Page 1 of 18 Syringe Pump Procedure Section 1: Investigating Normal Operation Section 2: Determining Cause of Malfunction Appendices A: Open Chassis B: Loading and Starting the Syringe Pump C: Using a Multimeter Warnings Always use proper size and shape of screw driver Note: screws attached to vibrating components might turn in opposite direction. STOP if screwdriver turns and screw does not. Screw will strip and be unusable.
Page 2 of 18 Section 1: Investigating Normal Operation In this section you will observe and familiarize yourself with the operation of a working syringe pump in order to better locate broken parts of malfunctioning machines. Getting started a. Gather necessary tools a. Screwdriver set b. Multimeter c. Pliers d. Syringes e. Syringe tubing f. Cup of water b. Find and Identify major components shown in pictures below
*note: you can ID the parts in the next two pictures during step 5 Page 3 of 18
Page 4 of 18 *note: you can ID the parts in the bellow picture during step 4 Step 1: Checking Overall Function In this step you will check if the syringe pump can infuse a liquid from a syringe at a given rate. a. Plug in pump and press Power button b. Loading and Starting the Syringe Pump a. Place Syringe in three holders i. Barrel ii. Flange iii. Plunger 1. Push plunger lever down to move plunger flippers up iv. Note: arrows on the screen will point to unconnected points
v. b. Select dosing option i. Note: ML/HR is the simplest c. Select syringe type i. B D is being used in this course ii. Ensure correct size is being read d. Enter rate i. Chose fast rate to speed up testing e. Press green Start button f. Ensure: i. Plunger is moving to the left ii. Three green lights on display syringe are flashing iii. Ignore syringe near empty alarm 1. Stop alarm by pressing Alarm Silencer button g. Press stop button i. Make sure syringe stops h. Press start i. Make sure syringe starts again i. When syringe is empty ensure: i. Plunger stops moving ii. Syringe Empty alarm comes up c. Checked infusion rate a. Fill Syringe Completely with water b. Connect syringe to tubing c. Loading and Starting the Syringe Pump (Appendix B) d. Place tubing so liquid flows into graduated cylinder e. Select volume/time Page 5 of 18
Page 6 of 18 i. Input any volume ii. Input shortest time f. Calculate how much time it should take the pump to infuse the volume of liquid in the syringe g. Clear TVD with option on screen h. Using a stopwatch, time the infusion from start to finish i. Press start j. When infusion is complete ensure: i. Volume of water infused matches TVD on shown on screen ii. Time from stopwatch matches calculated time from step (f) Step 2: Checking Normal Biomed Settings The Biomed setting is used to help diagnose problems with the syringe pump. Go through the all of the settings in the diagnostics section to get a sense of what a properly functioning syringe pump reads. a. Turn pump on b. From main screen press more c. Press 2: Biomed d. Password=2580 e. Press 2: Diagnostics f. Explore 1 8 on the first page a. For 5: motor analog sensors, 6: monitor digital sensors, and 8: drive train test i. Load in a syringe and press start ii. Observe the readings Step 3: Checking Alarms In this step you will check the function of a few of the pumps alarms. There are several alarms; they and the manual can help troubleshoot many problems. a. Syringe empty alarm a. Loading and Starting the Syringe Pump (Appendix B) b. Ensure Syringe Empty Error comes up b. Syringe Near Empty Alarm c. Battery Not Working Alarm a. Turn off and Unplug Machine b. Remove battery compartment cover i. 2 screws c. Disconnect cord connecting battery and device at the device end d. Replace cover e. Plug in and Turn on machine f. Ensure Battery Not Working Alarm comes up ` g. Replace Battery i. Note: you may need to open chassis to accomplish this
Page 7 of 18 d. Check Clutch/ Plunger Lever a. Loading and Starting the Syringe Pump (Appendix B) b. Press start c. While device is infusing pull down plunger lever d. Ensure Check Clutch/Plunger Lever comes up e. Check Syringe Flange Sensor: indicates problem with flange or flange sensor a. Turn Machine off b. Place screwdriver or other object in flange clamp to hold it out c. Turn machine on d. Ensure check syringe flange sensor comes up f. Check Syringe Plunger Sensor: indicates problem with plunger or plunger sensor a. Turn machine off b. Place Syringe in plunger but not flange or barrel c. Turn machine on d. Ensure check syringe plunger sensor comes up g. Occlusion Check Infusion Line a. Loading and Starting the Syringe Pump (Appendix B) b. Place finger over syringe hole c. Hold for roughly 1 minutes d. Ensure Occlusion check Infusion line comes up Step 4: Checking Plunger Head (ID parts from Getting Started ) In this step you will check the plunger head which includes syringe sensors, force sensors, and the clutch. a. Pull plunger as far away from chassis as possible b. Caution: beware of springs in plunger head c. Remove plunger cover a. 4 screws d. Inspect inside for broken or misplaced parts:
Page 8 of 18 a. Springs are in place b. Force sensor cover is in place c. Gears sit three teeth from spring d. No wires are frayed or detached i. Open Chassis 1. Remove battery cover (2 screws) 2. Remove screw under battery 3. Remove screw in bottom left corner of chassis 4. Pull apart two sides of chassis 5. Unplug wire connecting the two sides of chassis ii. Locate multicolored wires on upper chassis power distribution board 1. Labeled connection from plunger on ID picture iii. Test connection from multicolored wires on plunger to multicolored wires on upper chassis power distribution board e. Examine Plunger Head Contents (SPRINGS MAY POP OUT ) i. Remove screw connecting force sensor to bottom cover (bottom cover will slide down)
Page 9 of 18 ii. Inspect for damage or worn parts iii. Replace bottom cover e. Replace cover a. Replace springs i. Push both small flippers all the way down ii. Check picture above to make sure alignment of all pieces is correct iii. Place springs in place first THEN match teeth and gears iv. Using a small screw driver or pliers push end of spring into alignment b. Check picture above to make sure alignment of all other pieces is correct c. Push flipper on cover up to cover screw hole d. Line up alignment and clutch bar with corresponding hole in cover e. Make sure gray prong on cover sits here f. Replace 3 visible screws, screwing in only half way g. Replace black sealing band h. Push back flipper on cover to reveal 4 th screw hole and replace i. Check that flipper on cover moves the two smaller flippers Step 5: Checking the Power supply and Battery (ID parts from Getting Started ) In this section you will make sure power is reaching the entire device from both an external power source and the battery. a. Run syringe pump both with and without AC power b. Turn off and unplug pump c. Open chassis
Page 10 of 18 d. Test connections of battery input e. Test connection to and from power supply a. Do not remove power supply board from chassis (wires are too fragile) i. Test connections of wires going 1. Into power supply 2. From power supply to power distribution board b. Because you cannot remove the power supply you will not be able to test individual components, but note that in real world cases testing these components should always be preformed Step 6: Checking the Alarm speaker In this section you will make sure the speaker that indicates many malfunctions is functioning properly. a. Turn on machine and make sure beeps can be heard b. Open chassis c. Remove connection between speaker and power distribution board a. Test electrical connection from power distribution board to speaker d. Test resistance of speaker a. Ensure it matches resistance indicated on speaker Step 7: Checking Components in Upper Chassis In this section you will make sure that all electrical connections on the upper power distribution are functioning, and you will check the mechanical components of the pump. a. Checking Flange and Barrel Pressure Sensor Connections
Page 11 of 18 a. Locate sensor wires i. Ensure the wires are connected and there is no damage b. Test all major electrical components and note their connectivity for later comparison in Section 2 a. Resistors over ~100 ohms should not be continuous b. Resistors under ~100ohms should be continuous c. Capacitors should not be continuous d. Diodes should not be continuous e. Bridge rectifiers should not be continuous f. Wires should be continuous c. Remove circuit board and motor system
Page 12 of 18 a. Remove 5 screws on circuit board b. Unplug all removable wires on circuit board (8) c. Flip Circuit board over right the side of the chassis i. Avoid damage to wires that are still connected
Page 13 of 18 d. Remove 5 screws attaching metal plate to chassis e. Using clutch, pull plunger all the way out f. Lift motor/metal plate out of chassis g. Pull motor/metal plate out to the right h. Twist motor/metal plate to reveal underside i. The final position should look like this d. Checking the Clutch a. Push down clutch/ plunger lever i. Ensure plunger can move freely
Page 14 of 18 b. While pushing down clutch check that corresponding parts move e. Checking the motor a. Make sure motor pulls plunger in when pump is turned on (if not already done in step 1) b. Check wires electrical connections to motor c. Make sure there is no grease on the motor or gears f. Checking motor rotation counter a. Note: this reflective surface uses IR beams to count the RPM of the motor b. Visually Ensure four surfaces reflective c. Wipe down with cotton ball or Kim wipe
Page 15 of 18 g. Reattach metal plate to chassis a. Pull plunger and slide motor/plunger/metal apparatus back into place i. Make sure thick black wire is between right and middle plastic posts b. Place teal grounding strip under bottom right screw c. Replace 5 screws d. Replace circuit board (5 screws, 8 plugs) i. Note: do not put a screw in bottom right hole e. Reconnect plug connecting upper and lower power distribution boards f. Reassemble chassis g. Replace 4 screws on outside of chassis
Page 16 of 18 Section 2: Determining Cause of Malfunction In this section you will troubleshoot and fix malfunctioning devices. Using what was collected from Section 1 and the 5 steps of troubleshooting, determine the damaged part(s) of the device. You will rotate between three machines with different problems. Instructions: Read background of the device Go through 5 steps of troubleshooting Locate damaged part(s) Confirm choice with TA Replace damaged part(s) Reconnect machine Check overall function (step 1) Appendix A. Opening chassis a. Remove battery cover i. 2 screws b. Detach battery c. Remove screw under battery and screw next to speaker d. Disconnect gray wire connecting both sides using flathead to pry connection apart B. Loading and Starting the Syringe Pump a. Place Syringe in three holders i. Barrel ii. Flange iii. Plunger 1. Push plunger lever down to up plunger flippers iv. Note: arrows on the screen will point to unconnected points
Page 17 of 18 v. b. Select dosing option i. Note: ML/HR is the simplest c. Select syringe type i. B D is being used in this course ii. Ensure correct size is being read d. Enter rate i. Chose fast rate to speed up testing e. Press green Start button C. Using a Multimeter a. To test connectivity i. Set dial to alarm setting
Page 18 of 18 ii. Meter will beep if circuit is complete iii. Test by touching the red and black probes together b. To test voltage i. Set meter to AC or DC setting ii. Touch probes to opposite sides of voltage being tested c. To test Resistance i. Set meter to ohms ii. Touch probes to either side of capacitance being measured iii. Note the units if applicable