Abbott aim Operating manual

ABBOTT
6
aim”
ABBOTT
aim plus
Technical
Service
Manual
For use with the following list numbers:
13038-04, Abbott AIM
13967-04, Abbott AIM Plus
ABBOTT LABORATORIES
NORTH CHICAGO, IL 60064
USA 430-600035-002 (Rev. 11/99)

© Copyright 1999 Abbott Laboratories AllRights Reserved
This document and the subject matter disclosed herein are proprietary information. Abbott
Laboratories retains all the exclusive rights of dissemination, reproduction, manufacture, and
sale. Any party using this document accepis it in confidence, and agrees not to duplicate it in
whole or in part nor disclose it to others without the written consent of Abbott Laboratories.

List of
Changes
Part Number
430-600035-001
(Rev. 12/96)
430-600035-002
(Rev. 10/99)
AIM/AIM Plus Technical Service Manual i 430-600035-002 (Rev. 11/99)
Remove and
Description of Change Destroy Pages
Original issue. N/A
Second issue. All
Section 5: (1) Updated pump inspection
checklist to match current service training. (2)
Added alternate PVT procedures for
performing the motor test, servo calibration,
encoder test, and current supply test without a
torque brake. Revised PVT Data Form to add
alternate results.
Section 6: Added procedure for setting
February 29 on leap years.
Section 7: Added alternate instructions for
RTV sealing.
General: Added Seiko DPU414 as compatible
printer.
Insert
Change
Pages
N/A
All

Changes
430-600035-002 (Rev. 11/99)
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AIM/AIM Plus Technical Service Manual

Table of
Contents
Section 1 Introduction
1.1 Scope .
1.2 AIM and AIM Plus Overview .
1.2.1 Pump Description . .
1.2.2. AIM and AIM Plus Differences .
1.3 Conventions .
Section 2 Warranty
Section 3 System Operating Manual .
Section 4 Theory of Operation.
4.1 General Description .
4.2 Circuit Block Diagram
4.3 Detailed Circuit Description
4.3.1 CPU System
4.3.1.1
4.3.1.2
4.3.1.3
4.3.1.4
4.3.1.5
4.3.1.6
4.3.1.7
4.3.1.8
4.3.1.9
4.3.1.10
4.3,1.11
Microprocessor (CPU)
EPROM . . o.
Microprocessor Supervisory Circuit
RAM . . . . .
Time Of Day Clock
Display .
Encoder Interface Circuit.
Backup Microprocessor .
Keypad Interface .
Bolus Switch Interface .
Serial Interface
4.3.2 Analog Circuits
4.3.21
4.3.2.2
4.3.2.3
4.3.2.4
Power Circuits
Audible Alarm . . -
Air and Occiusion Optics Interface
Motor Drive Circuit .
Section 5 Maintenance and Service Tests . .
5.1 Cleaning the Pump . o.
5.2 Inspecting the Pump and Accessories .
5.2.1 Pump Inspection .
AIM/AIM Plus Technical Service Manual
4-10
4-10
4-10
4-11
4-11
4-11
4-12
4-13
4-13
5-1
5-2
5-4
5-4
430-600035-002 (Rev. 11/99)

Section 6 Troubleshooting .
6.1
6.2
6.3
64
Technical Assistance . .
Setting February 29 on Leap Years .
Troubleshooting Tables.
6.3.1 Alert Messages.
6.3.2 Alarm Codes
6.3.2.1 Function Alarms 001-007 .
6.3.2.2 Hardware and Software Alarms 008-143 .
6.3.3 Servo Calibration Failure Codes .
6.3.4 Troubleshooting Problems and Solutions
6.3.5 Port Assignments
6.3.6 IC Location Codes
Software Diagnostic Tests
Section 7 Replaceable Parts and Repairs
7.1. Spare Parts Price List .
7.2 Safety Precautions . .
7.3. Pump Disassembly Procedure
74 Pump Reassembly Procedure. - o.
7.4.1. Alternate Assembly instructions for RTV Sealing
75 Back Case Assembly .
7.5.1 AIM Beeper
7.6 Optics Assembly
7.7 Motor Assembly.
7.8 Latch Assembly.
7.8.1 Latch Spring .
7.9 PCB Assembly .
7.9.1 ALM Plus Beeper.
7.10 Front Case Assembly .
7.10.1 Keypads
7.10.2 Display Window .
740.3 Front Case Labels
7.10.4 Bolus Jack.
7.10.5 AC Power Jack - ，
7.10.6 Battery Connector Cable and Jumper
7.11 Display Module .
7.11.1 FFC Jumper .
7.11.2 Spacer Cushion .
AIM/AIM Plus Technical Service Manual v
6-14
Contents
6-1
6-1
6-1
6-2
6-2
64
6-5
6-6
6-15
6-21
6-24
6-26
7-1
7-1
7-1
7-2
7-5
7-8
7-14
7-12
7-13
7-14
7-15
7-16
7-18
7-18
7-19
7-19
7-20
7-20
7-21
7-21
7-22
7-23
7-24
7-24
430-600035-002 (Rev. 11/99)

Contents
Section 8 Specifications .
Section9 Drawings . .
430-600035-002 (Rev. 11/99) vi AIM/AIM Plus Technical Service Manual

List of
Figures
Figure 4-1. Assemblies . 4-1
Figure 4-2. Motor Frame 4-2
Figure 4-3. Motor Assembly 4-3
Figure 4-4. Optics Assembly Detail . 4-3
Figure 4-5. Latch Assembly 4-4
Figure 4-6. Circuit Block Diagram 46
Figure 5-1. Cartridge Channel Detail 5-3
Figure 5-2. Basic Equipment Setup . 5-8
Figure 5-3. Optics Test Block Placement . 5-14
Figure 7-1. Back Case Screws 7-2
Figure 7-2. Front Case Connections. o. 7-3
Figure 7-3. Motor, Optics, and Beeper Connections . 7-4
Figure 7-4. AIM and AlM Plus PCBs to Back Cases . 7-5
Figure 7-5. Pump Assembly 7-6
Figure 7-6: RTV Sealing for Printer Port 7-8
Figure 7-7. RTV Sealing for Side, Bottom Case . 7-8
Figure 7-8. RTV Sealing for Motor Frame . 7-9
Figure 7-9. Motor Frame Seal. . 7-9
Figure 7-10. Back Case Labels . 7-11
Figure 7-11. AIM Beeper Installation , 7-12
Figure 7-12. Optics Carrier to Motor Frame . 7-13
Figure 7-13. Motor Assembly to Motor Frame 7-14
Figure 7-14. Latch Assembly to Motor Frame 7-15
Figure 7-15. PCB Front View 7-17
Figure 7-16. Front Case Keypads and Labels 7-20
Figure 7-17. Bolus and AC Power Jack Installation. 7-21
Figure 7-18. Battery Connections . 7-22
Figure 7-19. Display Module Installation . 7-23
Figure 9-1. AIM Analog Schematic Fold-out
Figure 9-2. AIM Microprocessor (CPU) Schematic. . . . . . . .. Fold-out
Figure 9-3. AIM Power and Miscellaneous Circuitry Schematic. . . . Fold-out
Figure 9-4. AIM PC Board, Front Side Fold-out
Figure 9-5. AIM PC Board, Back Side Fold-out
Figure 9-6. AIM Plus Analog Schematic . . . Fold-out
Figure 9-7. AIM Plus Microprocessor (CPU) Schematic . . . Fold-out
Figure 9-8. AIM Plus Power and Miscellaneous Circuitry Schematic . . Fold-out
Figure 9-9. AIM Plus PC Board, Front Side . Fold-out
Figure 9-10. AIM Plus PC Board, Back Side Fold-out
AIM/AIM Plus Technical Service Manual vii 430-600035-002 (Rev. 11/99)

Figures
430-600035-002 (Rev. 11/99)
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viii AIM/AIM Plus Technical Service Manual

List of
Tables
Table 1-1. AIM and AIM Plus Hardware Differences .
Table 1-2. AIM and AIM Plus Software Differences .
Table 5-1. Cleaning Solutions. ..
Table 6-1. AIM/AIM Plus Alert Messages .
Table 6-2. AIM/AIM Plus Alarm Codes 001 - 007.
Table 6-3. AIM/AIM Plus Alarm Codes 008 - 143.
Table 6-4. Servo Calibration Failure Codes .
Table 6-5. Troubleshooting . o
Table 6-6. AIM/AIM Plus Port Assignments .
Table 6-7. AIM/AIM Plus IC Location Codes .
AIM/AIM Plus Technical Service Manual ix
1-3
1-3
5-2
6-3:
6-5
6-14
6-15
6-21
6-24
430-600035-002 (Rev. 11/99)

Tables
430-600035-002 (Rev. 11/99)
This page intentionally ieft blank.
AIM/AIM Plus Technical Service Manual

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Section 1
Introduction
11
Scope
This Technical Service Manual presents technical information about the Abbott Ambulatory
Infusion Manager (AIM™) and Abbott Ambulatory Infusion Manager Plus (AIM® Plus) infusion
pumps. It is intended for the trained technician experienced in analysis, troubleshooting and repair of
analog and digital microprocessor-based equipment.
It is organized into the following nine sections:
Section 1 Introduction
Section2 Warranty
Section 3 System Operating Manual
Section 4 Theory of Operation
Section 5 Maintenance and Service Tests
Section 6 Troubleshooting
Section 7 Replaceable Parts and Repairs
Section 8 Specifications
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Section9 Drawings
Note: In this manual, the terms “pump” and “pumps” refer to all configurations of both the AIM and
AIM Plus unless otherwise specified.
Note: Figures are rendered as graphic representations to approximate the actual product; therefore,
figures may not exactly reflect the product. Display screens and touchswitch labels may vary slightly,
depending on the configuration of the pump in use.
Ifa problem in the infusion system operation cannot be resolved using the information in this manual,
contact Abbott Laboratories Technical Support Operations (see Section 6.1, Technical Assistance).
AIM/AIM Plus Technical Service Manual 1-1 430-600035-002 (Rev. 11/99)

Section 1, Introduction
12
AIM and AIM Plus Overview
The pumps share the same design and functionality other than the hardware and software differences
noted in Section 1.2.2, AIM and AIM Plus Differences.
1.2.1
Pump Description
The Abbott AIM and AIM Plus are single-channel infusion pumps designed to deliver fluids
intravenously or epidurally. Special safety features integrated into the design include an
over-pressure (occlusion) alarm, an air-in-line alarm, a back-up (safety) microprocessor, motor
parameter monitoring, and numerous failure backup modes to prevent single point failures from
endangering the patient.
The pump is powered by four 1.5V AA alkaline batteries, optional nickel metal hydride rechargeable
battery packs, or an AC power supply. The pump is microprocessor-based and is programmed
through a 24-key keypad on the front of the unit. The state of the pump is displayed using a
16-character by 4-line alphanumeric liquid crystal display (LCD) module. The unit requires
dedicated cartridges to deliver fluids through rotary peristaltic pumping action. Control of the pump
and of the cartridge assure accurate fluid delivery.
The pump detects occlusions and air in the fluid cartridge. Ifthe pressure at the cartridge exceeds the
specification occlusion alarm pressure, the instrument sounds an alarm and stops delivery. If air in
the cartridge exceeds. the pre-set sensitivity limit, the pump will alarm, stop delivering and not
proceed until the air is cleared (the air sensitivity setting is variable, and for the AIM Plus can be
deactivated, refer to the pump’s System Operating Manual for more information).
The pump has several programming modes: TPN, Pain Management, Intermittent Delivery,
Variable Time Delivery and Continuous Delivery.
The pump contains a time-of-day clock and history storing capability. Significant events that take
place with the pump can be reviewed on the LCD display, along with time and date of occurrence.
The pump contains a printer connector that also allows printout of this history information when the
pump is connected to one of the two recommended compatible printers. Two different special printer
cables (depending on printer choice) are available from Abbott as accessory items.
For specific instructions regarding pump operation, refer to the AIM System Operating Manual or the
AIM Plus System Operating Manual.
430-600035-002 (Rev. 11/99) 1-2 AIM/AIM Plus Technical Service Manual

1.2.2
Section 1, Introduction
AIM and AIM Plus Differences
The AIM and AIM Plus have the following significant hardware differences:
Table 1-1. AIM and AIM Plus Hardware Differences
Item AIM AIM Plus
Beeper Piezo element mounted on the Audio transducer mounted on the PCB;
bottom case; frequency frequency approximately 2 KHz;
approximately 4 KHz protection diode added to beeper circuit
(R135 replaced with 15S353 diode) and
resistor value changed in backup audio
transducer oscillator circuit (R95 from
100K, 1% to 200K, 1%)
Function Keypad Four raised profile switches with Three raised profile switches with
4-450z. actuation force 4-150z. actuation force; STOP key has
flat profile and 6-200z. actuation force
Bottom Case No molded recess; hole to emit Molded recess (0.020 inch) aids in
installation of kapton insulator; no hole
for beeper (AIM Plus beeper mounted on
the PCB)
beeper sound
The AIM and AIM Plus have the following significant software differences:
Table 1-2. AIM and AIM Plus Software Differences
Item Significant AIM Plus Differences
Air Alarm Sensitivity | Air alarm can be turned completely off if air eliminating filter in use
Rate Change Lock New feature added that allows programmable ranges for continuous and bolus
tates to be locked in Pain Management programs
End of Infusion END OF INFUSION alert added fo TPN and Intermittent programs
Dose Frequency Dose frequency increased from 24 to 96 hours in Intermittent programs
interrupt Messages Number of message screens displayed for a program interruption reduced in
Intermittent and Variable programs
Program Review Program review not required if pump is off less than 5 minutes; pump can be
unlocked at power-on without program review
Change Mode When changes are being made to a program, only those screens that can be
altered are displayed
Lock Sequence AIM is 13038, AIM Plus is 13967 (product list numbers)
Number
AIM/AIM Plus Technical Service Manual 1-3 430-600035-002 (Rev. 11/99)

Section 1, Introduction
13
Conventions
The following conventions are used throughout this manua!:
С Touchswitches are described in all caps and enclosed in brackets, e.g., “Press [1], [0], [0] and
[ENTER] to select a 100 mL container size.”
Q Screen displays referenced in the text are in all caps, e.g., “When resetting is complete two
beeps sound and the INITIALIZE NVRAM OR USE ARROWS display returns.”
Throughout this manual, warnings, cautions, and notes are used to emphasize important information
as follows: -
WARNING:
A warning contains special safety emphasis and must be observed at all times.
Failure to observe a warning is potentially life threatening.
CAUTION: A caution contains information that could prevent irreversible equipment
damage or failure.
Note: A note highlights information that helps explain a concept or a procedure.
430-600035-002 (Rev. 11/99) 1-4 AIM/AIM Plus Technical Service Manual

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Warranty
Subject to the terms and conditions herein, Abbott Laboratories, herein referred to as Abbott,
warrants that the product shall conform to Abbott’s standard specifications and be free from defects
in material and workmanship under normal use and service for a period of two years after purchase.
Abbott makes no other warranties, express or implied, as to merchantability, fitness for a particular
purpose, or any other matter.
Purchaser’s exclusive remedy shall be, at Abbott’s option, the repair or replacement of the product. In
no event shall Abbott’s liability arising out of any cause whatsoever (whether such cause be based in
contract, negligence, strict liability, tort, or otherwise) exceed the price of such product, and in no
event shall Abbott be liable for incidental, consequential, or special damages or losses or for lost
business, revenue, or profits. Warranty product returned to Abbott must be properly packaged.
The foregoing warranty shall be void in the event the product has been misused, damaged, altered, or
used other than in accordance with product manuals so as, in Abbott’s judgment, to affect its stability
or reliability, or in the event the serial or lot number has been altered, defaced, or removed.
The foregoing warranty shall also be void in the event any person, including the Purchaser, performs
or attempts to perform any major repair or other service on the product without having been trained
by an authorized representative of Abbott and using Abbott documentation and approved spare parts.
For purposes of the preceding sentence, “major repair or other service” means any repair or service
other than the replacement of accessory items such as batteries.
In providing any parts for repair or service of the product, Abbott shall have no responsibility or
liability for the actions or inactions of the person performing such repair or service, regardless of
whether such person has been trained to perform such repair or service. It is understood and
acknowledged that any person other than an Abbott representative performing repair or service is not
an authorized agent of Abbott.
AIM/AIM Plus Technical Service Manual 2-1 430-600035-002 (Rev. 11/99)

Section 3
System Operating Manual
A System Operating Manual is included with every AIM and AIM Plus kit. Insert a copy in this
binder’s pockets for convenient reference. Ifa copy of the System Operating Manual is not available,
contact Abbott Laboratories Technical Support Operations (see Section 6.1, Technical Assistance).
AIM/AIM Plus Technical Service Manual 3-1 430-600035-002 (Rev. 11/99)

0 lå
Section 4
Theory of Operation
This section describes the theory of operation of the AIM/AIM Plus. The pump has a modular
construction as shown in Figure 4-1, Assemblies.
Front case
assembly
AC
power
jack
assembly
Bolus jack
assembly
Displa
module
Mylar
Washer
Battery door
Motor frame seal
Motor frame with
optics assembly,
motor assembly, and
latch assembly
PCB
assembly
Back case
assembly .
AIM Assembly
(AIM Plus beeper is mounted on PCB)
5A-12a 75
Figure 4-1. Assemblies
AIM/AIM Plus Technical Service Manual 41 430-600035-002 (Rev. 11/99)

Section 4, Theory of Operation
41
General Description
The pump case is constructed of durable, shock resistant plastic that contains or is coated with a
conductive material to provide enhanced ESD and EMI protection for the pump electronics. The
front half of the case houses the Liquid Crystal Display (LCD) and membrane contact keys. The
motor frame is side mounted. Access to the electro-mechanical assembly of the pump is
accomplished by the removal of retaining screws located on the rear case half. Battery compartment
access is accomplished by removal of the battery door. Positive and negative terminals are
constructed of spring clips. Positive and negative contacts are identified. The batteries are series
connected and isolated from the optional power supply via diodes.
The motor frame aligns the cartridge to the drive motor and optical sensors, and completes the outer
part of the pumping mechanism (refer to Figure 4-2, Motor Frame). Air-in-line and occlusion
detection
systems require correct cartridge alignment to function properly.
50-19 25
Figure 4-2. Motor Frame
The location, height, and perpendicularity of the dowel pins determine the location of the cartridge
within the motor frame. Dowel pin insertion into the motor frame is made by using specially designed
equipment; for that reason, replacement of the motor frame must be performed by Abbott
Laboratories.
The mechanical drive consists ofa motor assembly (refer to Figure 4-3. Motor Assembly). The motor
consists of a DC brush type, iron-less core motor with attached gearbox and integral Hall effect
encoder built into the motor. The gearbox or transmission of the motor contains a 64/1 gear reduction
to transform the relatively high speed, low torque output of the motor to the slower speed, higher
torque requirements necessary to drive the rotary peristaltic cartridge pumping mechanism. The
drive motor can be driven at various speeds, depending on the rate programmed.
The motor assembly includes an encoder, or tachometer. The encoder consists of a magnetic disc
mounted on the motor shaft on the end of the motor opposite the gearbox. The disc contains multiple
magnetic pole pairs. The encoder contains two Hall effect magnetic sensors, in quadrature, that
create 16 pulses for every one motor shaft turn. The motor encoder outputs these 16 pulses, 90° out of
pulse, on both phase 1 and phase 2 outputs. For each 64 by 16 tach pulses or 64 motor turns, the
gearbox output shaft going to the cartridge completes one full turn, resulting in a fluid delivery of
approximately 0.0876 mL. The pump’s software keeps track of volume of fluid delivered by
counting encoder pulses.
430-600035-002 (Rev. 11/99) 4-2 AIM/AIM Plus Technical Service Manual