Baxter Healthcare Corporation Ipump User manual

Ipump Pain Management System
SERVICE MANUAL
For use with Ipump devices with hardware revision 2 (HW Rev 2).

Disclaimer
The information in this document has been carefully examined, and is believed to be entirely reliable. However,
no responsibility is assumed for inaccuracies. Furthermore, Baxter reserves the right to make changes to any
products herein to improve readability, function, or design. Baxter does not assume any liability arising out of
the applications or use of any product or circuit described herein; neither does it cover any license under its
patent rights nor the rights of others.
Documentation Copyrights
Duplication or distribution of this manual and any information contained within (except for the data sheets), is
strictly prohibited without the express written permission of Baxter. This manual and any information contained
within, may not be reproduced, distributed, or transmitted in any form, or by any means, for any purpose
without the express written permission of Baxter.
Computer Software Copyrights
Copyright 2006, Baxter Healthcare Corporation. All rights reserved.For use only by Baxter Healthcare
Corporation. The software contains proprietary information belonging to Baxter Healthcare Corporation. The
software must not be reproduced or disclosed to others without prior written approval. Any unauthorized use of
this information may subject the user to substantial liability.
Patent Information
This pump is protected under one or more U.S. and Foreign patents.
Trademark Information
Baxter and Ipump are trademarks of Baxter International Inc.
All other trademarks and product names appearing within this manual are the property of their respective
owners.
Copyright 1999 - 2007, Baxter Healthcare Corporation. All rights reserved.

07-19-A8-092 Ipump Pain Management System Service Manual i
Contents
Chapter 1 - Introduction
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Pump Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
Manual Layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
Factory Service & Assistance - - - - - - - - - - - - - - - - - - - - - 1-3
Technical Assistance, Service, & Repairs - - - - - - - - - - - - - - - 1-4
Safety Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
Definitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
Warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Cautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Notes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
Labeling Symbol Definitions - - - - - - - - - - - - - - - - - - - - - 1-6
Chapter 2 - Theory of Operation
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
System Components - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
MPU Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
BUS Subsystem - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
Keypad & Sensors - - - - - - - - - - - - - - - - - - - - - - - - 2-4
PROM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
Supervisory Subsystem (SS) - - - - - - - - - - - - - - - - - - - 2-5
Power Subsystem (PS) - - - - - - - - - - - - - - - - - - - - - - 2-5
LCD Subsystem- - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
Silent Shutdown Circuit - - - - - - - - - - - - - - - - - - - - - - 2-6
Motor Subsystem - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
Occlusion Detection Circuit - - - - - - - - - - - - - - - - - - - - 2-7
Air Sensor Circuit - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
Printer Adapter Interface Circuit - - - - - - - - - - - - - - - - - - 2-7

ii Ipump Pain Management System Service Manual 07-19-A8-092
Contents
Chapter 3 - Care & Routine Maintenance
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Cleaning and Disinfecting - - - - - - - - - - - - - - - - - - - - - - - 3-1
Chapter 4 - Troubleshooting
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Reviewing the Alarm Log- - - - - - - - - - - - - - - - - - - - - - - - 4-1
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
System Error Codes - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
Range 10 - 2V -- Peripheral/Sensor Errors - - - - - - - - - - - - - 4-5
Range 30 - 47 -- Motor Control Errors - - - - - - - - - - - - - - - - 4-6
Range 50 - 52 -- RTC Errors - - - - - - - - - - - - - - - - - - - - 4-7
Range 60 - 62 -- Power Supply Errors- - - - - - - - - - - - - - - - 4-7
Range 70 - 74 & L0 -- MPU Errors - - - - - - - - - - - - - - - - - 4-7
Range 75 - 8D -- Processing Errors - - - - - - - - - - - - - - - - - 4-8
Range 90 - 9Z & M0 - P3 -- Data Corruption Errors - - - - - - - - - 4-8
Range A0 - J1 -- Processing Errors - - - - - - - - - - - - - - - - 4-10
Chapter 5 - Functional Tests
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
General Information - - - - - - - - - - - - - - - - - - - - - - - - 5-2
Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Optional Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Exterior Visual Inspection - - - - - - - - - - - - - - - - - - - - - - - 5-3
Configuration Settings - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
Flow Rate Accuracy Test- - - - - - - - - - - - - - - - - - - - - - - - 5-6
Test Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
Procedure Using the Gravimetric Method - - - - - - - - - - - - - - 5-7
Procedure Using the Volumetric Method - - - - - - - - - - - - - - 5-8
Downstream Occlusion Calibration Pressure Test - - - - - - - - - - - 5-8
Operational Checks - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Test Set Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Power-On Self Test (POST) - - - - - - - - - - - - - - - - - - - - 5-9
Keypad Operation Test - - - - - - - - - - - - - - - - - - - - - - 5-10
Bag Cover Lock/Unlock Test - - - - - - - - - - - - - - - - - - - 5-10

07-19-A8-092 Ipump Pain Management System Service Manual iii
Contents
Tubing Sensor Test - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Occlusion Sensor Test - Downstream - - - - - - - - - - - - - - - 5-11
Occlusion Sensor Test - Upstream - - - - - - - - - - - - - - - - 5-11
Air Sensor Test - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
PCA Cable & Button Test - - - - - - - - - - - - - - - - - - - - - 5-13
AC Adapter Test (Optional) - - - - - - - - - - - - - - - - - - - - 5-13
History Retention Test (Backup Battery Check) - - - - - - - - - - 5-14
Printer Test (Optional) - - - - - - - - - - - - - - - - - - - - - - - 5-14
Unintended Shutdown Circuit Test- - - - - - - - - - - - - - - - - 5-14
Functional Test Data Sheet - - - - - - - - - - - - - - - - - - - - - - 5-15
Chapter 6 - Disassembly & Reassembly
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-2
Tools & Materials - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-2
Required Tools & Equipment - - - - - - - - - - - - - - - - - - - 6-2
Consumable Materials - - - - - - - - - - - - - - - - - - - - - - 6-3
Baxter-Created Tools & Equipment - - - - - - - - - - - - - - - - 6-3
Disassembly Procedures - - - - - - - - - - - - - - - - - - - - - - - 6-4
General Disassembly Information - - - - - - - - - - - - - - - - - 6-4
Bag Cover Assembly Removal - - - - - - - - - - - - - - - - - - 6-4
MPU PCBA Handling Guidelines - - - - - - - - - - - - - - - - - 6-5
Rear Case Assembly Removal - - - - - - - - - - - - - - - - - - 6-6
Mechanism Assembly, DDMM PCBA, & Battery Wall Removal - - - 6-7
MPU PCBA Removal - - - - - - - - - - - - - - - - - - - - - - - 6-8
ESD Flex Circuit Removal - - - - - - - - - - - - - - - - - - - - - 6-9
LCD Module Removal - - - - - - - - - - - - - - - - - - - - - - - 6-10
Optional Procedures - - - - - - - - - - - - - - - - - - - - - - - - - 6-11
3V Backup Battery Replacement - - - - - - - - - - - - - - - - - 6-11
Initializing the 3V Backup Battery - - - - - - - - - - - - - - - - - 6-12
Keypad Replacement - - - - - - - - - - - - - - - - - - - - - - - 6-12
Assembly Procedures - - - - - - - - - - - - - - - - - - - - - - - - 6-15
Torque Specifications - - - - - - - - - - - - - - - - - - - - - - - 6-15
Installing the Front Case & Keypad Assembly - - - - - - - - - - - 6-15
Installing the ESD Flex Circuit - - - - - - - - - - - - - - - - - - - 6-15
Installing the Display ESD Shield - - - - - - - - - - - - - - - - - 6-18
Installing the LCD Module - - - - - - - - - - - - - - - - - - - - - 6-18

iv Ipump Pain Management System Service Manual 07-19-A8-092
Contents
MPU PCBA Handling Instructions - - - - - - - - - - - - - - - - - 6-19
Installing the MPU PCBA - - - - - - - - - - - - - - - - - - - - - 6-19
Installing the Battery Wall & DDMM PCBA - - - - - - - - - - - - 6-23
Installing the DDMM PCBA Hold-down Foam - - - - - - - - - - - 6-24
Installing the Mechanism Assembly - - - - - - - - - - - - - - - - 6-24
Installing the Battery Door - - - - - - - - - - - - - - - - - - - - 6-25
Pump Calibration - - - - - - - - - - - - - - - - - - - - - - - - - 6-25
Internal Inspection - - - - - - - - - - - - - - - - - - - - - - - - 6-26
Closing the Case - - - - - - - - - - - - - - - - - - - - - - - - - 6-27
Pump Functional Tests - - - - - - - - - - - - - - - - - - - - - - 6-28
Optional Assembly Procedures- - - - - - - - - - - - - - - - - - - - 6-28
Installing the Bag Cover Assembly - - - - - - - - - - - - - - - - 6-28
Chapter 7 - Internal Tests & Pump Calibration
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
3V Backup Battery Test - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Battery Load Test - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Battery No Load Test - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Calibration Procedure - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - 7-4
Initial Setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
Downstream Occlusion Calibration - - - - - - - - - - - - - - - - - 7-5
Upstream Occlusion Calibration- - - - - - - - - - - - - - - - - - - 7-6
Air Sensor Calibration - - - - - - - - - - - - - - - - - - - - - - - 7-8
Downstream Occlusion Calibration Pressure Test - - - - - - - - - - 7-9
Calibration Data Sheet - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Chapter 8 - Electronic Assembly Drawings
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Interconnecting Wiring Diagram - - - - - - - - - - - - - - - - - - - - 8-1
Keypad Cable & Motor Connectors - - - - - - - - - - - - - - - - - - 8-2
Mechanism Assembly Flex Circuit Connector - - - - - - - - - - - - - - 8-2
MPU PCBA Assembly - - - - - - - - - - - - - - - - - - - - - - - - - 8-3
Direction & Drive Motor Module PCBA (DDMM) Daughter Board - - - - 8-4

07-19-A8-092 Ipump Pain Management System Service Manual v
Contents
Chapter 9 - Repair Parts
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1
Assembly Parts List - - - - - - - - - - - - - - - - - - - - - - - - - 9-2
Bag Cover Assembly - - - - - - - - - - - - - - - - - - - - - - - 9-2
Rear Case Assembly - - - - - - - - - - - - - - - - - - - - - - - 9-3
Pump Mechanism & Battery Compartment Assemblies- - - - - - - 9-4
MPU Board Assembly - - - - - - - - - - - - - - - - - - - - - - - 9-5
LCD Circuit Board & Front Case Assemblies - - - - - - - - - - - - 9-6
Alphabetical Parts List - - - - - - - - - - - - - - - - - - - - - - - - 9-7
Numerical Parts List - - - - - - - - - - - - - - - - - - - - - - - - - 9-9
Chapter 10 - Product Updates
Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-1
Limited Warranty

vi Ipump Pain Management System Service Manual 07-19-A8-092
Contents

07-19-A8-092 Ipump Pain Management System Service Manual 1-1
1 - Introduction
In this section Page
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Pump Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Factory Service & Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Technical Assistance, Service, & Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Labeling Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Overview
The Ipump Pain Management System (hereafter referred to as the “pump”) is indicated
for the controlled delivery (continuous, intermittent, and continuous plus intermittent) of
analgesic, sedative, and anesthetic solutions through clinically acceptable routes of
administration including intravenous, subcutaneous, and epidural, and for regional (local)
analgesia applications.
This lightweight, compact pump can be battery operated for portability or connected to an
AC power source for stationary use. A specially designed optional locking pole-mounting
clamp allows the pump to be attached to a standard IV pole. With the pole clamp removed,
the pump can be placed into a comfortable carrying case.
This manual contains service and maintenance information for all Ipump Pain
Management System products (product codes 2L3107, 2L3107R, and 2L3107K) with
hardware revision 2 (HW Rev 2). This information is intended for qualified biomedical
personnel and Baxter authorized service representatives.
This manual provides a basic understanding of the internal workings of the pump,
functional test procedures, troubleshooting, complete assembly/disassembly instructions,
and a replacement parts list.
For complete operational and precautionary information, pump specifications, and
cleaning instructions, refer to the Ipump Pain Management System Operator’s Manual
(p/n 07-19-x4-766). For pump installation and configuration, refer to the Ipump Pain
Management System Configuration Manual (p/n 07-19-x4-768).
CAUTION
Only trained, qualified personnel should perform procedures in this
manual. Except for the procedures and replacement parts included in
this document, no other disassembly or repair should be attempted.

1-2 Ipump Pain Management System Service Manual 07-19-A8-092
1 - Introduction
Baxter Healthcare Corporation provides a one-year limited warranty for new Ipump
devices. If a pump requires warranty service, call Baxter Healthcare Corporation for
repair. Unauthorized repair of a pump before the warranty has elapsed voids the warranty.
Pump Accessories
Manual Layout
This manual is divided into the following sections:
Chapter 1 (Introduction) provides an overview of the contents of this Service Manual
and includes Warnings and Cautions concerning the use and care of this product.
Warnings and Cautions are also located where needed throughout this manual.
Chapter 2 (Theory of Operation) details the functional features of the pump. A general
overview of the pump’s operation and a functional block diagram are provided.
Chapter 3 (Care & Routine Maintenance) includes the routine maintenance and
cleaning procedures with recommended cleaning agents. Battery replacement procedures
are also included.
Chapter 4 (Troubleshooting) contains troubleshooting tables and procedures for
localizing mechanical or electronic faults. A table of System Error Codes is also included.
Description Catalog Number
100 mL Bag Cover 2L3218
250 mL Bag Cover 2L3220
250 mL Extended Bag Cover 2L3217
250 mL Extended Bag Cover, Amber 2L3261
500 mL Bag Cover 2L3221
Printer Adapter 2L3400
Printer Adapter Cable 2L3402
Patient Controlled Analgesia (PCA) Button B069140003RP
Locking Pole Mount Clamp 2L3211
Non-locking Pole Mount Clamp 2L3212
Pump Carrying Case (250 mL) 2L3219
AC Adapter (220-230V) 2L3205K
AC Adapter (100-120V) 2L3210
AC Adapter Holder 2L3214
Configuration Transfer Cable 2L3112
Yellow Face Plate Label 072742210

07-19-A8-092 Ipump Pain Management System Service Manual 1-3
1 - Introduction
Chapter 5 (Functional Tests) provides the tests that are to be used to ensure that the
pump operates properly. Baxter recommends that these tests be performed on an annual
basis as a preventive maintenance procedure. In addition, these tests must be performed
whenever the Mechanism Assembly and/or the MPU PCBA is removed or replaced.
Chapter 6 (Disassembly & Reassembly) provides disassembly, replacement, and
reassembly instructions. Required tools and test equipment are specified. Adjustment
procedures are provided along with the required torques and tolerances. Replacement
procedures for the 3V Backup Battery and the Keypad are also included.
Chapter 7 (Internal Tests & Pump Calibration) contains the procedures required to
test the 3V Backup Battery and to calibrate the pump. The calibration procedures must be
performed after replacement of either the Mechanism Assembly or the MPU PCBA.
Chapter 8 (Electronic Assembly Drawings) contains the assembly drawings for the
interconnecting cables and flex circuits used in the pump.
Chapter 9 (Repair Parts) provides exploded view drawings and parts lists of field-
replaceable parts and assemblies.
Chapter 10 (Product Updates) contains major updates and additional information for
the pump. This information will be listed by hardware and software revision numbers
and/or product serial number. Product Service Bulletins should also be placed in this
chapter of the manual.
Factory Service & Assistance
Baxter Healthcare Corporation provides a one-year limited warranty for each pump. (See
the inside back cover of this manual for warranty details.) If a pump requires warranty
service, call Baxter Healthcare Corporation for repair. While under Baxter Warranty,
Service Agreement (optional), or Lease Agreement, the pump must not be opened by
unauthorized personnel. Unauthorized repair of a pump before the warranty has elapsed
voids the warranty.
If factory service is desired, pumps may be returned to Baxter Healthcare Corporation for
repair. Always call for a return material authorization number before shipping any pump
to Baxter Healthcare Corporation.
When calling for service, please be prepared to provide the product code and serial
number of the pump. A brief written description of the problem should be attached to the
pump when it is returned for service.
Shipping costs for all pumps returned to Baxter shall be paid for by the customer. The
pump must be packed in its original container or in another container that will provide
adequate protection during shipment. To ensure prompt return, a Baxter authorized service
representative must be notified before shipping any pump for repair.
Baxter Healthcare Corporation will not be responsible for unauthorized returns or for
pumps damaged in shipment due to improper packing.

1-4 Ipump Pain Management System Service Manual 07-19-A8-092
1 - Introduction
Technical Assistance, Service, & Repairs
For technical assistance, parts ordering, and service return authorization, contact the
Baxter Healthcare Service Center:
Inside the U.S.: Call 1-800-THE-PUMP (843-7867)
Outside the U.S.: Contact your local Baxter representative.
Safety Summary
General precautions to observe while using the pump are shown below. Standards under
which this product is designed, built, and marketed are also included.
• Before operating the pump, carefully read the operator’s manual to fully understand the
pump’s functionality and to ensure safe and proper operation. An operator’s manual is
shipped with each pump.
• Although the pump has been designed and manufactured to exacting specifications, it
is not intended to replace trained personnel in the supervision of infusion therapy.
• Read and understand this manual before attempting to perform service or maintenance
on the pump.
• To ensure that the pump continues to perform within specifications, perform the
Routine Maintenance procedures described in Chapter 3 of this manual when
recommended.
• This manual has been developed with consideration to the requirements in the
International Standard, IEC 60601-2-24 (1998-02) Medical Electrical Equipment —
Part 2-24: Particular Requirements for Safety of Infusion Pumps and Controllers.
• This product is classified by Underwriters Laboratories Inc. with respect to electric
shock, fire and mechanical hazards only in accordance with UL 60601-1 Medical
Electrical Equipment - Part 1: General Requirements for Safety.
Definitions
Certain items in this manual are highlighted by special messages. The definitions of the
various types of message are provided below.
! WARNING !
Indicates a possible hazard which, if ignored, could result in
severe personal injury or death.
CAUTION
Indicates a problem or unsafe practice which, if not avoided, could
result in minor or moderate personal injury, or product or property
damage.
NOTE: Provides supplemental information to the accompanying text.

07-19-A8-092 Ipump Pain Management System Service Manual 1-5
1 - Introduction
Warnings
Cautions
! WARNING !
This pump should be repaired only by trained, qualified
personnel using Baxter-recommended parts. There are risks
associated with using anything other than Baxter-recommended
parts and procedures. Baxter will assume no responsibility for
incidents which may occur if the product was not repaired by
qualified Baxter employees.
! WARNING !
If the pump has been dropped or appears to be damaged, it
should be taken out of service and inspected by qualified
service personnel.
! WARNING !
To ensure safe and proper operation, read the Ipump Pain
Management System Operator’s Manual and any instructions
accompanying disposables or accessories before operating the
pump.
! WARNING !
When attaching the pump to an IV pole, ensure it has been
securely clamped and locked.
! WARNING !
As with all medical electronic equipment, care must be exercised
to avoid exposing this pump to powerful sources of
electromagnetic interference. Using the pump near operating
equipment which radiates high energy radio frequencies (such
as electrosurgical/cauterizing equipment, two-way radios, or
cellular telephones) may cause false alarm conditions. If this
happens, reposition the pump away from the source of
interference.
CAUTION
In the U.S., use of this pump is restricted by federal law (USA) to sale
or use by, on the order of, or under the supervision of a physician or
other licensed health care professional.
CAUTION
DO NOT operate this infusion pump in the presence of flammable
anesthetics, ether, oxygen-enriched, or explosive atmospheres.
CAUTION
DO NOT expose the pump to X-rays, gamma rays, or other ionizing
radiation, or to strong electric or magnetic fields.
CAUTION
Wipe off spills immediately. DO NOT allow fluid or residue to remain
on the pump.
CAUTION
Ensure proper maintenance of the pump by following the cleaning
schedule and methods described in this manual.
CAUTION
Do not clean, disinfect, or sterilize any part of the pump by
autoclaving, or with ethylene oxide gas. Doing so may damage the
pump and void the warranty. Only external parts of the pump should
be disinfected.
CAUTION
Refer all service, repair, and calibration to trained, qualified
personnel.
CAUTION
To reduce the risk of electrical shock, only trained, qualified personnel
should disassemble this product.
CAUTION
For best performance, routine maintenance procedures must be
performed. (Refer to Chapter 3 of this manual.)

1-6 Ipump Pain Management System Service Manual 07-19-A8-092
1 - Introduction
Notes
Baxter requests that parties acquiring this pump:
• Promptly report the receipt of this pump to the manufacturer.
• Report the pump’s purchase, receipt in trade, return after sale, loss, destruction, or
retirement.
• If this is an initial purchase from the manufacturer, please return a signed copy of the
packing list to the manufacturer.
Labeling Symbol Definitions
CAUTION
Wear a grounding wrist strap when disassembling and reassembling
the pump.
CAUTION
DO NOT lay the pump face down on any surface which could scratch
or damage the keypad or the display.
CAUTION
When troubleshooting the pump, do not inject or apply signals of any
kind. Damage to the pump or its sub-assemblies could result.
CAUTION
Motor and sensor magnets may attract metal debris to motors or
circuit boards. To prevent debris from entering the pump mechanism,
always maintain a clean work area when performing procedures
involving the pump mechanism.
CAUTION
To avoid personal injury, ensure that the IV pole is stable and secure.
Ensure that the pole is able to support the pump, along with any other
devices, without tipping or falling. The pole diameter should be
between 0.5" and 1.25" (1.3 cm and 3.2 cm).
IPX1 Drip-proof equipment: enclosed equipment protected against
dripping fluids.
Connection port for the AC to DC converter/adapter.
CAUTION, Consult Accompanying Documents
Type CF applied part. (The “Type CF Applied Part”symbol
indicates the level of electric shock protection for the patient-
contacting parts such as the PCA button and the IV set.
UL/IEC/EN 60601-1 defines Type CF as providing greater
protection than Type B or Type BF.)
Electrostatic Sensitive Devices
(The pins of the PRINTER/COMM connector are subject to
Electrostatic Discharge and should not be touched. Refer to
page 2-7 for additional information.)

07-19-A8-092 Ipump Pain Management System Service Manual 1-7
1 - Introduction
Recyclable, dispose of properly.
This product is classified by Underwriters Laboratories Inc.
with respect to electric shock, fire, and mechanical hazards
only in accordance with UL 2601-1 (UL 60601-1),
CAN/CSA C22.2 No. 601.1, and IEC 60601-2-24.
Symbol (WEEE 2002/96/EC) Crossed-out wheeled bin
For product disposal, ensure the following:
- Do not dispose of this product as unsorted municipal waste.
- Collect this product separately.
- Use collection and return systems available to you.
Bar below bin
- Product distributed after August 13, 2005.
For more information on return, recovery, or recycling of
this product, please contact your local Baxter representative.
Manufacturer
Authorized Representative in the European Community
Catalog Number
Serial Number
EC REP
REF
SN

1-8 Ipump Pain Management System Service Manual 07-19-A8-092
1 - Introduction

07-19-A8-092 Ipump Pain Management System Service Manual 2-1
2 - Theory of Operation
In this section Page
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Ipump System Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . 2-2
MPU Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
BUS Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Keypad & Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
PROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Supervisory Subsystem (SS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Power Subsystem (PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
LCD Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Silent Shutdown System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Motor Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Occlusion Detection Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Air Sensor Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Printer Adapter Interface Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Overview
The Ipump Pain Management System is a small, lightweight, linear peristaltic pump that
may be operated from battery or AC power. An optional pole-mounting clamp allows the
pump to be unlocked and easily removed for pump placement into a convenient carrying
case. See the list of pump accessories on page 1-2.
The user can program the pump with prescribed values for the therapy desired. A number
of security options are available in order to enter prescription parameters from the keypad.
Once programmed with prescription parameters, the pump operates with these settings
until the operator turns the pump off or re-enters the programming screens and changes the
prescription. A record of the previous prescription and therapy history are retained while
the pump is in operation or turned off. The user can choose to use the previous
prescription, review the history by pressing the HISTORY key, or clear the history by
pressing the CLEAR key.
The pump can be configured to require a key to unlock and open the pump bag cover to
change a prescription. The pump can also be configured to require either a security code,
or both a key and a security code, to gain applicable access.
The pump can be programmed for specific modes, units, and/or prescription limits. This is
accomplished by accessing the configuration screens during initial start-up. To access the
configuration mode refer to the Ipump Pain Management System Configuration Manual
and the Ipump Pain Management System Operator's Manual. Once programmed, the
pump will remain in that configuration until purposely changed.

2-2 Ipump Pain Management System Service Manual 07-19-A8-092
2 - Theory of Operation
The pump configuration can be transferred between two Ipump devices for the
configuration of multiple pumps. An optional configuration transfer cable, available from
Baxter, is required. See the list of pump accessories on page 1-2.
The remainder of this chapter provides a basic explanation of the pump's internal
operation.
System Components
The pump is divided into modules and subsystems. Figure 2-1 is a functional block
diagram of the system and not intended to illustrate component location. The modules and
subsystems listed below are discussed later in this chapter.
Figure 2-1. Ipump System Functional Block Diagram
• MPU Circuit • LCD Subsystem
• Bus Subsystem • Silent Shutdown Circuit
• Keypad • Motor Subsystem
• PROM • Occlusion Detection Circuit
• Supervisory Subsystem • Air Sensor Circuit
• Power Subsystem • Printer Adapter Interface Circuit
A I R
S E N S O R
C I R C U I T
P R I N T E R
A D A P T E R
I N T E R F A C E
C I R C U I T
O C C L U S I O N
D E T E C T I O N
C I R C U I T
M P U C I R C U I T
B U S
S U B S Y S T E M
M O T O R
S U B S Y S T E M
P R O M
K E Y P A D
S U P E R V I S O R Y
S U B S Y S T E M
L C D
S U B S Y S T E M
P O W E R
S U B S Y S T E M
S I L E N T S H U T D O W N
C I R C U I T

07-19-A8-092 Ipump Pain Management System Service Manual 2-3
2 - Theory of Operation
MPU Circuit
The pump uses a 16-bit micro-controller and an external PROM. The 16-bit micro-
controller contains hardware timers, analog to digital converter, RAM and PROM, and
the microprocessor. This application of the micro-controller uses the internal RAM and
PROM whenever possible to save power, which is a major feature of this pump. The
memory expansion mode is only used when accessing functions on the external bus. The
microprocessor has eight input/output (I/O) ports which are used to control or monitor the
following functions:
A number of power-up tests are performed to ensure that the pump is running properly.
The power-up tests include testing of the LEDs, memory, display, beeper, backup battery,
and input voltages. If an error is detected, the processor will initiate a 2-character error
code which will produce an alert message and an audible alarm.
Included in the processor subsystem is the real time clock (RTC) circuit. The RTC
provides time of day information to the microprocessor. The RTC circuitry keeps track of
time while the pump is off, through the use of a backup battery mounted to the
microprocessor circuit board. The backup battery is also used to preserve the contents of
the microprocessor RAM when operating power drops below a minimum voltage. The
RTC also contains a small amount of RAM that is used by the system software to
determine whether there has been a loss of backup battery power.
BUS Subsystem
The BUS has the capacity to provide for a 24 bit address and 8 bit data path. The
microprocessor uses the BUS subsystem to transfer data or instructions to seven different
functions. These functions are:
• PROM • LCD Subsystem
• Motor Subsystem • Watchdog
• Keypad • Switches
• Silent Shutdown Circuit • Real Time Clock Circuit
• Occlusion Detection Circuit • Air Sensor Circuit
• Various voltages
• PROM • LCD Command and Data Register
• Motor Drive • Watchdog
• Keypad • Switches
• Real Time Clock (RTC)

2-4 Ipump Pain Management System Service Manual 07-19-A8-092
2 - Theory of Operation
Keypad & Sensors
The Keypad is comprised of nine keys which enable the user to turn the pump Off and On,
enter the prescription data, and START and STOP an infusion. In addition to monitoring
each of these keys, the microprocessor also checks the status of ancillary inputs consisting
of internal switches, sensors, and connectors. Refer to Table 2-1 and Table 2-2 for a
description of the Keypad keys and ancillary inputs.
Key Description
The START key begins the operation of the pump and can also be configured to act as
a PCA button. If all of the required programming values have been entered, the START
key initiates the infusion from any programming screen.
Following the resolution of most alerts or alarms, pressing the START key resumes the
infusion if the condition no longer exists.
The STOP key must be pressed twice within 1 second to stop the operation of the
pump. After the pump is stopped, you can press the ON/OFF key to turn the pump off.
The ENTER key sets the value displayed on the Liquid Crystal Display (LCD) screen.
The ON/OFF key powers up and powers down the pump. If the pump is on, you can
press the key:
•once to deactivate the programmed settings, which can be retrieved.
•twice to power off the pump.
The CLEAR/SILENCE key either clears the data shown on the LCD screen or silences
an alert or alarm signal generated by the pump.
The HISTORY key displays the infusion history on the LCD screen. Pressing this key
again allows you to scroll through the history screens.
The left and right arrow keys move the cursor on the display screen to
the left and right.
The scroll (up arrow) key displays the next available option on the pump’s screen.
Table 2-1. Keypad Keys