mains inlet Remove 2 screws securing Mains inlet and retainer. Remove Mains inlet and retainer. Remove magnet. Reassemble in reverse order. (A) Mains inlet assembly Magnet (item D) can be held in place with a plastic covered proximity magnet placed over IR window.

  • Page 48: Pe Stud And Pole Clamp

    Spare Parts Replacement Procedures PE Stud and Pole Clamp Remove nut securing earth wire. Remove nut securing PE Stud. Remove the three screws and remove the pole clamp assembly. Reassemble in reverse order. (C) Fixing screws (x3) (D) Label protective earth (A) PE stud (B) Pole clamp assembly A modified Knob Pole Clamp screw has been designed which incorporates a metal tip added to its...

  • Page 49: Labels

    Spare Parts Replacement Procedures Labels Item Description Part Number ASENA GW, LBL, LABEL SET (240V) UNIVERSAL 1000LB00371 ASENA GW, LBL, LABEL SET (110V) UNIVERSAL 1000LB00384 LABEL PROTECTIVE EARTH (x2) 1000LB00292 Item B not shown - located on pumping block and inside rear case. Alaris®...
  • Page 50 Spare Parts Replacement Procedures Labels (continued) After fitting label, verify all LEDs are fully visible at their correct locations. English language sample shown. See parts list below for language specific options. Item Description Part Number ASENA GW, LBL, FRONT PANEL ENGLISH 1000LB00251 ASENA GW, LBL, FRONT PANEL FRENCH 1000LB00287...
  • Page 51 Spare Parts Replacement Procedures Labels (continued) English language sample shown. See parts list below for language specific options. Item Description Part Number ASENA GW, LBL, ALARM ENGLISH 1000LB00374 ASENA GW, LBL, ALARM GERMAN 1000LB00386 ASENA GW, LBL, ALARM FRENCH 1000LB00396 ASENA GW, LBL, ALARM ITALIAN 1000LB00397 ASENA GW, LBL, ALARM SPANISH...

  • Page 52: Appendix

    Appendix A Specifications In this appendix Electrical Environmental Infusion System accuracy General specifications Recycling Electromagnetic Compatibility...
  • Page 53 Specifications Specifications Electrical Class I Equipment Type CF Equipment (degree of protection against electrical shock) Electrical Safety Complies with EN60601-1-1 (IEC601-1) and EN60601-2-24 (IEC601-2-24). Electromagnetic compatibility (EMC) Complies with EN60601-1-2 and EN60601-2-24. Electrical safety EN60601-1 (IEC 601-1) - typical earth leakage current 40µA. Dielectric strength Proof strength test 1.5kV dc (live and neutral to earth).
  • Page 54 Specifications Specifications System accuracy Rate Accuracy ±5% at 25 ml/h under nominal conditions Tested to EN60601-2-24 (90% confidence interval / 95% population). Bolus Volume Accuracy ±10% @ 5ml under nominal conditions Tested to EN60601-2-24. Under all conditions the bolus volume accuracy should be de-rated as for rate accuracy. Occlusion Pressure Accuracy ±150 mmHg under nominal conditions ±250 mmHg under all conditions...
  • Page 55 Specifications Specifications General specifications (continued) Calibration units of measure The units of measurement used in the calibration procedure are: 1. Millilitres (ml) volume of fluid. 2. Millilitres per hour (ml/h) for volumetric flow rate. 3. Millimetres of mercury (mmHg) or KpA for pressure. 4.
  • Page 56 Specifications Electromagnetic Compatibility Warning: • The use of any accessory, transducer, or cable with the Alaris® GW Volumetric Pump other than those specified may result in increased emissions or decreased immunity of the pump. • The Alaris® GW Volumetric Pump should not be used adjacent to or stacked with other equipment and that is adjacent or stacked use is necessary, the Alaris®...
  • Page 57 Note 3—Performed at the Minimum and Maximum Rated Input Voltage. Note 4—Cardinal Health recommends using signal cables of less than 3 meters in length and this requirement is applicable only if signal cables are 3 meters or more in length. (EN 60601-1-2:2002, Clause 36.202.4) Alaris®...
  • Page 58 Specifications Electromagnetic Compatibility (continued) Guidance and Manufacturer’s Declaration—Electromagnetic Immunity LIFE SUPPORT Equipment The Alaris® GW Volumetric Pump is intended for use in the electromagnetic environment specified below. The customer or the user of the Alaris® GW Volumetric Pump should ensure that it is used in such an environment. EN 60601-1- Compliance Immunity Test...
  • Page 59 Specifications Electromagnetic Compatibility (continued) Recommended Separation Distances for LIFE SUPPORT Equipment between portable and mobile RF communications equipment and the Alaris ® GW Volumetric Pump The Alaris® GW Volumetric Pump is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled.

  • Page 60: Disposal

    Appendix B Disposal In this appendix Disposal Battery Removal...
  • Page 61 If you wish to discard electrical and electronic equipment, please contact your Cardinal Health affiliate office or distributor for further information.

  • Page 62: Spare Parts Listing

    Appendix C Spare Parts Listing In this appendix Labels & Publications Front case components Rear case components Electrical components Mechanical components...

  • Page 63: Labels & Publications

    Spare Parts Listing Spare Parts Listing Labels & Publications Part Number Description 1000LB00386 ASENA GW, LBL, ALARM GERMAN 1000LB00398 ASENA GW, LBL, ALARM SPANISH 1000LB00396 ASENA GW, LBL, ALARM FRENCH 1000LB00374 ASENA GW, LBL, ALARM ENGLISH 1000LB00397 ASENA GW, LBL, ALARM ITALIAN 1000LB00400 ASENA GW, LBL, ALARM DUTCH 1000LB00399...

  • Page 64: Rear Case Components

    Spare Parts Listing Spare Parts Listing Rear case components Part Number Description 1000SP00339 ASENA GW, KIT, REAR CASE 230V GERMAN 1000SP00324 ASENA GW, KIT, REAR CASE 230V SPANISH 1000SP00322 ASENA GW, KIT, REAR CASE 230V FRENCH 1000SP00261 ASENA GW, KIT, REAR CASE 230V ENGLISH 1000SP00326 ASENA GW, KIT, REAR CASE 110V ENGLISH 1000SP00323...

  • Page 65: Electrical Components

    Spare Parts Listing Spare Parts Listing Electrical components Part Number Description 1000SP00427 ASENA GW, KIT, POWER SUPPLY UNIT (PSU) 1000SP00330 ASENA GW, KIT, PRESSURE SENSOR 110V 1000SP00265 ASENA GW, KIT, AIR SENSORS 1000SP00256 ASENA GW, KIT, PRESSURE SENSOR 230V 1000SP00099 ASSY SPEAKER ALARM P8000 1000SP01076 ASSY CABLE 4 WAY...

  • Page 66: Fitting And Replacement Guidelines

    Appendix D Fitting and Replacement Guidelines In this appendix General assembly information Torque guide...
  • Page 67 Fitting & Replacement Guidelines Fitting & Replacement Guidelines General assembly information  A wide range of self-tapping fasteners are available.  PT screws are for plastic, self-tapping applications.  Almost all fasteners on the Asena® GW Volumetric Pump are self tapping and have the potential to be over tightened (over torqued). ...
  • Page 68 Fitting & Replacement Guidelines Fitting & Replacement Guidelines Torque guide (continued) Rear Case Assembly: Established Stage Description Component Description Torque Process Mains Inlet Assembly to Rear Case Screw PKT30x12 CSK Torx Rogard 500 70 cNm Stud PE connector to Rear Case Nut M6 ZP+P 1.5 cNm Pole Clamp Assembly to Rear Case...

  • Page 69: Compatible Iv Infusion Sets

    Appendix E Compatible IV Infusion Sets In this appendix Compatible IV infusion sets...
  • Page 70 Compatible IV infusion sets Compatible IV infusion sets Compatible IV infusion sets The Alaris® GW Volumetric Pump uses a standard, single use, disposable set with luer-lock connector, of the following types. Standard Infusion Sets 73-001 Infusion set with 15µm filter in drip chamber, and anti-siphon valve.
  • Page 71 Compatible IV infusion sets Compatible IV infusion sets Compatible IV infusion sets (continued) A list of accessories that can be used with the Alaris® GW Volumetric Pump: Secondary Sets 713 Secondary / Piggyback set with 18G needle and hanger. (approx. 84 cm) Open Burette Sets C018...

  • Page 72: Configuration Records

    Appendix F Configuration Records In this appendix Configured options record sheet Alaris® GW Volumetric Pump...
  • Page 73 Configuration Records Configuration Records Configured options record sheet Alaris® GW Volumetric Pump Enter the pump- specific information for your records on a copy of this page. Description Range Default Setting Enable Volume / Time Infusions (ON / OFF) Maximum Priming Volume (OFF, 1 - 40ml) 40ml Clear Infusion Parameters...

  • Page 74: Service Contacts

    Appendix G Service Contacts In this appendix Service Contacts...
  • Page 75 Service Contacts Service Contacts For service, contact your local Affiliate Office or Distributor. Cardinal Health, Cardinal Health, Cardinal Health, PO Box 5527, Avenida Valdeparra 27, Solbråveien 10 A, Dubai, Edificio Alcor, 1383 ASKER, United Arab Emirates. 28108 - Alcobendas, Madrid, Norge.

  • Page 76: Document History

    Appendix H Document History In this appendix Document History...
  • Page 77 Document History Updates Document History Issue Date Description Updated Logos and Marks and Front cover. Updated with new software features and changes. 21/05/04 Data Transfer section updated due to new functionally. New case images. Updated with new section on Electromagnetic Compatibility Updated part numbers 12/05/05 Added section on storage...

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