Cardinal Health Alaris GP Operating manual

Alaris®GP Volumetric Pump
Technical Service Manual

Alaris® GP Volumetric Pump 2/84 1000SM00013 Issue 3
© 2006-2008. Cardinal Health, Inc. or one of its subsidiaries All rights reserved.
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.
tCardinal Health, 1180 Rolle, Switzerland
Alaris®, IVAC®, Guardrails® and Asena® are registered trademarks of Cardinal Health, Inc. or one of its subsidiaries.
All other trademarks belong to their respective owners.
This product uses zlib (http://www.zlib.net/) © 1995-2005 Jean-loup Gailly and Mark Adler
Technician Mode uses the lwIP communication stack (http://www.sics.se/~adam/lwip/)
© 2001, 2002 Swedish Institute of Computer Science. All rights reserved.
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Alaris® GP Volumetric Pump 3/84 1000SM00013 Issue 3
Contents
Chapter
1. General Information 4
2. Configuration & Calibration 8
3. Preventative Maintenance 19
4. Troubleshooting 39
5. Circuit Descriptions 44
6. Corrective Maintenance 48
Appendix
A. Electromagnetic Compatibility 68
B. Disposal 73
C. Spare Parts Listings 75
D. Service Contacts 81
E. Document History 83

Chapter 1
General Information
In this chapter
Introduction 5
Features of the Pump 6
General Precautions 7

General Information
Alaris® GP Volumetric Pump 5/84 1000SM00013 Issue 3
Introduction
The Alaris® GP Volumetric Pump and the Alaris® GP Guardrails® Volumetric Pump (hereinafter referred to as 'Pump') is a
small lightweight volumetric infusion pump that provides accurate and reliable infusions over a range of rates.
The pump is designed to meet the infusion requirements as specified in the Directions For Use (DFU) for all hospital
departments including general wards, critical and intensive care, operating rooms and accident and emergency rooms.
This pump is suitable for use by appropriately trained clinicians or nurses. This pump can be used for intravenous infusion
modes. Supporting fluid & drug therapy, blood transfusions and parenteral feeding.
Product Familiarity
Ensure that you are fully familiar with the pump by carefully studying the Directions for Use (DFU) prior to operation and
prior to attempting any repairs or servicing. As part of continuous improvement, product enhancements and changes are
introduced from time to time.
Purpose of this Manual
This Technical Service Manual describes how to set up, test and maintain the Alaris® GP Volumetric Pump and the Alaris®
GP Guardrails® Volumetric Pump.
This manual is intended for use by personnel experienced in medical equipment testing and maintenance procedures.
Conventions Used in this Manual
BOLD Used for Display names, self-test codes, controls and indicators referenced in this manual, for
example, Battery Indicator, access code 212, ON/OFF button.
'Single quotes' Used to indicate cross-references made to another section of this manual. For example, see
Chapter 2, 'Configuration & Calibration'.
underline Used to indicate a link to another section within this manual.
Italics Used to refer to other documents or manuals. For example, refer to the relevant Directions for Use
(DFU) for further information. Also used for emphasis, for example, ...if the gap still measures less
than...
Wherever this symbol is shown a Hints & Tips note is found. These notes provide useful advice or
information that may help to perform the task more effectively.
Wherever this symbol is shown a Toolbox note is found. These notes highlight an aspect of test
or maintenance that is important to know about. A typical example is drawing attention to a
software upgrade that you should check has been installed.

General Information
Alaris® GP Volumetric Pump 6/84 1000SM00013 Issue 3
Alarm indicator
Flow sensor
connector (cover
removed for clarity)
RS232/Nursecall
connector (cover
removed for clarity)
Release lever for rotating cam
Folded pole clamp
Rotating cam to lock onto
horizontal rectangular bars.
Mains fuses
Mains inlet
IR communications port
Potential Equalisation (PE)
Connector
Alaris®
GP
Display
Run
Bolus
Hold
Options
AC power indicator
Softkeys
Chevrons
Mute
Pressure
Battery indicator
On/Off
Door
Door Lever
Handle
Medical device
interface (MDI)
Features of the Pump

General Information
Alaris® GP Volumetric Pump 7/84 1000SM00013 Issue 3
General Precautions
wAttention consult accompanying documents: Prior to using this pump, carefully read the Operating
Precautions described in the Directions for Use (DFU).
VThis pump contains static-sensitive components. Observe strict precautions for the protection of static
sensitive components when attempting to repair and service the pump.
BAn explosion hazard exists if the pump is used in the presence of flammable anaesthetics. Exercise care
to locate the pump away from any such hazardous sources.
Dangerous Voltage. An electrical shock hazard exists if the casing of the pump is opened or removed.
Refer all servicing to qualified service personnel.
MThis pump is protected against the effects of high energy radio frequency emissions and is designed
to be fail safe if extremely high levels of interference are encountered. Should false alarm conditions
be encountered, either remove the source of the interference or regulate the infusion by another
appropriate means.
Alaris®
GP
If the pump is dropped, subjected to excessive moisture, humidity or high temperature, or otherwise
suspected to have been damaged, remove it from service for inspection by qualified service personnel.
When connected to an external power source, a three-wire (Live, Neutral, Earth) supply must be used. If
the integrity of the external protective conductor in the installation or its arrangement is in doubt, the
pump should be operated from the battery.

Chapter 2
Configuration and Calibration
In this Chapter
Entering Service Mode 9
Service Mode - Factory Defaults 10
Service Mode - Configuration 11
Service Mode - Data Set Transfer 14
Service Mode - Calibration 15

Configuration and Calibration
Alaris® GP Volumetric Pump 9/84 1000SM00013 Issue 3
Entering Service Mode
Service Mode can be accessed via a three-digit access code that is entered using the following procedure:
1. Hold down band turn the pump ON a.
2. Enter the access code 212 using the fkeys and the NEXT softkey.
3. When the code shows on screen, press OK to confirm.
SERVICE
QUIT
SELECT WITH
Factory Defaults
Configuration
Data Set Transfer
Calibration
Test Verification/PVP
OK
Select the required option using the fkeys and the OK softkey.
For the Alaris® GP Volumetric Pump the options will be as follows:
Factory Defaults Load a default data set. Confirm to perform a
cold start.
Configuration This menu comprises a list of options which are
configurable by the user.
Data Set Transfer Upload a data set to pump.
Calibration This menu comprises a list of calibrations which
can be performed by the user.
Test Verification/PVP Performance Verification Procedure Tests.
Warning -
At no time should Service Mode be entered while the pump is connected to a patient.
Service Mode should only be accessed by qualified and trained personnel.
SERVICE
QUIT
SELECT WITH
CQI Events Download
Data Set Transfer
Configuration
Calibration
Test Verification/PVP
Factory Defaults
OK
For the Alaris® GP Guardrails® Volumetric Pump the options will be as follows:
CQI Events Download For future implementation
Data Set Transfer Upload a data set to pump.
Configuration This menu comprises a list of options which are
configurable by the user.
Calibration This menu comprises a list of calibrations which
can be performed by the user.
Test Verification/PVP Performance Verification Procedure Tests.
Factory Defaults Load a default data set. Confirm to perform a
cold start.

Configuration and Calibration
Alaris® GP Volumetric Pump 10/84 1000SM00013 Issue 3
Service Mode - Factory Defaults
Cold Start Confirm
1. Press OK to confirm performing a cold start.
DEFAULT DATA SET
QUIT
******WARNING! ******
Restoring factory
default data set will
delete the clinically
approved data set
installed.
Delete approved and
restore factory default?
OK
COLD START CONFIRM
QUIT
******WARNING! ******
All data set and cal
data will be reset to
default!
The pump will require a
full calibration before
returning to clinical use.
OK
Default Data Set
1. Press OK to confirm loading the default data set.
Factory Defaults
Select the required option using the fkeys and the OK softkey.
Default Data Set Replace the current data set with a default data
set.
Cold Start Confirm Confirm clearing and resetting the data set and
calibration data to the factory defaults.
Clear CQI Log File* Confirm clearing all pump history and resetting
the data set to the factory default.
* Alaris® GP Guardrails® Volumetric Pump only.
FACTORY DEFAULTS
QUIT
SELECT WITH
Default Data Set
Cold Start Confirm
Clear CQI Log File
OK

Configuration and Calibration
Alaris® GP Volumetric Pump 11/84 1000SM00013 Issue 3
Service Mode - Configuration
Select the required option using the fkeys and the OK softkey.
Date/Time Sets the current date and time used for event
logging.
Software Versions Displays the pump software versions.
Serial Number Configure the displayed serial number.
Pump Reference Pump specific text to be displayed in user
mode at start up. (20 characters max.)
Language Configure the Language used for display
messages.
Backlight & Contrast Adjust the Backlight and Contrast values
Current Data Set File Displays the current data set file details.
Date/Time
1. Set the correct date and time using the fkeys.
2. Press NEXT to continue to next item to change.
3. Press OK to confirm.
DATE / TIME
AUG–04–2006
09:48
QUIT NEXT
ADJUST WITH
OK
SERVICE CONFIGURATION
QUIT
SELECT WITH
Date/Time
Software Versions
Serial Number
Pump Reference
Language
Backlight & Contrast
Current Data Set File
OK
Service Mode - Factory Defaults (continued)
CLEAR CQI LOG FILE
QUIT
******WARNING! ******
This will remove all
instrument history and will
restore the factory default
data set by deleting the
clinically approved
installed data set.
Clear current log?
OK
Clear CQI Log File
1. Press OK to confirm clearing the CQI Log File.

Configuration and Calibration
Alaris® GP Volumetric Pump 12/84 1000SM00013 Issue 3
Service Mode - Configuration (continued)
Serial Number
1. Set the serial number required (maximum 9 characters) using the
fkeys.
2. Press NEXT to continue to next item to change.
3. Press OK to confirm.
SERIAL NUMBER
8026 - 00000
Write Success: .
QUIT NEXT
ADJUST WITH
OK
Pump Reference
1. Set the Pump Reference required using the fkeys.
2. Press NEXT to continue to next item to change.
3. Press OK to confirm.
PUMP REFERENCE
QUIT NEXT OK
ADJUST WITH
---------------------
Software Versions
Press1. OK to exit after verifying Software Version fitted, display will vary depending on software version fitted.
SOFTWARE VERSIONS
QUIT
SWV 001.009.000
PKG 001.009.000
MPU 001.009.000
MPT 001.009.000
FDP 001.007.016
SP 001.005.000
LANGUAGE 001.004.005
OK
SOFTWARE VERSIONS
QUIT
SRP 001.005.004
MP 001.005.004
FDP 001.005.004
SP 001.005.004
OK

Configuration and Calibration
Alaris® GP Volumetric Pump 13/84 1000SM00013 Issue 3
Service Mode - Configuration (continued)
Backlight & Contrast
1. Use the fkeys to adjust Backlight and Contrast to required
setting.
2. Press PARAM to change between Backlight and Contrast.
3. Press OK to confirm.
BACKLIGHT & CONTRAST
Backlight = 30%
Contrast = 70%
Dimming = 25%
QUIT PARAM
ADJUST WITH
OK
CURRENT DATA SET
QUIT
Data Set ID: ABCD
Name:
Data_set_EXAMPLE
Version: 2
Last update:
01-Jun-2006 12:34
Hospital name:
Basingstoke General
OK
Current Data Set File
1. Press OK to exit after verifying current data set information.
Select the Dimming parameter to see what the display
would look like when dimmed.
Language
1. Select the required Language using the fkeys.
2. Press OK to confirm.
LANGUAGE
ENGLISH
NORSK - NORWEGIAN
DEUTSCH - GERMAN
FRANCAIS - FRENCH
NEDERLANDS - DUTCH
SVENSKA - SWEDISH
ESPAñOL - SPANISH
ITALIANO - ITALIAN
NONE - VANILLA
QUIT OK
SELECT WITH
Languages available will be dependant on the pump
software version.

Configuration and Calibration
Alaris® GP Volumetric Pump 14/84 1000SM00013 Issue 3
Upload data set to an Alaris® GP Volumetric Pump
Equipment required:
Alaris® GP Editor Software Kit (1000SP01310) - includes the Alaris® GP Transfer Tool•
RS232 cable (1000SP01183)•
USB to RS232 Converter cable (1000EL00979) - optional•
USB to RS232 converter 4 way hub (1000EL00980) - optional•
PC - for requirements see Upgrading Firmware PC requirements•
Using the Alaris® GP Transfer Tool allows a released data set to be uploaded to an Alaris® GP Volumetric Pump.
Warning -
At no time should the Alaris® GP Transfer Tool be used to upload to an Alaris®
GP Volumetric Pump while the pump is connected to a patient.
For more information relating to the Alaris® GP Editor Software or the Guardrails®
Editor V3.1 Software refer to the relevant Directions For Use supplied with the
software.
In Service Mode select Data Set Transfer using the fkeys and the OK softkey.
Using the Alaris® GP Transfer Tool select data set to be uploaded.1.
Press the2. RS232 or IrDA softkey to select the Comms mode being used.
Connect the pump to PC.
3.
Press the4. START softkey to begin transfer.
Please ensure the data set ID shown on the pump is identical to the one transferred.5.
Press6. PASS softkey to confirm correct transfer and exit.
To transfer the data set to another pump repeat steps 2 to 6.7.
Service Mode - Data Set Transfer
Upload data set to an Alaris® GP Guardrails® Volumetric Pump
Equipment required:
Guardrails® Editor V3.1 Software Kit (1000SP01389) or Guardrails® Editor V3.1 Transfer Tool Software Kit (1000SP01390)•
RS232 cable (1000SP01183)•
USB to RS232 Converter cable (1000EL00979)•
USB to RS232 converter 4 way hub (1000EL00980) - optional•
PC - for requirements see Upgrading Firmware PC requirements•
Using the Guardrails® Editor V3.1 Transfer Tool allows an approved data set to be uploaded to an Alaris® GP Guardrails®
Volumetric Pump.
Warning -
At no time should the Guradrails® Editor V3.1 Transfer Tool be used to upload
to an Alaris® GP Guardrails® Volumetric Pump while the pump is connected to
a patient.
In Service Mode select Data Set Transfer using the fkeys and the OK softkey.
Using the1. Guardrails® Editor V3.1 Transfer Tool Transfer Tool select data set to be uploaded.
Connect the pump to PC.
2.
Press the3. START softkey to begin transfer.
Please ensure the data set ID shown on the pump is identical to the one transferred.
4.
Press5. ACCEPT softkey to confirm correct transfer and exit.
To transfer the data set to another pump repeat steps 2 to 5.6.
Caution: Loading the Data Set Transfer Tool software is considered a non-clinical service activity.
Interconnecting the pump with a PC may cause the safety or electromagnetic environment to
change while the connection exists. The threat of higher leakage currents or EMI disturbances may
be present. Disconnect the IrDA or RS232 cable connection at both ends following software upload
activities.

Configuration and Calibration
Alaris® GP Volumetric Pump 15/84 1000SM00013 Issue 3
Service Mode - Calibration
Zero Point Calibration
Select the required option using the fkeys and the OK softkey.
Wait for the pressure sensors to park.1.
Ensure that an infusion set is not installed.2.
Press the3. START softkey.
Pump will countdown for 15 seconds.4.
Press the5. ACCEPT softkey.
Press the6. PASS softkey.
CALIBRATION
QUIT
SELECT WITH
Zero Point Cal
Pressure Cal
Volumetric Cal
Battery Cal
OK
CALIBRATION
QUIT
SELECT WITH
Zero Point Cal
Pressure Cal
Volumetric Cal
Battery Cal
OK
Pressure Calibration
Equipment required:
Calibrated Pressure Gauge, minimum specification of•
Accuracy = 0.10% of full scale•
Full scale = 1500mmHg•
Pressure Calibration Set (1000SP01422) Use to calibrate 10 pumps•
and then change
Set up equipment as per figure 2-1 and allow 30 seconds before
proceeding.
Select the required option using the fkeys and the OK softkey.

Configuration and Calibration
Alaris® GP Volumetric Pump 16/84 1000SM00013 Issue 3
Service Mode - Calibration (continued)
Alaris®
GP
Figure 2 - 1 Pressure Calibration Equipment Set Up
Turn 3-way tap to close from atmosphere.1.
Press the2. START softkey.
Apply a pressure of 200mmHg and pump will countdown for 15 seconds.3.
Press the4. ACCEPT softkey.
Apply a pressure of 800mmHg and pump will countdown for 15 seconds.5.
Press the6. ACCEPT softkey.
Turn 3-way tap to vent to atmosphere.7.
Turn 3-way tap to close from atmosphere.8.
Press the9. NEXT softkey to proceed to Verification Procedure.
Verification Procedure
Software version v1.7.x and below Software version v1.9.0 and above
Apply a pressure of 200mmHg and wait for 510.
seconds.
Press the11. NEXT softkey.
Apply a pressure of 400mmHg and wait for 512.
seconds.
Press the13. NEXT softkey.
Apply a pressure of 600mmHg and wait for 514.
seconds.
Press the15. NEXT softkey.
Apply a pressure of 800mmHg and wait for 516.
seconds.
Press the17. NEXT softkey.
Turn 3-way tap to vent to atmosphere.18.
Press the19. PASS softkey.
Apply a pressure of 500mmHg and wait for 510.
seconds.
Press the11. NEXT softkey.
Turn 3-way tap to vent to atmosphere.12.
Press the13. PASS softkey.
Pressure Calibration continued
Pressure
Gauge
Pressure source
(50ml/100ml syringe
or similar device)
Vent to
atmosphere

Configuration and Calibration
Alaris® GP Volumetric Pump 17/84 1000SM00013 Issue 3
Service Mode - Calibration (continued)
Volumetric Calibration
Select the required option using the fkeys and the OK softkey.
Load the primed Infusion Set (60793) into the Pump and set-up1.
as shown in Figure 2-2 below and adjust the fluid level so that the
meniscus is level with the zero mark.
Press2. START to begin. Test will run and fluid will be delivered into
the burette.
When3. Volume delivered! is displayed, check accumulated air
in line value is less than 100µl then enter the volume delivered
into the burette using the fkeys and the OK softkey. If
accumulated air in line value is greater than 100µl then repeat test.
CALIBRATION
QUIT
SELECT WITH
Zero Point Cal
Pressure Cal
Volumetric Cal
Battery Cal
OK
VOLUMETRIC CALIBRATION
QUIT
START to begin...
STARTDETAILS
Rate 125ml/h
VTBI 20.0ml
Cal Value 920
Acc’d Air 0μl
Alaris®
GP
450mm
± 20mm
Figure 2 - 2 Volumetric Calibration Equipment Set Up
If measured value is 19.3ml or less then enter
19.2ml and if value is 20.6ml or higher then enter
20.7ml.
If no calibration is required (Volume delivered within limits of4.
19.4ml to 20.5ml) then press PASS to confirm and exit.
If the Calibration value is changed automatically then press5.
VERIFY and repeat steps 2 to 4.
If the pump still fails replace the Platen and Fingers then repeat6.
the calibration procedure.

Configuration and Calibration
Alaris® GP Volumetric Pump 18/84 1000SM00013 Issue 3
Service Mode - Calibration (continued)
Battery Calibration
Select the required option using the fkeys and the OK softkey.
Connect AC Mains to the Pump and press1. CAL to begin.
When calibration is complete it will display2. CALIBRATION
SUCCESS or CALIBRATION FAILURE. Press PASS to confirm
successful calibration or REPEAT to perform calibration again.
CALIBRATION
QUIT
SELECT WITH
Zero Point Cal
Pressure Cal
Volumetric Cal
Battery Cal
OK
BATTERY CALIBRATION
QUIT DETAILS
Serial No 12345
Current 0mA
FCC 2502mAh
Chrg Remain 2453mAh
Rel Chrg 98%
Temperature 22°C
Calibration 
CAL to calibrate!
CAL can exceed 10 hrs!
CAL
BATTERY CALIBRATION
QUIT DETAILS
Serial No 12345
Current -340mA
FCC 2502mAh
Chrg Remain 2453mAh
Rel Chrg 98%
Temperature 22°C
Calibration 
CALIBRATING . . .
Discharge 89%
CAL
BATTERY CALIBRATION
QUIT REPEAT
Serial No 12345
Current 0mA
FCC 2335mAh
Chrg Remain 2332mAh
Rel Chrg 100%
Temperature 26°C
Calibration 
CALIBRATION SUCCESS
PASS
BATTERY CALIBRATION
QUIT REPEAT
Serial No 12345
Current 0mA
FCC 2502mAh
Chrg Remain 2453mAh
Rel Chrg 100%
Temperature 22°C
Calibration X
CALIBRATION FAILURE

Chapter 3
Preventative Maintenance
In this chapter
Preventative Maintenance 20
Visual Inspection 20
Recommended Cleaning and Storage 21
Updates 23
Battery Test and Replacement 25
Service Mode - Test Verification/PVP 25
Performance Verification Procedure 38

Preventative Maintenance
Alaris® GP Volumetric Pump 20/84 1000SM00013 Issue 3
Preventative Maintenance
To ensure the pump remains in good operating condition, routine and preventative maintenance inspections are
required. Routine maintenance inspections should be performed by hospital/facility before each use, see Directions For
Use for details.
Preventative maintenance inspections should be performed at least every year.
For the preventative maintenance inspection the following should be performed:
Full visual inspection of the pump, internal and external•
Fitting of all updates required•
Battery test and/or replacement•
Clean the pump•
Performance Verification Procedures
•
Visual Inspection
Open the pump, as per Chapter 6 ‘Corrective Maintenance’and visually inspect the interior of the pump.
Visually inspect the exterior of the pump checking the following:
Labels should be replaced as required if not flat, legible or fully adhered.
•
Check Keypad for any sign of wear and replace as required.•
Case components must be checked for damage and replaced if necessary.•
Check the pole clamp is not damaged and that it functions correctly.•
Inspect the AC power supply plug and cable for damage.•
The case should be clean and free from IV solution residue, especially near moving parts.•
Check for dried solution deposits on accessible areas of pumping mechanism.•
Following all spare part replacement and repair activities, testing must be performed in
accordance with the Performance Verification Procedure (PVP). Additional testing and
calibration may be required after certain repairs are completed, see table in Chapter 6
‘Corrective Maintenance’ for more information.