KL-602 Syringe Pump

Service Manual

Beijing KellyMed Co., Ltd.

 KL-602 Service Manual

Importance
This manual provides information needed to service the Syringe Pump. This manual is intended for use
by certified biomedical engineering technicians or personnel with equivalent experience and training in
servicing this type of equipment. It is recommended that the user complete the training class geared
specifically to the Syringe Pump.

Revision History
The following revision history table summarizes changes in this document.
Revision No. Revision Date Description of Changes
1.0 21/05/2010/ Initial version
1.1 16/04/2015 Update pictures of front cover, front view and rear view.
 KL-602 Service Manual

Contents
1. Description of pump .............................................................................................................. 1

1.1 Specifications ............................................................................................................................. 1

1.2 Front view .................................................................................................................................. 2

1.3 Rear view.................................................................................................................................... 3

1.4 Syringe view ............................................................................................................................... 3

2. System block diagram ........................................................................................................... 4

3. Tools and equipments (for service and test) .......................................................................... 5

4. Troubleshooting .................................................................................................................... 6

5. Check power supply .............................................................................................................. 8

6. Chang a battery.....................................................................................................................12

7. Exchange FPC line between motor driving board and inner transferring board ..................15

8. Adjust the syringe detector board .........................................................................................18

9. Check new version of firmware. ..........................................................................................20

10. Syringe calibration .............................................................................................................21

11. Occlusion calibration ..........................................................................................................23

12.1 Tools and program.................................................................................................................. 25

12.2 Connect PC and pump with RS232 ........................................................................................ 26

12.3 Firmware upgrade process. ..................................................................................................... 28

 KL-602 Service Manual

1. Description of pump

1.1 Specifications
230V AC, 50Hz
POWER REQUIREMENTS
8 * AA NIMH battery 9.6VDC

BATTERY LIFE 1.5~2 years

POWER CONSUMPTION ≤ 15VA

0.1 ~ 99.9mL/h (in 0.1mL/h increments)

100 ~ 1300mL/h (in 1mL/h increments)
0.1~400mL/h for 10mL syringes.
FLOW RATE
0.1~600mL/h for 20mL syringes.
0.1~800mL/h for 30mL syringes.
0.1~1300mL/h for 50mL syringes.

ACCURACY ±2%

0.001 ~ 99.999ml (in 0.001ml increments)

VOLUME 100.00 ~ 999.99ml (in 0.01ml increments)
1000.0 ~ 9999.9ml (in 0.1ml increments)
0.1 ~ 99.9ml（in 0.1ml increments）
DELIVERY LIMIT
100 ~ 9999ml（in 1ml increments）

KVO 0.1mL/h~1.0ml/h (user selected)

SYRINGE SPECIFICATION 10ml, 20ml, 30ml, 50ml

ANTI-BOLUS Release pressure when pump get occluded

BOLUS 1 ml ~ 5ml

BOLUS RATE Maximum Rate of each syringe type

OPERATION CONDITIONS 5~40℃, 20~90% RH (no condensation)

STORAGE CONDITIONS -20~55℃, ≤93% RH (no condensation)

WARRANTY 1 years

Table 1.1 Specifications

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1.2 Front view

Figure 1.1 Front view

1 LCD DISPLAY 2 CHARGE LED 3 AC LED

4 ALARM LED 5 WORKING LED 6 [ON/OFF]KEY

7 [START/STOP] KEY 8 [SILENCE]KEY 9 [MENU]KEY

10 [MODE]KEY 11 [PURGE] KEY 12 [UP]KEY

13 [DOWN]KEY 14 [ENTER]KEY 15 [SHUTTLE]KEY

16 SYRINGE INSTALL 17 SYRINGE PLATE 18 WATERPROOF

SLOT CLOTH
19 PRESSURE SENSOR 20 OPEN NUT 21 PLUNGER HOOK

22 PUSHER 23 V SHAPE SLOT

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1.3 Rear view

Figure 1.2 Rear view

1 CASCADE SCREWS 2 CASCADE BAR 3 PUMP FEET

4 BATTERY COVER 5 MODEL TAG 6 PUMP HANDLE

7 COMMUNICATE 8 AC POWER INLET 9 CLAMP SCREW

PORT
10 CLAMP FOLDING 11 POLE CLAMP 12 HAND WHEEL
SWITCH
1.4 Syringe view

Barrel Finger grips Plunger Push-button

Figure 1.3 Syringe view

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2. System block diagram

KeyBoard Jog & Shuttle LCD Power

I/O
DC-DC Battery
SPI
Motor I/O
MCU IIC

Electric
Driver EEPROM

Battery Voltage
data
processing RS-232(Debug)
UART
Feed Back
AD/Interrupt/IO
Reduction Gear

PM
Motor Near OP
Nut
Empty Sensor
Sensor
Screw

Machine
Syringe
Pusher

Syringe
Detecting
sensor
Syringe Press
Sensor

Figure 2.1 System block diagram

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3. Tools and equipments (for service and test)

1 Power Power cord

New battery（8 * AA NIMH battery 9.6VDC）

2 Replace Battery
Cross-screwdriver
Cross-screwdriver
3 Replace fuses An electric soldering iron
One fuse（2A 250V）

4 Disassembly Cross-screwdriver

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4. Troubleshooting

No. The symptom of failure Cause Solution

1、Calibrate pressure sensor (See Chapter 11)

2、Check and see if there is stuff in the pipe(remove)
3、Check the plane of PRESSURE SENSOR(Front view 1.1 (19)) Whether above shell(if not,
1 Occlusion alarm Alarm when the pump working
replace Pressure Sensor)
4、Check with the value of Pressure sensor change when press it with finger(if not, replace
Pressure Sensor)
1、Adjust the sensitive of occlusion alarm
The set value is too sensitive
2、Calibrate pressure sensor(See Chapter 11)
Bad connection in the circuit
2 Occlusion but not alarm Check the connecting point and reinstall in the original status(see Chapter 7)
board

Bad Pressure sensor Replace a new one

Failure of the system Replace a new main board

Abnormal LCD & LED

3 Bad LCD Replace a new one
display

The indicator fails to work Replace a new lamp or send back the circuit board and repair

4 Key fails to work Bad key Replace a new key

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The battery out Connect to the AC and charge the battery

5 Low battery alarm
No AC display or low battery
Check the power supply circuit(see Chapter 5 )
alarm

Motor is weak or fail to work Replace a new motor

6 The pump fail to work
Failure in the Driver IC or circuit
Check the circuit board and replace a new driver IC
board
Injection accuracy big
7 Injection accuracy above 2% Repeat defining a custom syringe.(see Chapter 10)
error
repeat install syringe
Install syringe error
Press the [PURGE] key twice, and the second keep pressing is about two seconds
8 Fix error alarm
Bad Pressure sensor Replace a new one

Press the [PURGE] key twice, and the second keep pressing is about two seconds until the
NUT no installation position
“Nut Err” disappeared on LCD
9 Nut error alarm
Bad connection in the circuit
Check the connecting point and reinstall in the original status(see Chapter 7)
board
Syringe Plate Syringe detect board position
10 Adjust the syringe detect board position(see Chapter 8)
Detection error error
AC power cord is not inserted
Check the AC power cord connection.
properly
Pump cannot be turned Stop the operation of the pump and replace with a new battery through your local authorized
11 Internal battery is out
on. dealer.
The voltage of the internal Recharge the battery fully for more than 8 hours by connecting the pump to an AC power
battery is low. outlet and turn it on.

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 KL-602 Service Manual

5. Check power supply

Connect AC plot
Step 1 If 230VAC absent, Please check the power supply socket connection to the board.
Step 2 If not 230V, please replace fuse.
Step 3 If not 14.75V-15V, please replace the power supply board.
Step 4 If not above 9.0V, please charging for the internal battery.
Step 5 If not about 5.0V, please replace the main board.

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STEP 2： STEP 1：
AC 230V AC 230V STEP 4：
Battery >9.2V

STEP 3:
DC‐DC OUTPUT 14.75‐15V

Figure 5.1 Power Supply Board

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STEP 5:
DC‐DC OUTPUT: 5.0V

Figure 5.2 Main board

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Other boards in pump

Jog& shuttle board

Motor driver board

Syringe detect board

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6. Chang a battery
Step 1 New battery (Internal battery must be supplied by the manufacturer)

Step 2 Open the cover of battery

Use a cross screwdriver

Step 3 Pull off the conjunction, take the failed battery out

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Pull off the

conjunction

Step 4 Put a new battery in the battery position

Step 5 Put the conjunction into the slot

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Step 6 Take on the cover

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7. Exchange FPC line between motor driving board and inner

transferring board
Step 1 Prepare a new FPC Line（Must be Supplied by Mfr）
Step 2 Open the Shell

Scroll off the 5 Screws

Step 3 Take off the bad FPC Line

Pull off the conjunction press

board

Step 4 Exchange the new FPC Line

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Put the FPC into the

conjunction by clip then put
on the press board

Put the FPC into the

conjunction

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Push in the press board with

the clips under the FPC Line

Step 5 Close the shell and fix it

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8. Adjust the syringe detector board

Step 1 Open the shell
Step 2 Scroll the screws off with a cross screwdriver

using cross screwdriver

Adjust the position of syringe detector

board in or out

Step 3 Adjust the position of syringe detector board in or out

Step 4 Test the detector function status

Turn on the Syringe Pump then press [START/STOP]KEY into the bellowed interface

Syringe Size brand ： QIAOPAI

May be 10ml nn ml Scale：78.2mm
20ml 30ml 50ml CONFIRM CANCLE

M‐Rate BAT.

In this interface loaded different syringe size ( 10ml 20ml 30ml 50ml )，can display syringe size
correctly, if not display correctly, return STEP3, Adjust the position of syringe detector board in or
out slightly Until finding the correct position.

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Step 5 After the detector function adjustment, fix the screws on.

Step 6 Close the shell and fix it

NOTE：
If adjust the position of syringe detector board in or out failed, please enlarge the holes in which
the screw in by filing then copy the above steps.

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 KL-602 Service Manual

9. Check new version of firmware.

Through the following steps to check the firmware version

1） Turn on the pump
2） Press [MENU] KEY to enter the main menu
Rate Mode(ml/h)
VOL‐Time Mode
Weight Mode

MENU BAT.

3） Select “Special Setting” from main menu and press “enter” key to enter “Special Setting”
menu
Default Setting
Log
Product Info.

Special BAT.

4） Select “Product Info” from “Special Setting” menu and press “enter” key to enter Product
Information Display
Ver. ：L602.01.05
Date : XXXXXXXX
S/N : XXXXXXXXX

Product BAT.

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 KL-602 Service Manual

10. Syringe calibration

The Syringe Pump support custom two brand : custom 1, custom 2, Each of four types: syringe
including 10ml, 20ml 30ml 50ml
Tools:
1. Vernier caliper, or ruler
2. syringe
Ready:
1） Measure A (barrel length) and B (plunger length) and record.

2） Install syringe (Example 10 ml)in pump (According to the instructions of the installation
method of installation).
3） Into custom syringe interface.
4） When the brand for black when we show, Press [ENTER]KEY. Let custom 1 or 2 against the
white custom, the diagram below:
Brand： CUSTOM 1
A 76.00mm B 28.00mm
Confirm Cancel

Custom BAT.

5） Choose the name of self-define syringe(self-define 1 and self-define 2) by turning shuttle key.
This selection custom 2, the diagram below:

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Brand： CUSTOM 2
A 76.00mm B 28.00mm
Confirm Cancel

Custom BAT.

6） Press [ENTER]KEY. After confirm, turning shuttle key or use [UP]KEY [DOWN]KEY
choose A . show as the diagram below:
Brand： CUSTOM 1
A 76.00mm B 28.00mm
Confirm Cancel

Custom BAT.

7） Input the value of A and Press [ENTER]KEY confirm.

Such as measuring the length of a syringe effective scale for 75.8 mm, syringe push handle length
b for 25.8 mm A study is adjusted for 75.8, adjust the numerical values of item B for 25.8
8） Adopt the same method, set the data item B.
9） Confirm input. Syringe custom finish.
10） Into syringes options, check the definition of syringe parameters are now stored. As
shown in figure
Brand：CUSTOM2
10ml 75.80 25.80
20ml 00.00 00.00
30ml 00.00 00.00
50ml 00.00 00.00

syringe BAT.

If you want to continue to define different types of syringe repeat the step 1) - step 8).

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 KL-602 Service Manual

11. Occlusion calibration

Through the following steps to calibrate the pressure sensor:

1) Turn on the pump.
2) Press [MENU] KEY to enter the main menu.
Rate Mode(ml/h)
VOL‐Time Mode
Weight Mode

MENU BAT.

3) Select “Special Setting” from main menu and press “enter” key to enter Special Setting menu.
Language
Default Setting
Maintenance

Special BAT.

4) Select “Maintenance” from Special Setting menu and press “enter” key to enter system
Maintenance Interface.(For example calibrate pressure sensor for 10ml).
AC：367 BAT：375 “nn” maybe is 10、20、 30
P:342 PUMP‐1 Snn or 50.
K：20 MARK1 SAVE S10 means 10ml syringe
Maintain. BAT.

5) Install syringe then connect syringe and manometer

6) Press [START/STOP] KEY of the pump when it displays as above picture shows. then motor
of the pump starts running. meanwhile “PUMP-1” changes to “PUMP-2”.
AC：367 BAT：375
P:342 PUMP‐2 S10
K：20 MARK1 SAVE

Maintain. BAT.

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7) Press [START/STOP] KEY of the pump When manometer displays 0.02MPa ,then press
[DOWN] KEY Select “MARK1”as shown below.
AC：367 BAT：375
P:342 PUMP‐1 S10
K：20 MARK1 SAVE

Maintain. BAT.

8) Press [START/STOP] KEY of the pump when display above. then motor of the pump starts
running. While “MARK1” into “MARK2”.
AC：367 BAT：375
P:342 PUMP‐1 S10
K：20 MARK2 SAVE

Maintain. BAT.

9) Press [START/STOP] KEY of the pump When manometer displays 0.10MPa ,then press
[DOWN] KEY Select “SAVE” as shown below.
AC：367 BAT：375
P:342 PUMP‐1 S10
K：20 MARK1 SAVE

Maintain. BAT.

10) Press [ENTER] KEY of the pump save the record. Calibrate pressure sensor for 10ml syringe
finished.

Repeat the above step4 to step10 to calibration pressure sensor for 20ml, 30ml and 50ml syringe

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12. Firmware upgrade

12.1 Tools and program.
1) RS232 Serial Port Connector Line.

2) Firmware Upgrade tool

3) Firmware (new version)

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12.2 Connect PC and pump with RS232

2.1) Operating system required
Win 9X/Me /2000/XP/ (Windows XP professional edition is recommended)
2.2) Connect PC and the Syringe Pump with RS232.

RS232 Connector

WARNING
A Disconnect the AC power cord.
B Turn off the Syringe Pump before connection

NOTE：
A If there is not RS232 communication port, replace it by a “USB/RS232 line”. Connection
diagram as below.

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B USB to serial line.

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12.3 Firmware upgrade process.

Step 1 Connect PC and Syringe Pump with RS232.

Step 2 Double-click this icon ，Open the firmware upgrade

tool--“Boot Loader Control.exe”，The tool’s interface is as below.

The file path of firmware new version

Communication Port
BaudRate

Step 3 Select COM Speed

Select the “COM Speed” value “115200”.as below.

Step 4 Select the Firmware program file（New version）.

Click the “Open S19 file” button ，Select the file name ” L602.01.05.abs.s19”.

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Step 5 The interface of selecting the firmware program file is as below.

Step 6 Click the button “Bootload”, Enter downloading interface.

Step 7 Press the [ON/OFF] KEY of the pump (Keep holding, don’t release) until waiting process
is finished. Firmware upgrade is process as below.

The Interface will be automaticly

closed when 100% displays

Please release the [ON/OFF] KEY of the pump when the interface closed automatically, firmware
upgrading is finished.

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NOTE:
1） If your computer has a firewall, please remove the restrictions on the upgrade tool

2） Double-click this icon when you use ” USB-RS232 line” to

replace RS232，Open the firmware upgrade tool--“Boot Loader Control.exe”，The tool’s
interface is shown as below.

“n “may be 1 to 8

3） If failed to upgrade procedures,（Such as: Release the [ON/OFF]KEY of the pump in the

process of upgrading or RS232 etc.），Please repeat the above step 1 to step 7 to upgrade

again.
4） If upgrade procedures is failed the pump will not startup.

NOTE:
Occlusion alarm occura frequently after the firmware upgrade, please follow the method to
calibrate pressure sensor.

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Beijing KellyMed Co., Ltd.
Room 115, 4 # Building, No. 2 Tiyuan West Road,
Haidian District, Beijing, 100084, China
Tel: +86-10-82490385
Fax: +86-10-65587908

Labcon GmbH
Benzstrasze 4, 64646 Heppenheim, Germany
DIMDI Code: DE0000046575